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BACKGROUND OF THE INVENTION
It has been generally accepted that the human body, its components, and functions are stressed, stimulated and thereby strengthened in all activities involving resistance to the extant gravitational pull or force.
It has been further established the body does not physiologically discern between the forces of inertia, acceleration and deceleration and gravitational pull. Hence G-force stress may be induced and experienced by acceleration or deceleration even when extant planetary G-force is essentially non-existant. Those G-forces of acceleration and deceleration can be induced in line with such existant G-force, when present, thereby combining with and producing the summary effect of both.
When people run, jump, play tennis, or are in any way move in resistance to G-forces, the body, its organs and cells are stressed and strengthening is induced. Body fluid circulation and waste functions are also stimulated and benefitted. Many people are, however, either disinclined or due to physical impairment or pain cannot participate in these exertions and as a result their bodies and components and functions deteriorate and fail.
The present invention utilizes all three sources of G-forces to induce those benefits for its users with minimal physical exertion by the individual user. In fact should the user be unable to activate the invention device himself, a second person or motor powered reciprocal drive can be used to provide the necessary motion to allow the device user the benefit from the invention device, even if the user is totally passive, incapacitated, in a wheelchair, or bed.
BRIEF DESCRIPTION OF THE PRIOR ART
Several devices utilizing a spring to provide bounce to a platform are shown in U.S. Pat. Nos. 2,764,413; 2,812,180; and 3,856,296. All of these devices, however, are directed to diving boards or springboards that do not maintain a horizontal plane. These would require skill by the user that an older or sick person may not have. Matton in U.S. Pat. No. 2,915,055 does show an exercising chair useful for flexing the limbs and exercising the joints. Movement of the chair is created by pivotally mounted arms engaging the chair and a motor mounted below the seat of the chair. However, the device of Matton provides only limited movement of selected areas of the body and does not strengthen the body cells of the entire body as does the invention device.
Trampolines provide a user with similar benefits combining the same G-forces of acceleration, deceleration, and extant gravity, but do not provide the platform, on which the user may sit, stand with shoes, or even be in a wheelchair, stably maintained horizontal and parallel to the base in the accelerated up and down motion as does the invention device. More over the use of trampolines, springboards or diving boards require skills and balance without which are considered unsafe, nor are they reasonably usable for the passive person or one confined to a wheelchair. The invention device can be used by anyone regardless of skill or strength or balance. With easily accomplished assistance the totally incapacitated person can use the invention device, even those where body joint movement or flexing of limbs would be undesirable or painful as may occur by use of the Matton device.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a therapeutic device that strengthens body cells and organs, and improves body functions and fluid circulation. The invention device comprises a platform that is pivotally attached to a vertical upright that is part of, or attached to, a base generally below and parallel to the platform. The pivotal attachment allows free up and down movement of the platform and at the same time maintains the platform rigidly horizontal and parallel to the base during the vertical movement cycle regardless of where on the surface of the platform the users/occupants weight is centered or located. This gives the user/occupant essentially perfect stability getting on and off the platform and during use.
The platform movement is either spring actuated or is actuated in combination with (or by) a reciprocal mechanical drive. Spring actuation is accomplished by any type spring such as compression, extension, torsion, etc.
The following are examples:
A. Compression
1. attached to the top of the base extending up (between) and attached to the bottom of the platform.
2. attached to and extending from the pivotal arms or extensions or attachments thereof.
B. Extension
1. attached to the top of either the pivotal arms or the platform or attachments or extension thereof and extending to any horizontal support above that is either attached to or an extension of the base.
2. attached to the pivotal arms or the platform or extensions or attachments thereof and extending to any part of the base, extension or attachment thereof, or otherwise secured.
C. Torsion
Located over the permanently horizontal part of one of the pivotal arms attached to a sprocket, worm gear drive, or an attachment or extension of the base and the other end to the supporting arms of the pivotal arm. In the use of the worm driven sprocket a motor drive or crank, can be used to increase or decrease tension for load adjustment or raising and lowering of the platform.
It must be further noted that platform raising or lowering, or changes in spring tension of any spring configuration, can be effected by making the spring end attachments moveable for the increase or decrease of compression or extension as well as torsion. This can be accomplished by parallel loading of a rotatable screw, turning of which may be either manual or motor driven. Other means common in the art may be utilized to accomplish the same function.
It is a further object of this invention to provide a therapeutic device comprising a spring or otherwise reciprocally actuated rigid platform having one or more rigid upright attachments or extensions slidably engaged with the vertical uprights, which are rigidly attached to (or extensions of) a base. Those vertical uprights or extensions may be slidably engaged with rollers or balls or other guides maintaining alignment and horizontal stability to the platform during up and down motion. Spring attachment or other reciprocal drive can be by any of those aforementioned methods or other known in the art.
It is a further object of the invention to have (a) hand support(s) or seat which may be attached to the platform.
It is a further object of the invention to have a platform that may be raised or lowered for easier entrance by the user; for example, loading with an individual in a wheelchair.
It is a further object of the invention that the up and down reciprocal motion can be supplied by mechanical/electrical means with or without springs.
It is a further object of the invention that in either of the basic configurations given, the verticals to which the platform is either pivotally or slidably attached may be rigidly secured to a floor or wall, thereby eliminating the necessity of a base.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective partially cut-away view of the invention therapeutic device showing a platform pivotally mounted and coil springs beneath the platform.
FIG. 2 is a sectionally cut-away view of the invention therapeutic device showing an alternative spring arrangement positioned on the actuating means of the device.
FIG. 3 is a perspective view of an alternative design of the invention therapeutic device showing uprights attached to a platform being guided by rollers in the vertical channels of the box-like outer structure.
DESCRIPTION OF THE PREFERRED EMBODIMENT
For a detailed description of the invention, reference is made to the attached drawings wherein the invention is illustrated and will be described. Identical reference characters will be utilized to refer to identical or equivalent components throughout the various views and the following description.
The invention body cell therapeutic device 10 shown in FIG. 1 comprises an outer box 12 having an outer box frame 14 with walls 13 attached thereto and an inner box 36 having an inner box frame 38 with walls 44 attached thereto and a spring-actuated rigid platform 27.
Outer box 12 is a U-shaped configuration with rearward verticals 16 and forward verticals 20 forming the four corner posts of the frame 14 with upper and lower horizontals 17 and 19, respectively, connecting the corner posts to form the box-like frame 14. These verticals 16 and 20 and horizontals 17 and 19 may be constructed of any sturdy, rigid, durable material, but are preferably made of steel or aluminum.
Attached to the outside edges of outer box frame 14 by conventional means are walls 13 and base 18. Any sturdy material may be used to form walls 13 and base 18 such as plywood, aluminum or sheet steel, with sheet steel being preferred. Walls 13 and base 18 provide enclosure means for the moving parts (to be discussed below) of the device for safety and aesthetic reasons.
Pivotally engaging the frame 14 of outer box 12 is inner box 36. Inner box 36 has a configuration similar to that of outer box 12, namely a U-shaped frame 38 having walls 44 attached to the outside thereof. Again, similar to outer box 12, inner box frame 38 comprises rearward verticals 40 and forward verticals 42 forming the corner posts of the U-shaped frame with lower horizontals 41 connecting the lower ends of the four verticals 40 and 42, and upper horizontals connecting the upper ends. However, in the inner box 36, although lower horizontals 41 are positioned relatively the same and perform the same function as the lower horizontals 19 in outer box 12, upper horizontals 48 connecting upper ends of the four corner posts not only provide connecting and support means for the inner box frame 38, but also function as handrails for the occupant of the device.
Handrails 48 are made possible by not bringing the inner box walls 44 flush with the top surface of the handrails 48 in contrast to the outer box 12 design. Walls 44 are extended up to within a few inches of the bottom of handrail 48 and then are bent outward to form an L-shaped lip 46. This lip 46 may serve the dual purpose of providing a "stop" for the downward motion of the inner box 36 when the lip 46 contacts the outer box horizontals 17, and prevent the hands of a person using the device from getting caught between the inner box 36 and outer box 12. The inner box wall 45 located on the front of inner box 36 is, however, flush with the top surface of cross bar 50 that connects forward verticals 42 in the same manner as the design of outer box 12.
The components of inner box 36 equivalent to those of outer box 12 are made of the same materials as used in outer box 12.
Platform 27 attached to the bottom of inner box frame 38 forms the surface on which a user of the invention device is located. As with other parts of the invention device, this platform 27 should be sturdy, durable and strong and must be rigid. Preferably the platform is made of steel, but other materials meeting the above requirements may also be used.
Located approximately midway on opposite sides of the platform 27 are attachment blocks 28. These attachment blocks 28, preferably also made of steel and secured to the platform 27 by any conventional well-known means, retain one end of the rocker arms 22 and 24 (to be discussed below) by means of pivot points 26, which may be bolts or other equivalent retaining means. Rocker arms 22 and 24 are free to pivot on pivot points 26.
Rocker arms 22 and 24 which are rigidly attached to horizontal arms 32 and 34 form the means by which the platform 27 is able to move and the invention device to operate. Located between the outer box side 13 and inner box side walls 44, lower rocker arm 22 and parallel upper rocker arm 24 are secured to attachment blocks 28 by their respective pivot points 26. The inner box side walls 44 are constructed and arranged so they do not interfere with the pivotal attachment rocker arms 22 and 24. Each rocker arm extends forward and parallel to the walls 13 and 44, passing through slot 30 in the lower portion of forward verticals 20 and into the space between the side walls 44 of inner box 36 and walls 13 of outer box 12. The lower rocker arm 22 is connected to lower horizontal arm 34 and upper rocker arm 24 is connected to upper horizontal arm 32, connection being such that rocker arms 22 and 24 can pivot with horizontal arms 32 and 34. The horizontal arms 32 and 34 are pivotally supported by forward verticals 20. The rocker arms 22 and 24 are of equal length and form two sides of a parallelogram being always maintained vertical. Therefore upon a perpendicular attachment of one of the vertical sides through attachment blocks 28 to the platform 27, the platform 27 is always maintained horizontal even though the platform 27 moves in the same size arc as rocker arms 22 and 24.
As mentioned previously, all of the support and movement mechanism for the inner box 36, with the exception of attachment blocks 28, are enclosed between the walls 44 of inner box 36 and the walls 13 of outer box 12. Additionally, as with the other components of the invention device, the rocker arms 22 and 24, and the horizontal arms 32 and 34 are made of a strong, sturdy, durable material such as steel, although any other material fulfilling the necessary requirements may also be utilized.
Certainly one of the most critical components of the invention device are the springs 52, one end of which is attached to the base 18 of the outer box 12 and the opposite end is attached to the underneath side of platform 27 of inner box 36. The coil-type springs 52 are aligned in the center of the device 10. Although FIG. 1 shows three aligned coil springs, similar results may be obtained from the invention device by utilizing any type of springs and any number of springs arranged in any pattern.
FIG. 2 shows the same invention device 10 as in FIG. 1 with the exception of the spring mechanism. Coiled around upper horizontal arm 32 is a spring of sufficient strength to perform its function in the device. Each end of spring 52 fits in notch 76 located in the forward portion of upper rocker arm 24 to tension hold the spring 52 in position. Located midway and on upper horizontal arm 32 is sprocket 56 to which spring 52 is engaged. Mounted to the outer box 12 by any conventional well-known means is motor 54 having attached thereto worm gear 58. When connected by electrical plug 60 to a source of electricity and activated by controls 62, motor 54 rotates worm gear 58 that is meshed with the teeth of sprocket 56. Movement of worm gear 58 rotates sprocket 56 which in turn increases or decreases the tension on spring 52 as desired. Dual controls 62 provide the selection means of increasing or decreasing the the tension on spring 52. By changing the tension of spring 52, the invention device can be selectively adapted to be used by any size individual from child to adult.
If desired motor 54 may have further controls (not shown) for automatic reversing to provide up and down movement of the inner box 36 without any outside influence.
FIG. 3, an alternative embodiment of the invention device, shows a body cell therapeutic device 10 comprising an open end outer box 12 and a platform 27, the platform 27 having a pair uprights 74 being received by the vertical channels 72 of outer box 12, the uprights 74 having mounted therein rollers 64, 66 and 68.
The frame 14 of outer box 12 comprises a pair of upper horizontals 17 spaced apart slightly wider than the width of platform 27 and a pair of lower horizontals (not shown) parallel to and spaced apart by the same distance as the upper horizontals 17. Connecting opposing lower horizontals are cross bars 21. To complete the outer box 12 and form the corner posts are a pair of rearward verticals (not shown, but generally the same as rearward vertical 16 of FIG. 1), and the previously mentioned pair of forward vertical channels 72. The rearward verticals (not shown) are attached to the underneath side of upper horizontals 17 in the same manner as described in FIG. 1.
The vertical channels 72 have a U-shaped configuration and are adapted to receive forward rollers 64, side rollers 66, and rearward rollers 68, which comprises a set of rollers. A set of rollers 64,66 and 68 are located near the top of vertical channels 72, and another set of rollers 64,66 and 68 are located near the bottom of vertical channels 72 in close proximity to and above platform 27.
The vertical channels 72 face each other and receive the uprights 74 attached to the forward end of platform 27. To connect uprights 74, and provide a stabilizing means for a user of the device 10, a hand bar 70 is connected between the upper ends of upright 74.
Springs 52 discussed in the description of FIG. 1 may be positioned underneath platform 27 and connect platform 27 to base 18 in the same manner as described in FIG. 1.
As with the devices shown in FIGS. 1 and 2 and described above, the device 10 in FIG. 3 is constructed of strong, sturdy durable materials. The outer box frame 14, the vertical channels 72 and uprights 74 may all be made of steel. Walls 13, base 18, and platform 27 may also be made of steel or wood or similar material having characteristics that would render it suitable for the intended use.
The platform 27 of all of the embodiments discussed and shown in FIGS. 1, 2, and 3 is rigid so as to enable a person confined to a wheelchair or otherwise unable to stand to also benefit from the invention device.
Handrails 48 shown in FIGS. 1 and 2 and hand bar 70 shown in FIG. 3 are for stability and provide a means for a device user to balance himself.
METHOD OF OPERATION
In any of FIG. 1, 2 or 3, a person is located on the platform 27 and is moved, by their own effort, that of someone else's, or by a motor driven reciprocal drive, in an up and down motion.
When operated by their own effort, the user bounces slightly in an up and down motion. This motion is transferred through the platform 27 to the springs 52 that compress (or extend) and respond accordingly causing the platform to rebound upward, and by gravity subsequently downward. The user by exerting slight effort to bounce adds to the downward thrust to initiate and sustain the motion as desired.
Someone else may aid the slight effort applied to the platform 27 to initiate and/or sustain the motion.
A reciprocal drive may be used either in combination with, or without, the springs to provide the up and down motion at a desired rate.
By repetitiously inducing controlled stress below the rupture threshold, with up and down motion, the three forces previously discussed (acceleration, deceleration and gravity) all act upon the body components, organs and functions with resultant strengthening and improvement. The rupture threshold is that point below which the body cells are not damaged, but benefit from the stress incurred.
The number of repetitions, frequency and height of each stroke may be best prescribed by a physician knowledgeable in the effects of the invention device and the present condition of the user.
The construction and operation of the device of this invention has been described in detail. What is desired to be claimed is all modifications and adaptations of this invention not departing from the scope of equivalents as defined in the appended claims.
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A therapeutic device comprising a base, usually resting upon a floor, and a platform, usually located above the base that is maintained rigidly parallel to the base in a horizontal plane throughout up and down cycles. The platform is attached either with (a) pivotally attached arm(s) or by (b) freely operating sleeve(s) on to one or more vertical extensions or rigid attachments to/of the base. The platform, upon which the user is located, is moved up and down in a cycle initiated and maintained by the sustained activity of a spring suspension, or by, or in combination with, a motor driven reciprocal drive. This up and down cycle of accelerating and decelerating in line with extant gravitational pull occurs resultant strengthening of the body cells and organs, and stimulates circulation and body functions for the occupant user.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a recording and/or reproducing method of recording and/or reproducing predetermined data to a recording medium on the basis of a command which is sent from a host computer through an SCSI (Small Computer System Interface).
2. Related Background Art
SCSI is an interface which has been deliberated in the X3T9.2 Work Committee of ANSI (American National Standard Institute) on the basis of the interface SASI (Shugart Associates System Interface) for connecting a small computer and its peripheral apparatuses made by Shugart Co., Ltd. in the U.S.A. and has been standardized as ANSI X3.131-1986. The SCSI is at present becoming a standard interface for connecting a personal computer and its peripheral apparatuses. In recent years, the work to standardize SCSI-2 as an expanded version of SCSI has progressed. A final decision of SCSI-2, however, has not yet made at the present point in time. There are the following five ranges of the SCSI interface rules which are specified by the ANSI.
(1) The kinds and definitions of interface signals and timings for transmission and reception of the signals.
(2) A protocol to specify the operation sequence as an interface and definitions of phases and the like.
(3) Physical interface conditions such as cable specifications, connector specifications, and the like, and electrical conditions of the transmitting system.
(4) Command systems to execute various controls of peripheral apparatuses and data transfer, formats of commands, functions of commands.
(5) A status byte format to inform the result of execution of the command to a host computer, and a structure of sense data to inform an abnormality state or the like during the execution of the command.
The command system in the above item (4) is as follows. First, an SCSI command is classified into eight kinds of groups. The first byte of a CDB (Command Descripter Block) indicates an operation code. Upper three bits of the first byte designate a group code and lower five bits designate a command code (code indicative of the kind of command) of each group. A length of CDB is specified for every group in the following manner.
______________________________________(1) group 0 6 bytes(2) group 1 10 bytes(3) groups 2-4 reserved(4) group 5 12 bytes(5) groups 6-7 vendor unique (specified by the manufacturer)______________________________________
The CDB of groups 6 and 7 is a group of commands which can be defined so as to be unique to the SCSI device. In each command, a logic block address is constructed by continuously arranging data blocks each having a fixed length on a logical unit.
FIG. 1 is a diagram showing a construction of a logic block in a hard disk device. In FIG. 1, a data block of a cylinder=0 and a sector=0 is set to a logic block address=0. The logic block address is increased by "1" each time each of the sector, track, and cylinder is increased by "1" in accordance with this order. An excellent point of the logic block address is that there is no need to be aware of a physical structure because an initiator (host computer) designates the logic block address of the first data block and the number of processing blocks and accesses the data. When the logic block addressing is used, therefore, in the case where the devices in which the number of cylinders, tracks, sections, and the like are mutually different are connected, they can be made operative by the same software.
FIG. 2 is a diagram showing a general example of a system construction of SCSI. As a logic unit, generally, as shown in FIG. 2, there are many cases where a physical device such as a hard disc or the like is connected. The logical unit number (LUN) can be assigned to the physical device or also can be assigned to a virtual device. In SCSI, ordinarily, eight logic units of LUN=0 to 7 can be connected to an SCSI bus. Further, by using an expansion message, up to 2048 logic units can be connected.
On the other hand, as an information recording medium, hitherto, a floppy disk to magnetically record and/or reproduce information, an optical information recording medium to optically record and/or reproduce information by using light, and the like are known. Various types such as disk shape, card shape, tape shape, and the like are known as a form of the optical information recording medium. Among such optical information recording media, the card-shaped optical information recording medium (hereinafter, referred to as an optical card) is small and light and is conveniently portable and a large demand is expected as an information recording medium of a relatively large capacity. The information recording medium is mainly classified into a type in which information can be erased and rewritten and a type in which the recorded information cannot be erased and rewritten in accordance with the characteristics of the medium. In general, the information of the optical card cannot be erased and rewritten, so that an application of the optical card is expected in the field such as a medical field or the like in which a fact that the recorded information cannot be rewritten becomes an advantageous.
As mentioned above, on the other hand, since the optical card is generally of the unerasable and unrewritable type, for instance, in the case where directory information or the like which ordinarily consists of several tens of bytes is recorded onto the optical card in which-a data capacity of one track is equal to 512 bytes or 1024 bytes, the remaining portion of one track becomes vain and the data capacity cannot be effectively used. Therefore, there is also proposed an optical card in which a plurality of sectors can be recorded on one track. In such an optical card, a plurality of sector types of different data capacities are prepared. For instance, in a case of the sectors such that a data capacity of one sector is equal to 1024 bytes, one sector is arranged in one track and is used for data recording. In a case of the sectors such that a data capacity of one sector is equal to 32 bytes, 12 sectors are arranged in one track and are used for recording a directory. Due to this, the information capacity of an optical card can be effectively used. In the SCSI system, however, there is a rule such that when information is recorded and reproduced by using the logic block address mentioned above, the logic blocks are handled as the same size (capacity). Therefore, the sectors in which data capacities (sector sizes) per sector differ as in the above optical card cannot be collectively used. Recording and reproducing commands also can be obviously prepared as vendor unique commands for every sector size. When the number of kinds of sector sizes is large, however, a number of vendor unique commands to execute the same recording and reproduction as a function exist, so that it is undesirable from a viewpoint of the compatibility with the other devices.
SUMMARY OF THE INVENTION
It is an object of the invention to solve the problems of the conventional techniques as mentioned above and to provide a data recording and/or reproducing method which can effectively use an information capacity of a recording medium by allowing sectors of different data capacities to collectively exist.
According to the invention, the above object is accomplished by a method of performing either the recording or reproduction of data by using an information processing system comprising a recording/reproducing apparatus for executing at least one of the recording of data on and reproduction of data from a recording medium on which a plurality of data tracks are formed, a controller to control the recording/reproducing apparatus, and a host computer connected to the controller through a small computer interface, wherein the method comprises the steps of: sending a partition command signal for dividing said data track into a plurality of logic partitions and for designating a sector size which is used in each of the partitions from the host computer to the controller through the small computer interface; storing parameters regarding the partition division and sector size into a memory in the controller on the basis of the partition command signal sent from the host computer; sending a selection command signal for designating either one of the divided partitions from the host computer to the controller through the small computer interface; and controlling the information recording/reproducing apparatus by the controller so as to execute either the recording or reproduction of the data to the data track of the partition designated by the selection command signal in accordance with the parameters stored in the memory.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram showing a construction of logic blocks in a conventional hard disc device;
FIG. 2 is a block diagram showing a construction of a conventional general SCSI system;
FIG. 3 is a plan view showing an example of a format of an optical card which is used as a recording medium in the invention;
FIG.4 is a schematic diagram showing an embodiment of a construction of a partition command signal which is used in the invention;
FIG. 5 is a schematic diagram showing an embodiment of a construction of a partition parameter which is included in the partition command signal in FIG. 4;
FIG. 6 is a schematic diagram showing an embodiment of a construction of a selection command signal which is used in the invention;
FIG. 7 is a block diagram showing an example of a construction of an SCSI system which is used in the invention; and
FIG. 8 is a flowchart for explaining an embodiment of a data recording method of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
An embodiment of the invention will be described in detail hereinbelow with reference to the drawings. A construction of an optical card used as an information recording medium in an information recording/reproducing method of the embodiment will be first explained. FIG. 3 is a plan view showing an example of the optical card. A plurality of tracking tracks 2 are provided in parallel on an optical card 1. A data track 3 to record information is provided between the adjacent tracking tracks 2, respectively. Physical track numbers 4 indicative of the physical position of the data track 3 have previously been formatted at both edges of the data track 3. The physical track numbers 4 are set in a manner such that the lower edge side of the optical card 1 is set to No. 0 and the number increases as the position approaches the upper edge side and the top edge is set to No. 2499. That is, No. 2500 data tracks 3 are provided on the optical card 1.
FIG. 4 is a diagram showing an example of a construction of the CDB of a command (partition command) for dividing the information recording medium into a plurality of logic partitions and for designating the sector size which is used in each of the partitions. In FIG. 4, an Operation Code of the byte 0 indicates a code number of the command. In the example shown, a code C3H (H indicates a hexadecimal number) is given as a vendor unique command of the group 6. The logical unit number of a target device is given to the Logical Unit Number of the bits 7 to 5 of the byte 1. Parameter list lengths shown in FIG. 5 are given to the bytes 3 and 4. The lengths of parameters differ depending on the number of partitions to be divided. All of the bits 4 to 0 of byte 1, the byte 2, and the byte 5 are set to 0.
FIG. 5 is a diagram showing an example of a construction of a parameter (partition parameter) which is transferred from the host computer by a partition command. In the example of FIG. 5, not only the sector size which is used in the partition but also a mode regarding whether information is recorded with an ECC (error correction code) or not can be designated. In the example of FIG. 5, the number of partitions of the byte 0 indicates the number of partitions to be divided. Such a byte is designated only once in the above parameter. A Partition Number of the byte 1 indicates the partition number. In the example shown, the numbers must start from 0 and be continuous. A first Physical Track Address of each of the bytes 2 and 3 indicates the first physical track number of the partition and must be (the final physical track number of one preceding partition)+1. A Number of Physical Track of each of the bytes 4 and 5 indicates the number of physical tracks which belong to the partition. A Sector Type of the byte 6 designates the sector type number shown in the following Table 1 by the ASCII codes (30H to 36H).
TABLE I______________________________________Type Sector/Track User Byte/Sector (with/without ECC)______________________________________0 1 1368/16801 1 1024/12962 2 512/7203 4 256/4004 6 128/2405 8 64/1446 12 32/96______________________________________
Further, an ECC Mode of the byte 7 designates whether the recording is executed with ECC or not. "0" indicates the recording without ECC. "1" indicates the recording with ECC. In the above, each of the divided partitions is provided with the bytes 1 to 7. The information corresponding to the bytes 1 to 7 about the next partition is designated in the byte 8 and subsequent bytes. In the designation of the parameters mentioned above, the parameters must be designated in a manner such that one or more physical tracks certainly exist in one partition. The partitions must not be designated in a manner such that there is a physical track which none of the partitions belongs or that one physical track belongs to a plurality of partitions. For instance, in the case where the optical card 1 is divided into two partitions (0 and 1) as shown in the following Table 2 and the partition 0 is used to record data and the partition 1 is used to record directory, the partition parameters are set to 02H, 00H, 00H, 00H, 07H, D0H, 31H, 01H, 01H, 07H, D0H, 01H, F4H, 36H, and 01H.
TABLE 2______________________________________ Partition 0 Partition 1______________________________________The number of 2000 500tracksSector type 1 6ECC mode With ECC With ECC______________________________________
FIG. 6 is a diagram showing an example of a construction of CDB of an SAP (Select Active Partition) command to designate the partition to be used for recording and reproducing according to the embodiment. Operation Code of the byte 0 indicates a code number of the command. In the example shown, a code C5H is given as a vendor unique command of the group 6. The logic unit number of the target device is given to the Logical Unit Number of the bits 7 to 5 of the byte 1. The number of the partition (active partition) to be used for recording and reproducing is given to the byte 4. All of the bits 4 to 0 of the byte 1 and the bytes 2, 3, and 5 are set to "0".
FIG. 7 is a block diagram showing an example of an SCSI system according to an information recording/reproducing method of the invention. In FIG. 7, reference numeral 5 denotes an SCSI controller. The SCSI controller 5 is constructed by an SCSI protocol circuit (SPC) 6 to sequence control the SCSI signal on the basis of the SCSI standard, a micro processing unit (MPU) 8 as a control unit to control the SCSI controller 5 in accordance with a program stored in a read only memory (ROM) 7, and a random access memory (RAM) 9 which is used as a buffer memory or the like. An information recording/reproducing apparatus 10 is connected to the SCSI controller 5. The optical card 1 shown in FIG. 3 is inserted in the apparatus 10. Reference numeral 13 in the diagram denotes a host adapter.
In the above arrangement, until a partition command is given from the host computer 12, the SCSI controller 5 interprets the optical card 1 inserted in the information recording/reproducing apparatus 10 in a manner such that the whole surface of the card corresponds to one partition and the sector type is the type 1 and the recording is executed with ECC, so that the SCSI controller 5 executes a command such as recording, reproduction, or the like for the optical card 1. In this case, as for the logic block address which is designated in the CDB of the recording/reproducing command (in a case of the SCSI command, each command of Write and Read), the data track at the lowest edge of the card is set to address=0 and the address number increases as the data track approaches the upper edge.
The case where the partition command has been given will now be described. It is now assumed that the SCSI controller 5 has been selected by the host computer 12. In this case, since the SCSI controller 5 has been selected, an interrupting command 11 is generated from the SPC 6 to the MPU 8. The MPU 8 controls the SPC 6 and shifts the phase of the SCSI bus to the command phase and receives the command. It is now assumed that the received command is the partition command of C3H. In this case, the MPU 8 controls the SPC 6 and shifts to the data out phase and receives the parameters shown in FIG. 5 and stores the information of each partition into the RAM 9. The parameters received in this instance assume the parameters which have already been described in the above example. After completion of the transfer of the parameters, the status phase and the message in phase are executed and the processing routine for the partition command is finished.
From the above operations, the SCSI controller 5 interprets the optical card 1 inserted in the information recording/reproducing apparatus 10 in a manner such that the whole surface of the card is divided into two partitions designated by the parameters and each partition is of the sector type similarly designated by the parameters and the recording is executed in the ECC mode. However, since the partition to be used is not yet designated, the SCSI controller 5 interprets that the partition to be used for recording and reproducing is the partition 0, so that the SCSI controller executes the command for recording, reproducing, or the like to the optical card 1. In this case, now assuming that the physical track number of the data track at the lowest edge of the card is equal to 0, since the partition 0 is constructed by one sector/track, the logical block address and the physical track number coincide. The ECC mode designated by the parameters for the partition 0 of the partition command is obviously used.
The case where the SAP command (C5H) has been given will now be described. When the received command is the SAP command, the active partition is designated by the byte 4 in the CDB. It is now assumed that the partition 1 has been designated as an active partition. On the basis of the partition information stored in the RAM 9, the MPU 8 interprets that the recording and reproducing commands are for the partition 1 until the next SAP command is subsequently given, so that the MPU 8 executes the recording and reproducing commands. That is, necessary operation parameters in the SCSI controller are set such that the number of bytes which are transferred in the data transfer phase (data in phase, data out phase) is determined on the basis of the sector type and ECC mode designated by the parameters of the partition command, or the like.
FIG. 8 is a flowchart showing an embodiment of an information recording/reproducing method of the invention described above. In FIG. 8, a check is first made in step 1 to see if the partition command has been sent from the host computer to the SCSI controller or not. If NO, step 2 follows and the whole surface of the optical card is set to one partition and the sector type of the partition is set to the type 1 and the data is recorded or reproduced.
When the partition command is sent from the host computer in step 1, the processing routine advances to step 3 and the parameter designated by the partition command is stored into the RAM. In the next step 4, a check is made to see if the SAP (Select Active Partition) command has been sent from the host computer to the SCSI controller or not. If NO, step 5 follows and the data is recorded into or reproduced from the partition 0 on the basis of the parameter stored in the RAM.
When the SAP command is sent in step 4, step 6 follows and the data is recorded into or reproduced from the partition designated by the SAP command on the basis of the parameter stored in the RAM.
The correspondence relation between the logical block address and the physical track number is as described below.
Generally, now assuming that the physical track number and the sector number start from 0, there are the following relations among the logical block address, the physical track number, and the sector number.
______________________________________Tr# = Tf + int(LBA/M)Sct# = MOD(LBA/M)where, Tr#: physical track numberSct#: sector numberTf: first physical track number of the partitionM: the number of sectors per track in the sector typeLBA: logical block addressint( ): function to obtain an integer part in the parenthesisMOD( ): function to obtain the remainder of the calculation in the parenthesis.______________________________________
For instance, the partition 1 starts from the data track of the physical track number 2000 (7D0H) and the sector type is the type 6 and is constructed by 12 sectors/track, so that Tf=2000 (7D0H) and M=12. Therefore, the sectors of the logical block address=0 are as follows. ##EQU1##
Those sectors correspond to the sectors at the leftmost edge of the track having the physical track number 2000. Similarly, the sectors of the logical block address =100 are as follows. ##EQU2##
Those sectors correspond to the sectors of the sector number 4 of the data track having the physical track number 2008 (7D8H).
The partition command in the embodiment is strictly logical and a physical recording such as a boundary of the partition or the like is never performed on the optical card. Therefore, the partition information which has once been set can be again changed by using the partition command. That is, as used in the above example, if it is determined that 1000 tracks are sufficient for the partition 0 while the partition is divided into two types of partitions of 2000 tracks and 500 tracks and is being used, the remaining 1000 tracks can be defined as a new partition 1 and the original partition 2 can be defined as a new partition 3. In the partition command of the embodiment, it is necessary that all of the tracks belong to either one of the partitions. Therefore, in the case where only two partitions each including 500 tracks are actually needed, by defining the remaining 1500 tracks as the third partition, if a need arises, such a partition can be again newly defined as, for instance, two partitions each including 750 tracks (namely, the partition is consequently divided into four partitions as a whole) which also can be used.
On the other hand, since the partition is strictly logical, a problem occurs in the case when the partition dividing state (sector type or ECC mode) of the optical card which has actually been inserted into the recording/reproducing apparatus differs from the partition parameter of the partition command generated from the host computer. To avoid such a problem, when the partition information which has once been set does not need to be changed after that by the host computer, it is desirable to record the partition information onto the optical card. In the above example, in a default state until the partition command is generated, the sector type is set to the type 1 and the ECC mode is set to the recording mode with ECC. There fore, for instance, prior to using the optical card, the partition information to be set is recorded onto the first track in the above default state. After that, the optical card is actually used in a desired partition division state. When such a card is inserted into the information recording/reproducing apparatus at the second time, the partition information recorded on the first track is read and the partition is divided by using the partition command on the basis of the read-out partition information. Due to this, the above problem can be avoided. In the above example, since the maximum number of divisions is equal to 128, the partition parameter is set to up to 897 (=1+7×128) bytes. As in the above example, even when the partition information is recorded onto the optical card, one track of the sector type 1 is merely consumed.
In the partition parameter shown in the above embodiment, the partition range has been defined by the first physical track number and the number of physical tracks included in the partition. However, the partition range also can be defined by the first physical track number and the last physical track number. The number of user bytes per sector of the sector type used in the embodiment and the number of sectors per track are not limited to the above values but also can be set to arbitrary numbers.
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Either one of recording or reproduction of data is effected by use of an information processing system that includes a recording/reproducing apparatus for effecting at least one of recording of data on or reproduction of data from a recording medium on which a plurality of tracks are provided, a controller for controlling the recording/reproducing apparatus and a host computer connected to the controller via a small computer interface. A partition command is sent from the host computer to the controller through the small computer interface so that the data tracks are divided into a plurality of logical partitions to designate the sector size to be used in each partition. The parameters for the partition division and the sector size are stored in the memory in the controller on the basis of the partition command signal sent from the host computer. A selection command for designating either one of the divided partitions is sent from the host computer to the controller via the small computer interface. The controller controls the information recording/reproducing apparatus so as to effect either one of recording of data on or reproduction of data from the data track in the partition designated by the selected command according to the parameters stored in the memory.
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[0001] This application is a continuation-in-part of application Ser. No. 14/054,049, filed on Oct. 15, 2013, which is a continuation of application Ser. No. 13/162,691, filed on Jun. 17, 2011, which claims the benefit of U.S. Provisional Patent Application No. 61/356,325, filed on Jun. 18, 2010.
BACKGROUND OF THE INVENTION
[0002] The present invention is related to an electronic brake stroke monitor for a vehicle brake. More specifically, the present invention is related to an electronic brake stroke monitor of an air disc brake for use on a heavy duty truck, transit bus or similar commercial vehicle.
[0003] The number of miles traveled by heavy-duty trucks and passenger busses increases significantly every year. Because the size of passenger cars being driven has become smaller due to the increased price of gasoline, it has become increasingly necessary to ensure the proper performance of brake actuators and brake systems of these heavy-duty vehicles to provide the truck operator every opportunity to avoid a loss of control. Therefore, various systems have been developed to monitor the stroke of a brake actuator for use on drum brakes widely used in industrial trucking.
[0004] However, on heavy-duty passenger vehicles, such as, for example, busses, the use of air disc brakes is becoming more popular. While broad based monitoring has been achieved for drum brakes, monitoring additional conditions known to cause unsafe driving conditions, such as, for example, low brake pad clearance has not been achieved.
[0005] Brake monitoring systems used on air drum brakes are directed toward monitoring the length of stroke of a pushrod projecting from inside a chamber of the brake actuator. The monitoring enables the user to determine if the brake actuator is functioning properly, is subject to an over-stroke condition, or is subject to a hanging or dragging brake condition. Monitoring these conditions by monitoring the stroke of the pushrod is possible because the pushrod of the brake actuator is fixedly attached to the actuation device of the drum brake. In the case of a hanging or dragging brake, the actuation device of the drum brake is immobilized in an actuated position preventing the pushrod from returning to an un-actuated position when the brake pedal is released by the vehicle operator.
[0006] However, the pushrod of an air disk brake actuator is not fixedly attached to the lever arm of a caliper that actuates the disk brake. Therefore, should a hanging or dragging brake condition occur, the lever arm becomes separated from the pushrod rendering the type of monitoring system used on a drum brake non-functional for a disk brake. An electronic sensor that monitors the stroke of the pushrod senses that the pushrod has returned to its un-actuated position and incorrectly senses that the brake is operating normally. Therefore, it has become necessary to develop a vehicle brake monitoring assembly that is capable of identifying and distinguishing between an over-stroke condition and a hanging brake condition of an air disk brake.
SUMMARY OF THE INVENTION
[0007] A vehicle brake monitor assembly for an air disk brake includes a brake actuator having a pushrod projecting from inside a chamber of the brake actuator. The pushrod releasably actuates a lever arm of the caliper moving the disk brake into braking position when the pushrod is disposed in an extended position and releases the disk brake from the braking position when the pushrod is disposed in a retracted position. The pushrod includes a pushrod shaft and a contact member biased in a telescoping relationship relative to the pushrod shaft. The lever arm of the caliper abuts the contact member and counteracts the bias of the contact member preventing the contact member from telescoping from the pushrod shaft. A sensor is integrated with the assembly proximate the contact member. The sensor detects movement of the pushrod relative to the lever arm and the pushrod shaft.
[0008] The sensor that is positioned proximate the contact member detects differences in transmission along a length of the contact member that enables the determination of the condition of the brake actuator. For example, the sensor detects when the brake is operating in a normal condition, is subject to a dragging brake condition, is subject to an over stroke condition, or subject to an out of adjustment condition. As set forth above, prior attempts to monitor all these conditions on an air disk brake have proven futile. In particular, prior monitoring devices have been unable to identify a hanging brake condition due to separation between the pushrod and a lever arm of the air disk brake. This separation results when the lever arm is immobilized in an actuated position and a vehicle operator releases a brake pedal causing the pushrod to retract into the brake actuator. The telescoping design of the present invention allows the sensor to detect when the lever arm is immobilized in an actuated position.
[0009] A further benefit of the present inventive assembly is its use with a conventional brake caliper without modification to the caliper. Prior attempts to monitor air disk brake systems require modifying the brake caliper in an attempt to determine if the lever arm is immobilized in an actuated position. By providing a sensor pack proximate the pushrod of the actuator, the inventive assembly has eliminated the need to modify the caliper of an air disk brake system, to detect a dragging brake condition.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] Other advantages of the present invention will be readily appreciated as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein:
[0011] FIG. 1 shows a side sectional view of the brake monitoring assembly of the present invention;
[0012] FIG. 2 a shows a first embodiment of the pushrod of the present invention;
[0013] FIG. 2 b shows an alternative embodiment of the pushrod of the present invention;
[0014] FIG. 3 shows an expanded view of the pushrod of the present invention;
[0015] FIG. 4 shows the brake actuator in an extended position in a normal operating condition;
[0016] FIG. 5 shows a partial sectional view of the brake actuator in an over stroke condition; and
[0017] FIG. 6 shows the brake actuator of the present invention having a hanging or dragging brake condition.
DETAILED DESCRIPTION OF THE INVENTION
[0018] A brake actuator is shown generally at 10 in FIG. 1 . The brake actuator 10 includes a brake monitor assembly 12 for determining if the brake actuator is functioning in a normal condition or a fault condition as will be explained further hereinbelow. The brake actuator 10 includes a pushrod 14 disposed inside a service chamber 16 . It should be understood by those skilled in the art that the service chamber 16 can also be used in cooperation with a secondary chamber or power spring chamber (not shown), and various other brake activator configurations, as might be necessary for a given vehicle braking system.
[0019] The service chamber 16 includes a diaphragm 18 that is secured between an upper housing member 20 and a lower housing member 22 . Therefore, the service chamber 16 is separated by the diaphragm 18 into a pressure side 24 (best seen in FIG. 4 ) and a return side (non-pressure) 26 which houses a return spring 28 . Pressurized air enters the pressure side 24 of the service chamber 16 through air pressure port 30 , the pressure of which is monitored by pressure sensor 32 . Although the pressure sensor 32 is shown proximate the service chamber 16 , it is contemplated by the inventors that the pressure sensor 32 is located at the treadle valve (brake pedal) of the vehicle. It should be understood to those of ordinary skill in the art that each embodiment also includes a separate pressure sensor (not shown) located at the brake pedal to identify pressure being applied by the vehicle operator to the brake pedal. When the operator actuates the brake pedal, pressurized air passes through the air pressure port 30 forcing the diaphragm 18 against the pushrod 14 causing the pushrod 14 to extend outwardly from the service chamber 16 in a known manner.
[0020] When the vehicle operator depresses the brake pedal, as set forth above, air pressure enters the pressure side 24 of the service chamber 16 through the air pressure port 30 forcing the pushrod 14 outwardly from the service chamber. A lever arm 34 disposed inside a caliper 36 is pivoted by the pushrod 14 , when extending outwardly, causing the brakes (not shown) of the vehicle to actuate in a known manner. When the vehicle operator removes pressure from the brake pad, air is vented from the pressure side 24 of the service chamber 16 and the return spring 28 forces the pushrod 14 inwardly of the service chamber 16 allowing the lever arm 34 to return to its unactuated position. It should be understood by those of skill in the art, that the caliper 36 described above functions in a normal manner.
[0021] Referring now to FIG. 2A , the pushrod 14 includes a contact member 38 that circumscribes a pushrod shaft 40 . The contact member 38 defines a terminal end 41 that abuts the lever arm 34 of the caliper 36 . The pushrod shaft 40 is received in a tubular opening 42 defined by the contact member 38 . An adjustment shim 44 is disposed at a base 46 of the tubular opening 42 and is sandwiched between a shaft stop 48 of the pushrod shaft 40 and the base 46 . The adjustment shim 44 is provided in a plurality of thicknesses from which the length of the pushrod 14 is adjusted to provide dimensional accuracy between terminal end 41 of contact member 38 and lever arm 34 as will become more evident below.
[0022] The pushrod shaft 40 defines an elongated opening 50 , which receives a biasing member 52 shown here in the form of a spring. The biasing member 52 is compressed between a floor 53 and a terminal wall 54 of the elongated opening 50 . Therefore, the biasing member 52 provides a biasing force that telescopes the contact member 38 from the pushrod shaft 40 , affectively lengthening the pushrod 14 .
[0023] The pushrod shaft 40 defines a circumscribing groove 56 into which a retaining member 58 that is fixedly attached to an inner wall 60 of the tubular member 42 is received. The retaining member 58 slides in an axial direction defined by the pushrod shaft 40 within an expanse of the groove 56 . A stop 62 prevents the biasing member 52 from separating the contact member 38 from the pushrod shaft 40 when abutted by the retaining member 58 . The stop 62 takes the form of a spring clip or equivalent received by a notch 63 ( FIG. 3 ) in the pushrod shaft 40 .
[0024] A sensor element 64 is sandwiched between the service chamber 16 and the caliper 36 . A sensor 66 is disposed inside the sensor element 64 and is provided sensing access to the contact member 38 , which is received through an opening 68 in the sensor element 64 . The sensor 66 communicates through communication line 70 with a controller or central processing unit 72 . The sensor 66 is contemplated by the inventors to take the form an optical sensor, a magnetic sensor, a mechanical sensor, or a radio frequency enhanced sensor. For clarity, however, the following description will describe an optical sensor, further contemplated to be an infrared sensor. The exemplary embodiment makes use of an Optek infrared optical OPB733TR sensor capable of both transmitting an infrared signal and receiving a reflected infrared input. However, it should be understood by those of skill in the art, that any of the sensors explained above are operable. As best represented in FIG. 2 a , the contact member 38 defines a non-reflective surface 74 , a semi-reflective surface 76 , and a fully reflective surface 78 .
[0025] As best seen in FIG. 1 , a sealing boot 80 seals to the pushrod shaft 40 at an upper end and to the sensor element 64 at an opposite end. Therefore, the contact member 38 , and the non-reflective, semi-reflective, and fully reflective surfaces 74 , 76 , 78 are protected from environmental contamination that is known to enter the service chamber 16 . A secondary seal 82 seals the sensor element 64 to the caliper 36 , which is fully enclosed to protect the lever arm 34 from environmental contamination. Therefore, the contact member 38 and the sensor 66 are completely protected from the environment, preventing the optical sensor 66 and the reflective surfaces 74 , 76 , 78 from becoming fouled.
[0026] An alternative embodiment is shown in FIG. 2 b where common elements have the same numbers as those elements disclosed in FIG. 2 a . The alternative embodiment makes use of an alternative contact member 84 and a linear sensor 86 . The alternative contact member 84 includes an alternative reflective coating 88 that has a variable reflective surface. A first end 90 of the contact member is more reflective than a second end 92 of the contact member with a gradual transition in between. The sensor detects the variation in the amount of reflectivity to determine the location of the alternative contact member 84 , and therefore the lever arm 34 as will become more evident in the description below.
[0027] The sequence of brake monitoring will now be described. It is contemplated by the inventors that the sensor 66 takes the form of an infrared sensor that transmits an infrared signal toward the contact member 38 which has varying degrees of reflectivity as described above to reflect the infrared signal back toward the sensor 66 , which in turn signals the controller 72 the degree of reflectivity via communication lines 70 . It should be understood to those of skill in the art that other optical sensors may be used, including photoelectric digital lasers, ordinary lasers, and equivalents.
[0028] During normal operation, when the brake is released (shown in FIG. 1 ), the optical sensor transmits a light signal toward the non-reflective surface 74 of the contact member 38 receiving no reflective signal from the contact member 38 . The brake application pressure, as indicated by the pressure sensor 32 , is less than or equal to about 2 psi. Therefore, no active fault is signaled to the vehicle operator.
[0029] Referring now to FIG. 4 , pressure is applied to the brake pedal by the operator causing air to fill the pressure side 24 of the service chamber 16 to actuate the lever arm 34 . Because the pushrod 14 is forced outwardly from the service chamber 16 by the diaphragm 18 , the sensor 66 is positioned proximate the semi-reflective surface 76 of the contact member 38 . The pressure sensor 32 signals air pressure of greater than or equal to about 2 psi indicating normal operation of the brake actuator 10 so long as the sensor 66 detects reflectivity from the semi-reflective surface 76 . It is contemplated by the inventors that the semi-reflective surface 76 reflects about thirty percent of the light transmitted from the sensor 66 . It should be noted that the biasing member 52 remains fully compressed because the lever arm 34 counteracts the biasing force of the biasing member 52 during normal, activated condition.
[0030] FIG. 5 shows an overstroke condition causing the controller 72 to signal the operator that a fault condition exists. In the overstroke condition, the pushrod 14 extends outwardly of the service chamber 16 beyond normal extension length so that the sensor 66 transmits light to the fully reflective surface 78 and detects a full reflectivity. The brake pressure, as detected by the pressure sensor 32 , is greater than or equal to about 2 psi. Therefore, the sensor 66 signals the controller 72 full reflectivity with normal application pressure causing the controller to signal an over stroke condition to the operator.
[0031] FIG. 6 represents a dragging brake condition. The dragging brake condition is identified by the controller 72 both when the vehicle is moving at road speed and when the vehicle is not moving at road speed. In the dragging brake condition, air pressure has been released from the pressure side 24 of the service chamber 16 causing the return spring 28 to retract the pushrod 14 into the service chamber 16 . However, because the brake is now subject to a dragging condition, the lever arm 34 is retained in the actuated position causing separation with the contact member 38 . Because the lever arm 34 is no longer counteracting the biasing force of the biasing member, the biasing member 52 causes the contact member 38 to telescope from the pushrod shaft 40 . Therefore, the sensor 66 now transmits light toward the semi-reflective surface 76 of the contact member 38 as opposed to transmitting light toward the non-reflective surface 74 as is typical of a normally functioning brake. Because the pressurized air has been vented from the pressure side 24 of the service chamber 16 , the brake application pressure now reads less than or equal to about 2 psi. The combination of the semi-reflective surface 76 being detected by the sensor 66 and the low air pressure of less than or equal to about 2 psi causes the controller 72 to indicate a dragging or hanging brake condition.
[0032] A further fault condition is indicated when the sensor 66 detects the non-reflective surface 74 when the brake pedal is depressed by the operator causing an air pressure reading of greater than or equal to about 12 psi. In this instance, the controller signals a non-functioning actuator condition to the operator.
[0033] Calipers used in heavy duty truck applications are typically self-adjusting to maintain a consistent running clearance between the brake pads and the rotor as the brake pad wears down. When functioning properly, the self-adjusting caliper adjusts to maintain consistent clearance as the brake pads wear over time. The self-adjusting caliper is known to malfunction and create an out of adjustment condition where the clearance between the brake pads and the rotor is less than desirable, e.g. less than 0.6 mm. In this situation, a normal use of the brake system causes faster brake pad wear, unwanted heat generation resulting in fires, or other issues.
[0034] An out of adjustment or low lining brake clearance condition can be detected by the controller 72 . For example, pressure is applied to the brake pedal by the operator causing air to fill the pressure side 24 of the service chamber 16 to actuate the lever arm 34 . Because the pushrod 14 is forced outwardly from the service chamber 16 by the diaphragm 18 , the sensor 66 is positioned proximate the semi-reflective surface 76 of the contact member 38 . The pressure sensor 32 signals air pressure of greater than or equal to about 2 psi indicating normal operation of the brake actuator 10 so long as the sensor 66 detects reflectivity from the semi-reflective surface 76 . As pressure continues to be applied to the brake pedal by the operator, the push-rod and lever 34 reach a hard stop because the brake pad clearance is low due to the out of adjustment condition. Depending on the severity of the out of adjustment condition, the sensor 66 may be positioned proximate the crossover point between the semi-reflective surface 76 and the non-reflective surface 74 . In this position, as normal variations in pressure occur the position of the sensor 66 will dither between the semi-reflective surface 76 and the non-reflective surface 74 . The combination of dithering and normal air pressure readings causes the controller 72 to indicate an out of adjustment condition. Variations in pressure occur even when the operator attempts to maintain a constant brake pedal position.
[0035] False positive out of adjustment signals are reduced by triggering an out of adjustment condition in response to a pre-defined number of pre-cursor out of adjustment faults in combination with a pre-defined number of non-function faults. A pre-cursor fault counter is used to detect the number of dithers between the semi-reflective zone 76 and the non-reflective zone 74 within an ignition cycle. A non-function fault counter is used to detect the number of non-function faults within a controller 72 power cycle. In this embodiment, an out of adjustment condition is identified after a pre-defined number of pre-cursor out of adjustment conditions and a pre-defined number of non-functioning faults are detected. For example, in one embodiment, two pre-cursor out of adjustment faults and two non-function faults trigger an out of adjustment condition.
[0036] As set forth above, instead of being non-reflective, semi-reflective, and fully reflective surfaces 74 , 76 , 78 , the surfaces include other pre-defined indicia capable of transmitting light to identify the amount of extension of the pushrod 14 . For example, in one embodiment, the surface 76 is a fully reflective surface, while the surfaces 74 and 78 are both non-reflective. In this way, the sensor 66 can provide a binary signal. In such an embodiment, the controller determines there is a fault condition, but additional logic may be implemented to determine the specific fault condition. When the sensor detects a non-reflective surface 74 or 78 during normal brake application pressures and the sensor never detects fully reflective surface 76 , then the controller 72 determines the non-reflective surface 74 was detected and the fault is a non-functioning brake fault. When the sensor detects a reflective surface 76 followed by a non-reflective surface 74 or 76 during normal brake application pressures, the controller 72 determines the fault condition is either an over-stroke condition or an out of adjustment condition. In one embodiment, the over-stroke condition and out of adjustment condition is distinguished by monitoring the return stroke of the pushrod. If the sensor detects the fully reflective surface 76 as the pressure falls to the resting pressure, then the controller 72 determines the non-reflective surface 76 was detected and the fault is an over-stroke fault. If the sensor does not detect the fully reflective surface 76 as the pressure falls, then the controller determines the non-reflective surface 74 was detected and the fault is an out of adjustment condition.
[0037] The invention has been described in an illustrative manner, and it is to be understood that the terminology that has been used is intended to be in the nature of words of description rather than of limitation.
[0038] Obviously, many modifications and variations of the present invention are possible in light of the above teachings. For example, a hall effect or equivalent sensor can be used in combination with a magnet affixed to the contact member 38 having varying degrees of magnetism. It is therefore to be understood that within the specification, the reference numerals are merely for convenience, and are not to be in any way limiting, the invention may be practiced otherwise than is specifically described.
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A vehicle brake monitor assembly for an air disk brake includes a brake actuator having a pushrod projecting from inside a chamber of said brake actuator. The pushrod releasably actuates a lever arm of a caliper thereby moving the disk brake into a braking position when the pushrod is in an extended position and releasing the disk brake from the braking position when the pushrod is in a retracted position. The pushrod includes a pushrod shaft and a contact member biased in a telescoping relationship relative to the pushrod shaft and the lever arm of the caliper abuts the contact member counteracting the bias of the contact member. A sensor is integrated with the assembly proximate the contact member and detects movement of the pushrod relative to the lever arm and to the pushrod shaft.
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FIELD OF INVENTION
This invention is related generally to dental flossing devices and, more particularly, to a two piece dental flossing device.
DESCRIPTION OF RELATED ART
Dental flossing has long been recognized as an effective means for removing food between teeth that normal brushing is unable to reach. In addition, flossing aids in reducing plaque buildup on teeth and in preventing various gum diseases. The most common method of flossing involves wrapping a strand of dental floss around the index finger of each hand. The fingers, with a section of floss suspended between them, are inserted into the mouth cavity and the fingers are appropriately moved to cause the suspended section of floss to enter the space between adjacent teeth and manipulate the floss against the tooth surfaces.
The disadvantages of this by-hand flossing method are two-fold. First, the floss wrapped around the finger tends to cut into the skin thereby causing pain to the flosser. Second, the size of the flossers fingers may make it difficult, if not impossible, to insert and manipulate the floss between his teeth, especially those teeth located toward the back potion of the mouth cavity.
Several attempts have been made to improve upon the two-handed finger method of flossing by providing a device which enables the user to easily floss the back teeth and which does not cut into the users fingers. Flossing devices developed to date may be characterized as unitary structures which have a fixed length gap at or near the distal end of the device across which a section of floss is tautly suspended. The user manipulates the shaft of the device with one hand to cause the suspended floss to enter the space between adjacent teeth and be properly manipulated against the tooth surfaces. See, for example, one-handed flossing devices disclosed in U.S. Pat. Nos. 911,068, 1,465,669, 1733,631, 1,966,463, 4,644,469, 4,655,234, 4,574,823, 4,790,336 and 4,898,196.
However, the one-handed devices have a serious drawback in comparison to the two-handed finger method of flossing in that the floss cannot easily be controlled and manipulated. Simply put, two hands working in synchronization allow for greater control of the position and movement of the floss than can be achieved with one hand performing the same task. What is needed is a two piece dental flossing device, one piece adapted to be held in each hand of the user, allowing for greater control by the user in the insertion and manipulation of the floss between adjacent teeth.
SUMMARY OF THE INVENTION
The two piece dental flossing device of the present invention comprises a dental floss dispensing member and a dental floss wrapping member which is detachable from the floss dispensing member. The floss wrapping member includes a body potion and an extending stem. The stem includes a w-shaped notch near a distal end. The dental floss dispensing member comprises a body portion with a generally cylindrical throughbore adapted to rotatably hold a floss dispensing assembly including a spool of dental floss. The dental floss dispensing member further includes a stem extending from the body portion and having a longitudinal channel in communication with the cylindrical throughbore.
The floss dispensing assembly includes an axle supporting the spool of floss and a hub affixed to one end of the axle. The opposite end of the axle abuts a plastic retaining cap which is affixed to the floss dispensing member body portion to secure the floss dispensing assembly in the cylindrical throughbore. The hub includes locking hubs extending radially outwardly from an outer periphery of the hub. In a locked position of the floss dispenser assembly, the locking hubs are held stationary in openings in an annular rim at one end of the body portion. Floss from the spool of floss extends through the channel and exits the dispensing member near a distal end of the stem.
When the user desires to dispense a section of dental floss for flossing, the hub is pressed inwardly, the retaining cover flexes sufficiently to permit the locking hubs to move out of engagement with the annular rim openings thereby permitting the floss dispensing assembly to rotate within the floss dispensing member body portion throughbore.
To use the device, the floss wrapping member is detached from the floss dispensing member and an end portion of the floss is wrapped around the w-shaped notch portion of the floss wrapping member, the "w" shape of the notch causes the floss to cross wrap on itself as the floss is wrapped around the notch thereby causing the floss to be securely wrapped with no slippage. The user then presses the hub inwardly and pulls the wrapping member in a direction away from the dispensing member until a desired length of floss bridges the two members.
An object of this invention is to provide a two piece dental flossing device, one piece adapted to be held in each hand of the user, thereby allowing for greater control by the user in the insertion and manipulation of the floss between adjacent teeth. Another object of this invention is to provide a two piece dental flossing device which allows a user of the device to easily dispense a section of floss for flossing and has a locking mechanism to prevent any additional undesired dispensing of floss. Another object of the invention is to provide a two piece dental flossing device having extending stem portions, the distal portions of which support a dispensed section of floss and which may easily be manipulated and function as extensions of the user's fingers in flossing with the dispensed floss section. Yet another object of this invention is to provide a two piece dental flossing device that allows the user to easily reach all of his or her teeth with the dispensed section of floss including those teeth located toward the back of the mouth cavity.
The aforementioned and other aspects of the present invention are described in more detail in the detailed description and accompanying drawings which follow.
BRIEF DESCRIPTIONS OF DRAWINGS
FIG. 1 is a side elevation view of the two piece dental flossing device of the present invention;
FIG. 1A is a side elevation view of an upper portion of a dental floss wrapping member of the dental flossing device of FIG. 1;
FIG. 2 is a perspective view of the dental flossing device of FIG. 1 with a dental floss dispensing member separated from the dental floss wrapping member and a dispensed section of floss bridging the dispensing member and the wrapping member as the device would be in use;
FIG. 3 is a exploded view of the dental floss dispensing member including a dental floss dispensing assembly;
FIG. 4 is a front elevation view of the dental floss dispensing member with the floss dispensing assembly removed;
FIG. 5 is a sectional view of the floss dispensing assembly and a retaining cap with a spool of floss removed from the assembly;
FIG. 5A is an enlarged section view of an end portion of the retaining cap of FIG. 5;
FIG. 6A is a view, partly is side elevation and partly in section, of a body portion of the dental floss dispensing member with the floss dispensing assembly in a locked position; and
FIG. 6B is a view of the body potion of the dental floss dispensing member of FIG. 6A with the floss dispensing assembly in an unlocked or floss dispensing position.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The two piece dental flossing device of the present invention is shown generally at 10 in FIG. 1. The device 10 comprises two pieces or members, a dental floss dispensing member 12 and a dental floss wrapping member 14. A clip 16 is affixed to a stem 18 of the floss wrapping member 14. The clip 16 snaps onto a stem 26 of the floss dispensing member 12 and functions to releasably attach the floss wrapping member 14 and the floss dispensing member 12 when the device 10 is not in use. The floss dispensing member 12 and the floss wrapping member 14 may be fabricated from plastic or any suitable material which is lightweight, strong and inexpensive. The dispensing member 12 includes a floss cutter 19 affixed to a lower portion of the dispensing member stem 26. The cutter 19 may comprise a small piece of metal with a center portion stamped out to a form a v-shaped cutting surface at the vertex of the stamped center portion and the remaining flat metal.
FIG. 2 illustrates the device 10 in a position in which it would be used. The floss dispensing member 12 and the floss wrapping member 14 are separated and a section of floss 22 bridges the two members 12, 14. As can best be seen in FIG. 1A, the floss wrapping member 14 includes a "w" shaped notch 15 near a distal end of the stem 18. An end potion of the floss 22 extending from a stem 26 of the dispensing member 12 is wrapped around the notch 15. The shape of the notch results in cross wrapping of a portion of the floss 22 wrapped around the notch. The cross wrapping of the floss around the notch 15 provides for a secure wrapping of the floss 22 on the floss wrapping member 14. The floss wrapped around the notch will not unravel, slip or pull free as the device 10 is used to floss the user's teeth.
The floss wrapping member 14 includes a cylindrical body portion 20 extending from the stem portion 18. A thin disk 21 is disposed within a throughbore defined by the body portion 20. The floss wrapping member 14 is sized to be comfortably grasped by one hand of a user. The body portion 20 of the floss wrapping member 14 is cradled within a palm of the user's hand and the user's thumb, index and middle fingers extend a portion of the way up the stem 18. Similarly, the floss dispensing member 12 includes a body portion 24 with the stem 26 extending therefrom. The floss dispensing member 12 is sized to be comfortably grasped by the other hand of the user with the body portion 24 cradled within a pair of the user's hand and the user's thumb, index and middle fingers extending a portion of the way up the stem. When the floss dispensing and floss wrapping members 12, 14 are grasped as described, precise manipulation of the floss section 22 within the user's mouth and between the user's teeth is facilitated. In essence, the stems 26, 18 function as extensions of the user's fingers and permit precise manipulation of the floss section 22. Moreover, the stems 26, 18 provide sufficient length to permit the user to easily floss hard to reach back teeth.
With reference to FIG. 1, suitable dimensions for the device 10 are as follows:
A=21/4"
B=2"
C=3/4"
D=1/8"
E=1/4"
F=1/8"
The floss dispensing member body portion 24 includes a cylindrical throughbore 25 (FIGS. 3 and 4) extending between opposite ends 25a, 25b (FIGS. 6A and 6B) of the floss dispensing member 12. Extending inwardly into the throughbore 25 from one end 25a of the body portion 24 is a narrow rim 26, as can best be seen in FIG. 4, spaced evenly around the rim are four notches 32 cut into an inwardly facing surface 30 (FIG. 4) of the rim 26. The notches 32 function as part of a locking mechanism to be described below. A floss dispensing assembly 40 rotatably fits with the throughbore 25 of the body portion 24.
The floss dispensing assembly 40 includes a spool of dental floss 48, a plastic axle 44 supporting the spool of dental floss and a bowed plastic hub 46 extending from one end of the axle, as can best be seen in FIG. 6A. The hub 46 and axle 44 may be one integral piece as shown in FIGS. 6A and 6B or may be separate pieces affixed together with adhesive or another suitable means. As can be seen in FIG. 3, the floss 22 extends from the spool of floss 48 and is threaded through a longitudinal channel 28 through the floss dispensing member stem 26 and exits a distal end of the stem where it is available to be wrapped around the notch 15 of the floss wrapping member and/or cut by the cutter 19.
A retaining cap 42, comprised of a flexible, resiliently deformable piece of plastic, secures the floss dispensing assembly 40, in place within the body portion throughbore 25. As can best be seen in FIG. 5A, an outer rim 49 of the retaining cap 42 is "c" shaped. An outer periphery 50 of the outer rim 49 is secured to an inner periphery of the body portion 24 defining the throughbore 25. Specifically, the outer periphery 50 is secured to a portion of the inner periphery of the body potion 24 adjacent the end 25b of the body potion. The retaining cap 42 may be secured to the body portion inner periphery with adhesive, ultrasonic welding or any other suitable method. An end 51 of the axle 44 abuts a central portion of the retaining cap 42. Preferably, a central portion of the retaining cap 42 is stiffer than the outer rim 49.
The locking mechanism of the floss dispensing member 12 will now be explained. The locking mechanism includes the four locking hubs 52, the four notches of the annular rim 26 and the retaining cap 42. When the retaining cap 42 in an undeflected position (FIG. 6A), it biases the four locking nubs 52 against the inwardly facing surface 30 (FIG. 4) of the rim 26. The four hubs 52 are evenly spaced about the periphery of the hub 46 and are sized to fit in the notches 32. If the nubs 52 are not in the notches 32, when the floss 22 is pulled, the axle 44 and hub 46 will rotate a portion of turn until the nubs and notches are aligned at which point the nubs will drop into the notches and prevent the axle and hub from rotating any further. When the nubs 52 are-within the notches 32, as seen in FIG. 6A, the axle 44 and hub 46 are prevented from rotating and no floss is dispensed from the spool of floss 48. This is referred to as the locked position.
To move the hubs 52 from a locked position to an unlocked or floss dispensing position, the user presses a central portion of the hub 46 inwardly in the direction shown by the arrows labeled P in FIG. 6B with a thumb or finger of the hand holding the floss dispensing device 12. Since the retaining cap 42 is resiliently deformable, a slight pressure on the central potion of the hub 46 will cause the outer rim 49 of the cap 42 to deflect outwardly (that is, in the direction pointed to by the arrows labeled P) while still remaining attached to the inner periphery of the body portion 24. The c shaped outer rim 49 of the cap 42 deflects as shown in FIG. 6B permitting the axle 44 and hub 46 to move laterally in the direction pointed to by the arrows labeled P.
The central portion of the retaining cap 42, being stiffer than the outer rim 49, does not deflect as much as the outer rim. Thus, a slight clearance space is maintained between the spool of floss 48 and the inner face of the retaining cap even when the cap is deflected outwardly (FIG. 6B). The clearance space avoids extra friction between the spool of 48 which rotates with respect to the stationary cap 42 as the floss 22 is pulled from the floss dispensing assembly 40. However, it should be appreciated that even if the retaining cap central portion is more flexible than shown in FIG. 6B and contacts the spool of floss 48 when the cap 42 is deflected, the floss 22 will still be appropriately dispensed, that is, the fictional force between the spool of floss and the cap will not be so great as to prevent the spool from rotating with respect to the cap when the floss 22 outside the stem 26 is pulled in a direction away from the floss dispensing member 12.
As the axle 44 and hub 46 move laterally, the locking nubs 52 moves laterally out of engagement with the notches 32 as shown in FIG. 6B. As the hub 46 is pressed, the user pulls on the floss 22 in a direction away from the floss dispensing member 12. As soon as the locking hubs 52 disengage the notches 32, the axle 44 and hub 46 will rotate as shown by the arrow labeled R within the throughbore 25 because of the force applied by the user in pulling on the floss 22 and floss will be dispensed from the spool of floss 48 through the channel 28. After a desired length of floss is dispensed, the user releases pressure on the hub 46 and pulls on the floss a fraction of a turn until the locking hubs 52 engage the notches 32 and the floss dispensing assembly is again in the locked position.
To use the device 10, the user separates the two members 12, 14. An end portion of the floss 22 extending from the floss dispensing member 12 (remaining after the floss was cut off on the floss cutter 19 after the previous use of the device) is wrapped around the floss wrapping member notch 15. After wrapping a sufficient portion of floss around the notch 15 to prevent the floss from sliding off the notch 15 during use, the user depresses the hub 46 of the floss dispensing member 12 with a finger or thumb of one hand to release the locking mechanism and simultaneously pulls the floss wrapping member 14 held in the other hand in a direction away from the floss dispensing member. Floss will be pulled out from the spool of floss 48 as the floss wrapping member 14 is moved away from the floss dispensing member 12. When a desired length of floss bridges the two members 12, 14, the hub 46 is released and the floss wrapping member 14 is pulled a very short additional distance away from the floss dispensing member 12 until the locking mechanism returns to the locked position.
After use of the dispensed floss section 22 by the user to floss his or her teeth, the portion of the floss wrapped around the notch 15 is unwrapped from the notch and the used floss is cut off using the cutter 19. If a new section of floss is desired during flossing, the above described method of wrapping and dispensing may be repeated. Furthermore, if desired, a short additional amount of floss may be dispensed via the method described above before cutting the used floss off to make sure that the floss extending from the stem 26 is clean, unused floss since this floss will be used as the notch wrapping floss in the next use of the device 10. After flossing is complete, the members 12, 14 are then clipped together using the clip 16 and the device 10 is put away. The device 10 is disposable and is discarded when the spool of floss 48 is exhausted.
The present invention has been described with a degree of particularity, but it is the intent that the invention include all modifications from the disclosed preferred design failing within the spirit or scope of the appended claims.
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A two-piece dental flossing device is disclosed. The device includes a floss dispensing member and a floss wrapping member which is detachable from the floss dispensing member. The floss dispensing member comprises a body portion with a generally cylindrical throughbore adapted to hold a floss dispensing assembly including a spool of dental floss. The spool is rotated within the throughbore to release floss which extends through a channel in a stem of the floss dispensing member extending from the body portion. The two members allow for two-handed flossing and function as extensions of the fingers facilitating the flowing process.
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BACKGROUND OF THE INVENTION
The present invention relates to a processor-for transforming time domain signals into frequency domain signals, or frequency domain signals into time domain signals, by means of an orthogonal transform such as a discrete Fourier transform (hereinafter referred to as DFT), a discrete cosine transform (hereinafter referred to as DCT) or the like.
Recently, a fast and small-sized circuit for achieving an orthogonal transform is needed as an important part of a method of compressing and coding image information, audio information or the like with high efficiency. A forward orthogonal transform is required in an encoder, while an inverse orthogonal transform is required in a decoder. U.S. Pat. No. 4,791,598 discloses the inner arrangement of a one-dimensional DCT processor serving as an orthogonal transform processor. This one-dimensional DCT processor employs technique of the first stage decimation-in-frequency and technique of distributed arithmetic for obtaining vector inner products without the use of multipliers. The decimation-in-frequency is known technique for reducing the number of required multiplications in a fast Fourier transform (hereinafter referred to as FFT) which is a fast algorithm of the DFT.
More specifically, the Nx1 DCT processor in U.S. Pat. No. 4,791,598 has an input shift register and a holding register as set forth below. The input shift register comprises N input registers (each having a M-bit width) so connected in cascade to one another as to successively enter N word data which form an input vector comprising one row or column out of one block having N×N word (M bits/word) data. The holding register comprises N bit shift registers (each having a M-bit width) having (i) inputs respectively connected to the corresponding input registers of the input shift register such that the inputs receive in parallel the N word data from the input shift register each time all the N input registers of the input shift register are filled up with data, and (ii) outputs for shifting out one bit per cycle as part of an N-bit bit-slice word. These input shift register and holding register form a bit-string distribution circuit with a size of 2×N×M bits.
The N×1DCT processor in U.S. Pat. No. 4,791,598 further comprises a butterfly unit and a ROM-and-accumulator circuit (hereinafter referred to as RAC circuit) as set forth below. In order to execute the first stage decimation-in-frequency operation, the butterfly unit comprises N/2 serial adders and N/2 serial subtracters connected to the outputs of the holding register such that there are produced a pair of N/2-bit words from the N-bit bit-slice word received from the holding register. For example, there are executed butterfly operations of x1+x8, x1-x8, x2+x7, x2-x7, x3+x6, x3-x6, x4+x5, x4-x5 for a data string comprising eight data of x1, x2, x3, x4, x5, x6, x7, x8. The RAC circuit comprises N ROMs and accumulators (hereinafter referred to as RACs) connected to the output of the butterfly unit. Each of the N RACs comprises (i) at least one ROM which contains, in the form of a look-up table, the partial sums of vector inner products based on a discrete cosine matrix, and (ii) an accumulator for adding, with the digits aligned, the partial sums successively retrieved from the ROM with the bit-slice words serving as addresses. The RAC circuit forms a distributed arithmetic circuit for concurrently calculating N vector inner products using no multipliers.
The N×1DCT processor in U.S. Pat. No. 4,791,598 further comprises an output shift register as set forth below. The output shift register comprises N output registers which are so connected to the corresponding accumulators of the N RACs as to receive, in parallel, N vector inner products from the RAC circuit and which are so connected in cascade to one another as to successively supply the N vector inner products thus received.
As thus discussed, the conventional DCT processor has a large-scale circuit arrangement having a large number of registers. This produces the problem that integrated processors require large chip area.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide an orthogonal transform processor smaller in size than a conventional one.
In the orthogonal transform processor of the present invention, a first address generator operates such that data are illustratively read from a first memory in the order of x8, x1, x7, x2, x6, x3, x5, x4 for a forward orthogonal transform, and thus obtained data string is supplied to a butterfly unit. This reduces in number the registers required for a decimation-in-frequency operation for a forward orthogonal transform.
The orthogonal transform processor of the present invention employs, as a bit-string distribution circuit, a register circuit comprising illustrative eight bit shift registers each having a 16-bit parallel input and a 2-bit shift output and the bit shift registers are different in bit width from one another. This reduces the bit-string distribution circuit in size to 8×16+(14+12+. . . +2) bits from 2×8×16 bits as in the conventional bit-string distribution circuit.
In the orthogonal transform processor of the present invention, illustrative four shift registers are disposed between the bit-string distribution circuit and a RAC circuit such that, when bit strings are entered, as delayed cycle by cycle, into eight RACs of the RAC circuit, the Final accumulation results are successively provided from the RACs in the order of F8, F1, F7, F2, F6, F3, F5, F4 for an inverse orthogonal transform. Thus obtained data string for an inverse orthogonal transform is supplied to the butterfly unit. This reduces in number the registers required for a decimation-in-frequency operation for an inverse orthogonal transform.
The butterfly unit of the present invention employs three registers, one multiplexer, and one parallel adder so as to be reduced in circuit arrangement.
The arrangements above-mentioned make it possible to realize a forward-, inverse- and bi-directional orthogonal transform processor in small size, so that integrated orthogonal transform, processors require less chip area. Furthermore, the above-mentioned butterfly unit having a small-scale circuit arrangement executes butterfly operations without changing the order of input data.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram illustrating the arrangement of a bi-directional DCT processor according to a first embodiment of the present invention;
FIG. 2 is a block diagram illustrating the inner arrangement of the product-sum unit in FIG. 1;
FIG. 3 is a block diagram illustrating the inner arrangement of one of the RACs in FIG. 2;
FIG. 4 is a block diagram illustrating the inner arrangement of the butterfly unit in FIG. 1;
FIGS. 5, 6, and 7 are timing charts of forward operations of the bi-directional DCT processor in FIG. 1;
FIGS. 8, 9, and 10 are timing charts of inverse operations of the bi-directional DCT processor in FIG. 1;
FIG. 11 is a block diagram illustrating the arrangement of a forward DCT processor according to a second embodiment of the present invention; and
FIG. 12 is a block diagram illustrating an inverse DCT processor according to a third embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The following description will discuss one-dimensional DCT processors according to embodiments of the present invention with reference to the attached drawings.
First Embodiment
With reference to FIGS. 1 to 4, the following description will discuss the arrangement of a bi-directional DCT processor according to a first embodiment of the present invention.
The bi-directional DCT processor in FIG. 1 comprises a 16bit width memory 10 of 8×8 words, an ad-dress generator 20, a 16-bit width pipeline register 30, a multiplexer 40 having 16-bit width first and second inputs and a 16-bit width output, a product-sum unit 300 having a 16-bit width input and a 34-bit S width output, a 34-bit width pipeline register 190, a multiplexer 50 having a 16-bit width first input, a 34-bit width second input and a 34-bit width output, a butterfly unit 60 having a 34-bit width input and a 16-bit width output, a 16-bit width pipeline register 66, a multiplexer 200 having a 34-bit width first input, a 16-bit width second input and a 16-bit width output, a 16-bit width pipeline register 210, a 16-bit width memory 220 of 8×8 words, and an address generator 230.
In FIG. 2, the product-sum unit 300 comprises a 30-bit width bit shift register 71, a 26-bit width bit shift register 72, a 22-bit width bit shift register 73, a 18-bit width bit shift register 74, a 28-bit width bit shift register 81, a 24-bit width bit shift register 82, a 20-bit width bit shift register 83, a 16-bit width bit shift register 84, a register circuit 70 comprising the bit shift registers 71 to 74, and a register circuit 80 comprising the bit shift registers 81 to 84. Each of the bit shift registers of the register circuit 70 is arranged to shift out bits by two bits in the order from the LSB to the MSB, and each of the bit shift registers of the register circuit 80 is arranged to shift out bits by two bits in the order from the LSB to the MSB. The product-sum unit 300 further comprises a 4-bit width bus 90, a 4-bit width bus 100, a 4-bit width bus 110, and a 4-bit width bus 120. The upper bit outputs (an upper bit slice word) of all of the registers of the register circuit 70 are collected to the bus 90, the lower bit outputs (a lower bit slice word) of all of the registers of the register circuit 70 are collected to the bus 110, the upper bit outputs (an upper bit slice word) of all of the registers of the register circuit 80 are collected to the bus 100, and the lower bit outputs (a lower bit slice word) of all of the registers of the register circuit 80 are collected to the bus 120. A shift register 130 comprises seven 4-bit width registers 31 to 137, a shift register 150 comprises seven 4-bit width registers 151 to 157, a shift register 140 comprises six 4-bit width registers 141 to 146, a shift register 160 comprises six 4-bit width registers 161 to 166, a ROM and accumulator circuit (RAG circuit) 170 comprises eight RACs 171 to 178 each having 4-bit width first and second inputs and a 34-bit width output for accumulating the partial products of the bi-directional DCT according to the distributed arithmetic, and a multiplexer 180 has 34-bit width first to eighth inputs and a 34-bit width output.
In FIG. 3, the RAC 171 comprises: a ROM 311 which has positive and negative outputs and into which the upper bit slice words are entered as 4-bit width addresses from the shift register 130; a multiplexer 312 having 16-bit width first and second inputs and a 16-bit width output; a ROM 313 into which the lower bit slice words are entered as 4-bit width addresses from the shift register 150; a parallel adder 314 having 16-bit width first and second inputs, a 34-bit width third input and a 34-bit width output; a 34-bit width shift register 315; and an initial value setting device 316 disposed for the shift register 315. The ROMs 311, 313 contain, in the form of look-up tables, the partial sums of vector inner products based on discrete cosine matrices for forward and inverse DCTs. The multiplexer 312 selects one of the outputs of the ROM 811 in order to subtract the last bit slice word of the MSBs for executing two's complement operations. The parallel adder 314 and the shift register 315 form an accumulator for adding, with the digits aligned, the partial sums retrieved from the ROMs 311, 313.
In FIG. 4, the butterfly unit 60 comprises a 34-bit width register 61, a 34-bit width register 62 having positive and negative outputs, a multiplexer 63 having 34-bit width first and second inputs and a 34-bit width output, a 34-bit width register 64, and a parallel adder 65 having 34-bit width first and second inputs and a 16-bit width output.
The following description will discuss a forward DCT operation of the bi-directional DCT processor of FIG. 1 with reference to FIGS. 5 to 7. In the forward DCT, the multiplexer 40 selects the output of the pipeline register 66, the multiplexer 50 selects the output of the pipeline register 30, and the multiplexer 200 selects the output of the pipeline register 190.
The address generator 20 reads out a data string x1 to x8 in the order of x8, x1, x7, x2, x6, x3, x5, x4 per one cycle from the memory 10, and the output of the memory 10 is entered into the pipeline register 80. The output of the pipeline register 30 is selected by the multiplexer 50, which in turn outputs the data string x1 to x8 in the order of x8, x1, x7, x2, x6, x3, x5, x4 per one cycle. A data string including x5 to x8 is stored in the register 62 of the butterfly unit 60 in the order of x8, x7, x6, x5 per two cycles. Further, a data string including x1 to x4 is stored in the register 61 of the butterfly unit 60 in the order of x1, x2, x3, x4 per two cycles.
In the butterfly unit 60, a data string x5 to x8 is supplied in the order of x8, x7, x6, x5 per two cycles from the positive output of the register 62, and an inversed data string !x5 to !x8 of the data string x5 to x8 is supplied in the order of !x8, !x7, !x6, !x5 per two cycles from the negative output of the register 62. The multiplexer 63 selects alternately the data string x5 to x8 and the data string !x5 to !x8 respectively supplied from the positive and negative outputs of the register 62, in the order of x8, !x8, x7, !x7, x6, !x6, x5, !x5, and the output of the multiplexer 63 is stored in the register 64. The parallel adder 65 adds the outputs of the registers 61, 64 to supply data x1+x8, x1-x8, x2+x7, x2-x7, x3+x6, x3-x6, x4+x5, x4-x5 per one cycle, and the output of the parallel adder 65 is stored in the pipeline register 66.
The pipeline register 66 supplies data x1+x8, x1-x8, x2+x7, x2-x7, x3+x6, x3-x6, x4+x5, x4-x5, and the output of the pipeline register 66 is selected by the multiplexer 40. In the product-sum unit 300, the data x1+x8 is entered into the register 71, the data x1-x8 is entered into the register 81, the data x2+x7 is entered into the register 72, the data x2-x7 is entered into the register 82, the data x3+x6 is entered into the register 73, the data x3-x6 is entered into the register 83, the data x4+x5 is entered into the register 74, and the data x4-x5 is entered into the register 84. Thus, the data x1+x8, x2+x7, x3+x6, x4+x5 are stored in the register circuit 70, and the data x1-x8, x2-x7, x3-x6, x4-x5 are stored in the register circuit 80. At this time, the data are respectively entered, as justified on the left side, into the eight registers 71 to 74 and 81 to 84 forming the register circuits 70, 80 successively with the largest bit-width register first. Each of the eight registers shifts out two bits per cycle in the order from the LSB to the MSB. Accordingly, when the 16-bit width register 84 is filled up with the 16-bit data x4-x5, each of the data in other registers 71 to 74 and 81 to 83 is justified on the right side and all the registers 71 to 74 and 81 to 84 concurrently shift out two bits at the next cycle. When two bits out of the 16-bit data x1+x8 are shifted out from the bit width register 71, a 16-bit width blank is formed in the register 71, so that the data x1+x8 derived from the next data string can immediately be written in this blank.
In the product-sum unit 300, the bit shift registers 71 to 74 of the register circuit 70 which hold the data x1+x8, x2+x7, x3+x6, x4+x5, successively shift out the respective least significant two bits per cycle. The respective upper bits out of these least significant two bits are supplied, as an upper bit slice data string a1, a3, . . . a13, a15, to the bus 90, and the respective lower bits out of the aforementioned least significant two bits are supplied, as a lower bit slice data string a2, a4, . . a14, a16, to the bus 110. Also, in the product-sum unit 300, the bit shift registers 81 to 84 of the register circuit 80 which hold the data x1-x8, x2-x7, x3-x6, x4-x5, successively shift out the respective least significant two bits per cycle. The respective upper bits out of these least significant two bits are supplied, as an upper bit slice data string b1, b3, . . . b13, b15, to the bus 100, and the respective lower bits out of the aforementioned least significant two bits are supplied, as a lower bit slice data string b2, b4, . . . b14, b16, to the bus 120. The data string a1, a3, . . . a13, a15 supplied from the register circuit 70 is entered into the shift register 130, the data string a2, a4, . . . a14, a16 supplied from the register circuit 70 is entered into the shift register 150, the data string b1, b3, . . . b13, b15 supplied from the register circuit 80 is entered into the shift register 140, and the data string b2, b4, . . . b14, b16 supplied from the register circuit 80 is entered into the shift register 160. The data of the data string a1, a3, . . . a13, a15 entered into the shift register 130 are entered into the first input of the RAC 171 after one cycle, into the first input of the RAC 172 after three cycles, into the first input of the RAG 173 after five cycles, and into the first input of the RAC 174 after seven cycles. The data of the data string a2, a4, . . . a14, a16 entered into the shift register 150 are entered into the second input of the RAC 171 after one cycle, into the second input of the RAC 172 after three cycles, into the second input of the RAC 173 after five cycles, and into the second input of the RAC 174 after seven cycles. The data of the data string b1, b3, . . . b13, b15 entered into the shift register 140 is entered into the first input of the RAG 175 after zero cycle, into the first input of the RAC 176 after two cycles, into the first input of the RAC 177 after four cycles, and into the first input of the RAC 178 after six cycles. The data of the data string b2, b4, . . . b14, b16 entered into the shift register 160 are entered into the second input of the RAC 175 after zero cycle, into the second input of the RAC 176 after two cycles, into the second input of the RAC 177 after four cycles, and into the second input of the RAG 178 after six cycles. The RACs 171 to 174 of the RAC circuit 170 accumulate, per cycle, the partial products corresponding to the data string a1, a3, . . . a13, a15 and the data string a2, a4, . . . a14, a16 for a period of eight cycles. The RACs 175 to 178 of the RAC circuit 170 accumulate, per cycle, the partial products corresponding to the data string b1, b3, . . . b13, b15 and the data string b2, b4, b14, b16 for a period of eight cycles. As a result, the final accumulation results X1, X2, X3, X4, XS, X6, X7, X8 are supplied, per cycle, from the RAG circuit 170 in the order of RACs 175, 171, 176, 172, 177, 173, 178, 174. The multiplexer 180 selects, per cycle, the data X1, X2, X3, X4, X5, X6, X7, X8, and the output of the multiplexer 180 is entered into the pipeline register 190.
The multiplexer 200 selects the output of the pipeline register 190, and the output of the multiplexer 200 is entered into the next-stage pipeline register 210. The data X1, X2, X3, X4, X5, X6, X7, X8 are entered, per cycle, into the memory 220 and the address generator 230 generates addresses such that the data X1, X2, X3, X4, X5, X6, X7, X8 are stored by continuous addresses in the memory 220.
The aforementioned operations are carried out for eight rows in a pipelined fashion to achieve a forward one-dimensional DCT.
The following description will discuss an inverse DCT operation of the bi-directional DCT processor of FIG. 1 with reference to FIGS. 8 to 10. In the inverse DCT, the multiplexer 40 selects the output of the pipeline register 30, the multiplexer 50 selects the output of the pipeline register 190, and the multiplexer 200 selects the output of the pipeline register 66.
The address generator 20 reads out a data string X1 to X8 in the order of X1, X2, X3, X4, X5, X6, X7, X8 per one cycle from the memory 10, and the output of the memory 10 is entered into the pipeline register 30. The pipeline register 30 supplies the data X1, X2, X3, X4, X5, X6, X7, X8. The output of the pipeline register 30 is selected by the multiplexer 40. In the product-sum unit 300, the data X1 is entered into the register 71, the data X2 is entered into the register 81, the data X3 is entered into the register 72, the data X4 is entered into the register 82, the data X5 is entered into the register 73, the data X6 is entered into the register 83, the data X7 is entered into the register 74, and the data X8 is entered into the register 84. Thus, the data X1, X3, X5, X7 are stored in the register circuit 70, and the data X2, X4, X6, X8 are stored in the register circuit 80.
In the product-sum unit 300, the bit shift registers 71 to 74 of the register circuit 70 which hold the data X1, X3, X5, X7, successively shift out the respective least significant two bits per cycle. The respective upper bits out of these least significant two bits are supplied, as an upper bit slice data string A1, A3, . . . A13, A15, to the bus 90, and the respective lower bits out of the aforementioned least significant two bits are supplied, as a lower bit slice data string A2, A4, . . . A14, A16, to the bus 110. Also, in the product-sum unit 300, the bit shift registers 81 to 84 of the register circuit 80 which hold the data X2, X4, X6, X8, successively shift out the respective least significant two bits per cycle. The respective upper bits out of these least significant two bits are supplied, as an upper bit slice data string B1, B3, . . . B13, B15, to the bus 100, and the respective lower bits out of the aforementioned east significant two bits are supplied, as a lower bit slice data string B2, B4, . . . B14, B16, to the bus 120. The data string A1, A3, . . . A13, A15 supplied from the register circuit 70 is entered into the shift register 130, the data string A2, A4, . . . A14, A16 supplied from the register circuit 70 is entered into the shift register 150, the data string B1, B3, . . . B13, B15 supplied from the register circuit 80 is entered into the shift register 140, and the data string B2, B4, . . . B14, B16 supplied from the register circuit 80 is entered into the shift register 160. The data of the data string A1, A3, . . . A13, A15 entered into the shift register 130 are entered into the first input of the RAC 171 after one cycle, into the first input of the RAG 172 after three cycles, into the first input of the RAG 173 after five cycles, and into the first input of the RAC 174 after seven cycles. The data of the data string A2, A4, . . . A14, A16 entered into the shift register 150 are entered into the second input of the RAC 171 after one cycle, the second input of the RAC 172 after three cycles, into the second input of the RAG 173 after five cycles, and into the second input of the RAG 174 after seven cycles. The data of the data string B1, B3, . . . B13, B15 entered into the shift register 140 are entered into the first input of the RAG 175 after zero cycle, into the first input of. the RAC 176 after two cycles, into the first input of the RAG 177 after four cycles, and into the first input of the RAC 178 after six cycles. The data of the data string B2, B4, B14, B16 entered into the shift register 160 are entered into the second input of the RAC 175 after zero cycle, into the second input of the RAC 176 after two cycles, into the second input of the RAC 177 after four cycles, and into the second input of the RAC 178 after six cycles. The RACs 171 to 174 of the RAG circuit 170 accumulate, per cycle, the partial products corresponding to the data string A1, A3, . . . A13, A15 and the data string A2, A4, . . . A14, A16 for a period of eight cycles. The RACs 175 to 178 of the RAC circuit 170 accumulate, per cycle, the partial products corresponding to the data string B1, B3, . . . B13, B15 and the data string B2, B4, . . . B14, B16 for a period of eight cycles. As a result, the final accumulation results F2, F1, F4, F3, F6, F5, F8, F7 are supplied, per cycle, from the RAC circuit 170 in the order of the RACs 175, 171, 176, 172, 177, 173, 178, 174. The multiplexer 180 selects, per cycle, the data F2, F1, F4, F3, F6, F5, F8, F7, and the output of the multiplexer 180 is entered into the pipeline register 190.
The output of the pipeline register 190 is selected by the multiplexer 50, which in turn outputs the data string F1 to F8 in the order of F2, F1, F4, F3, F6, F5, F8, F7 per one cycle. The data F2, F4, F6, F8 are stored in the register 62 of the butterfly unit 60 per two cycles, and the data F1, F3, F5, F7 are stored in the register 61 of the butterfly unit 60 per two cycles.
In the butterfly unit 60, the data F2, F4, F6, F8 are supplied per two cycles from the positive output of the register 62, and the inversed data !F2, !F4, !F6, !F8 of the data F2, F4, F6, F8 are supplied in this order per two cycles from the negative output of the register 62. The multiplexer 63 selects alternately the data string F2, F4, F6, F8 and the data string !F2, !F4, !F6, !F8 respectively supplied from the positive and negative outputs of the register 62, in the order of !F2, F2, !F4, F4, !F6, F6, !F8, F8, and the output of the multiplexer 63 is stored in the register 64. The parallel adder 65 adds the outputs of the registers 61, 64 to supply data x8=F1-F2, x1=F1+F2, x7=F3-F4, x2=F3+F4, x6=F5-F6, x3=F5+F6, x5=F7-F8, x4=F7+F8 per one cycle, and the output of the parallel adder 65 is stored in the pipeline register 66.
The multiplexer 200 selects the output of the pipeline register 66, and the output of the multiplexer 200 is entered into the next-stage pipeline register 210. The data x8, x1, x7, x2, x6, x3, x5, x4 are entered, per cycle, into the memory 220 and the address generator 250 generates addresses such that the data x1, x2, x3, x4, x5, x6, x7, x8 are stored by continuous addresses in the memory 220.
The aforementioned operations are carried out for eight rows in a pipelined fashion to achieve an inverse one-dimensional DCT.
Second Embodiment
As shown in FIG. 11, a forward DCT processor according to a second embodiment of the present invention has an arrangement similar to that shown in FIG. 1 except for the following points. In the second embodiment, there are not disposed three pipeline .registers 30, 66, 190 and three multiplexers 40, 50, 200 in FIG. 1, the output of a memory 10 is connected directly to the input of a butterfly unit 60, the output of the butterfly unit 60 is connected directly to the input of a product-sum unit 800 and the output of the product-sum unit 800 is connected directly to a pipeline register 210. The second embodiment employs a bit width suitable for the operational precision of a forward DCT. That is, the input of the butterfly unit 60 has a 16-bit width and the output of the product-sum unit 300 has also a 16-bit width. A RAC circuit 170 stores the partial sums of vector inner products solely for a forward DCT.
The operation of the forward DCT processor in FIG. 11 will be apparent from the aforementioned description of the forward DCT operation in connection with the bi-directional DCT processor in FIG. 1.
Third Embodiment
As shown in FIG. 12, an inverse DCT processor according to a third embodiment of the present invention has an arrangement similar to that shown in FIG. 1 except for the following points. In the third embodiment, there are not disposed three pipeline registers 30, 66,190 and three multiplexers 40, 50, 200 in FIG. 1, the output of a memory 10 is connected directly to the input of a product-sum unit 300, the output of the product-sum unit 300 is connected directly to the input of a butterfly unit 60 and the output of the butterfly unit 60 is connected directly to a pipeline register 210. In the third embodiment, each of the output of the product-sum unit 300 and the input of the butterfly unit 60 has a 34-bit width. A RAG circuit 170 stores the partial sums of vector inner products solely for an inverse DCT.
The operation of the inverse DCT processor in FIG. 12 will be apparent from the aforementioned description of the inverse DCT operation in connection with the bi-directional DCT processor in FIG. 1.
Each of the first to third embodiments has been described in terms of the DCT. However, the present invention may be applicable in other orthogonal transforms.
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The output of a butterfly unit is entered into a product-sum unit in a forward DCT and the output of the product-sum unit is entered into the butterfly unit in an inverse DCT. The product-sum unit employs, as a bit-string distribution circuit, a register circuit having eight bit shift registers each having a 16-bit parallel input and a 2-bit shift output and the bit shift registers are different in bit width from one another. Data are entered into the bit shift registers with the largest bit-width bit shift register first, such that the respective bit shift registers are shifted rightward by 2 bits per cycle. Four shift registers are disposed between the bit-string distribution circuit and a RAG circuit such that, when bit strings are entered, as delayed cycle by cycle, into eight RAGs of the RAC circuit, the final accumulation results are successively provided from the RACs in a proper order. This reduces the bi-directional DCT processor in circuit arrangement.
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This application claims priority from provisional U.S. application Ser. No. 60/007,032, filed Oct. 11, 1995.
FIELD OF THE INVENTION
This invention relates to endothelin antagonists useful, inter alia, for treatment of hypertension.
BRIEF DESCRIPTION OF THE INVENTION
Compounds of the formula ##STR3## its enantiomers and diastereomers, and pharmaceutically acceptable salts thereof are endothelin receptor antagonists useful, inter alia, as antihypertensive agents. Throughout this specification, the above symbols are defined as follows:
one of X and Y is N and the other is O; ##STR4## R 2 and R 3 are each independently (a) hydrogen;
(b) alkyl, alkenyl, alkynyl, alkoxy, cycloalkyl, cycloalkylalkyl, cycloalkenyl, cycloalkenylalkyl, aryl, aryloxy, aralkyl or aralkoxy, any of which may be substituted with Z 1 , Z 2 and Z 3 ;
(c) halo;
(d) hydroxyl;
(e) cyano;
(f) nitro;
(g) --C(O)H or --C(O) R 6 ;
(h) --CO 2 H or --CO 2 R 6 ;
(i) --SH, --S(O) n R 6 , --S(O) m --OH, --S(O) m --OR 6 , --O--S(O) m --R 6 , --O--S(O) m OH or --O--S(O) m OR 6 ;
(j) --Z 4 --NR 7 R 8 ; or
(k) --Z 4 --N(R 11 )--Z 5 --NR 9 R 10 ;
R 4 and R 5 are each independently
(a) hydrogen;
(b) alkyl, alkenyl, alkynyl, alkoxy, cycloalkyl, cycloalkylalkyl, cycloalkenyl, cycloalkenylalkyl, aryl, aryloxy, aralkyl or aralkoxy, any of which may be substituted with Z 1 , Z 2 and Z 3 ;
(c) halo;
(d) hydroxyl;
(e) cyano;
(f) nitro;
(g) --C(O)H or --C(O)R 6 ;
(h) --CO 2 H or --CO 2 R 6 ;
(i) --SH, --S(O) n R 6 , --S(O) m --OH, --S(O) m --OR 6 , --O--S(O) m --R 6 , --O--S(O) m OH or --O--S(O) m --OR 6 ;
(j) --Z 4 --NR 7 R 8 ;
(k) --Z 4 --N(R 11 )--Z 5 --NR 9 R 10 ; or
(l) R 4 and R 5 together are alkylene or alkenylene, either of which may be substituted with Z 1 , Z 2 and Z 3 , completing a 4- to 8-membered saturated, unsaturated or aromatic ring together with the carbon atoms to which they are attached;
R 6 is alkyl, alkenyl, alkynyl, cycloalkyl, cycloalkylalkyl, cycloalkenyl, cycloalkenylalkyl, aryl or aralkyl, any of which may be substituted with Z 1 , Z 2 and Z 3 ;
R 7 , R 8 , R 9 , R 10 and R 11 are each independently
(a) hydrogen; or
(b) alkyl, cycloalkyl, cycloalkylalkyl, cycloalkenylalkyl, aryl or aralkyl, any of which may be substituted with Z 1 , Z 2 and Z 3 ;
R 7 and R 8 together may be alkylene or alkenylene, either of which may be substituted with Z 1 , Z 2 and Z 3 , completing a 3- to 8-membered saturated or unsaturated ring together with the nitrogen atom to which they are attached;
any two of R 9 , R 10 and R 11 together may be alkylene or alkenylene, either of which may be substituted with Z 1 , Z 2 and Z 3 , completing a 3- to 8-membered saturated or unsaturated ring together with the atoms to which they are attached;
G 1 is
(a) hydrogen; or
(b) alkyl;
G 2 is
(a) hydroxyalkyl;
(b) --(CH 2 ) m OR 6 ; or
(c) --(CH 2 ) m --NR 12 R 13 ;
(d) mono-to hexa-halo substituted alkyl (i.e., alkyl substituted with one, two, three, four, five or six halogen atoms); or
(e) --(CH 2 ) n OR 14 ;
R 12 and R 13 are each independently
(a) hydrogen; or
(b) alkyl, cycloalkyl, cycloalkylalkyl, cycloalkenylalkyl, aryl or aralkyl, any of which may be substituted with Z 1 , Z 2 and Z 3 ; or
R 12 and R 13 together may be alkylene or alkenylene, either of which may be substituted with Z 1 , Z 2 and Z 3 , completing a 3- to 8-membered saturated or unsaturated ring together with the nitrogen atom to which they are attached, or, together with the nitrogen atom to which they are attached form ##STR5## R 14 is lower alkyl substituted with 1, 2 or 3 halogen atoms; Z 1 , Z 2 and Z 3 are each independently
(a) hydrogen;
(b) halo;
(c) hydroxy;
(d) alkyl;
(e) alkenyl;
(f) aralkyl;
(g) alkoxy;
(h) aryloxy;
(i) aralkoxy;
(j) --SH, --S(O) n Z 6 , --S(O) m --OH, --S(O) m --OZ 6 , --O--S(O) m --Z 6 , --O--S(O) m OH or --O--S(O) m --OZ 6 ;
(k) oxo;
(l) nitro;
(m) cyano;
(n) --C(O)H or --C(O)Z 6 ;
(o) --CO 2 H or --CO 2 Z 6 ;
(p) --Z 4 --NZ 7 Z 8 ;
(q) --Z 4 --N(Z 11 )--Z 5 --H;
(r) --Z 4 --N(Z 11 )--Z 5 --Z 6 ; or
(s) --Z 4 --N(Z 11 )--Z 5 --NZ 7 Z 8 ;
Z 4 and Z 5 are each independently
(a) a single bond;
(b) --Z 9 --S(O) n --Z 10 --;
(c) --Z 9 --C(O)--Z 10 --;
(d) --Z 9 --C(S)--Z 10 --;
(e) --Z 9 --O--Z 10 --;
(f) --Z 9 --S--Z 10 --;
(g) --Z 9 --O--C(O)--Z 10 --; or
(h) --Z 9 --C(O)--O--Z 10 --;
Z 6 is alkyl, alkenyl, alkynyl, cycloalkyl, cycloalkylalkyl, cycloalkenyl, cycloalkenylalkyl, aryl or aralkyl;
Z 7 and Z 8 are each independently hydrogen, alkyl, cycloalkyl, cycloalkylalkyl, cycloalkenylalkyl, aryl or aralkyl, or Z 7 and Z 8 together are alkylene or alkenylene, completing a 3- to 8-membered saturated or unsaturated ring together with the nitrogen atom to which they are attached;
Z 9 and Z 10 are each independently a single bond, alkylene, alkenylene or alkynylene;
Z 11 is
(a) hydrogen; or
(b) alkyl, cycloalkyl, cycloalkylalkyl, cycloalkenylalkyl, aryl or aralkyl;
or any two of Z 7 , Z 8 and Z 11 together are alkylene or alkenylene, completing a 3- to 8-membered saturated or unsaturated ring together with the atoms to which they are attached;
each m is independently 1 or 2; and
each n is independently 0, 1 or 2.
For compound I, it is preferred that:
R 2 and R 3 are each independently hydrogen or alkyl;
R 4 and R 5 are each independently alkyl; and
R 12 and R 13 , together with the nitrogen atom to which they are attached, form ##STR6##
Most preferred compounds are those wherein:
R 2 and R 3 are each hydrogen; and
R 4 and R 5 are each alkyl of 1 to 4 carbon atoms, especially methyl.
DETAILED DESCRIPTION OF THE INVENTION
Listed below are definitions of terms used in this specification. These definitions apply to the terms as used throughout this specification, individually or as part of another group, unless otherwise limited in specific instances.
The term "alkyl" or "alk-" refers to straight or branched chain hydrocarbon groups having 1 to 10 carbon atoms, preferably 1 to 7 carbon atoms. The expression "lower alkyl" refers to alkyl groups of 1 to 4 carbon atoms.
The term "alkoxy" refers to alkyl-O--. The expression "lower alkoxy" refers to lower alkyl-O--.
The term "aryl" or "ar-" refers to phenyl, naphthyl and biphenyl.
The term "alkeny", refers to straight or branched chain hydrocarbon groups of 2 to 10 carbon atoms having at least one double bond. Groups of two to four carbon atoms are preferred.
The term "alkyny", refers to straight or branched chain groups of 2 to 10 carbon atoms having at least one triple bond. Groups of two to four carbon atoms are preferred.
The term "alkylene" refers to a straight chain bridge of 1 to 5 carbon atoms connected by single bonds (e.g., --(CH 2 ) x -- wherein x is 1 to 5), which may be substituted with 1 to 3 lower alkyl groups.
The term "alkenylene" refers to a straight chain bridge of 2 to 5 carbon atoms having one or two double bonds that is connected by single bonds and may be substituted with 1 to 3 lower alkyl groups. Exemplary alkenylene groups are --CH═CH--CH═CH--, --CH 2 --CH═CH--, --CH 2 --CH═CH--CH 2 --, --C(CH 3 ) 2 CH═CH-- and --CH(C 2 H 5 )--CH═CH.
The term "alkynylene" refers to a straight chain bridge of 2 to 5 carbon atoms that has a triple bond therein, is connected by single bonds, and may be substituted with 1 to 3 lower alkyl groups. Exemplary alkynylene groups are --C.tbd.C--, --CH 2 --C.tbd.C--, --CH(CH 3 )--C.tbd.C-- and --C.tbd.C--CH(C 2 H 5 )CH 2 --.
The term "alkanoyl" refers to groups of the formula --C(O)alkyl.
The terms "cycloalkyl" and "cycloalkeny" refer to cyclic hydrocarbon groups of 3 to 8 carbon atoms.
The term "hydroxyalkyl" refers to an alkyl group including one or more hydroxy radicals such as --CH 2 CH 2 OH, --CH 2 CH 2 OHCH 2 OH, --CH(CH 2 OH) 2 and the like.
The terms "halogen" and "halo" refer to fluorine, chlorine, bromine and iodine.
Throughout the specification, groups and substituents thereof are chosen to provide stable moieties and compounds.
The compounds of formula I form salts which are also within the scope of this invention. Pharmaceutically acceptable (i.e., non-toxic, physiologically acceptable) salts are preferred, although other salts are also useful, e.g, in isolating or purifying the compounds of this invention.
The compounds of formula I may form salts with alkali metals such as sodium, potassium and lithium, with alkaline earth metals such as calcium and magnesium, with organic bases such as dicyclohexylamine, benzathine, N-methyl-D-glucamide and hydrabamine, and with amino acids such as arginine, lysine and the like. Such salts may be obtained by reacting compound I with the desired ion in a medium in which the salt precipitates or in an aqueous medium followed by lyophilization.
When the R 1 to R 5 substituents comprise a basic moiety, such as amino or substituted amino, compound I may form salts with a variety of organic and inorganic acids. Such salts include those formed with hydrochloric acid, hydrogen bromide, methanesulfonic acid, sulfuric acid, acetic acid, maleic acid, benzenesulfonate, toluenesulfonate, and various other sulfonates, nitrates, phosphates, borates, acetates, tartrates, maleates, citrates, succinates, benzoates, ascorbates, salicylates and the like. Such salts may be formed by reacting compound I in an equivalent amount of the acid in a medium in which the salt precipitates or in an aqueous medium followed by lyophilization.
In addition, when the R 1 to R 5 substituents comprise a basic moiety such as amino, zwitterions ("inner salts") may be formed.
Certain of the R 1 to R 5 substituents of compound I may contain asymmetric carbon atoms. Such compounds of formula I may exist, therefore, in enantiomeric and diastereomeric forms and in racemic mixtures thereof. All are within the scope of this invention. Additionally, compound I may exist as enantiomers even in the absence of asymmetric carbons. All such enantiomers are within the scope of this invention.
The compounds of formula I are antagonists of ET-1, ET-2 and/or ET-3 and are useful in treatment of conditions associated with increased ET levels (e.g., dialysis, trauma and surgery) and of all endothelin-dependent disorders. They are thus useful as antihypertensive agents. By the administration of a composition having one (or a combination) of the compounds of this invention, the blood pressure of a hypertensive mammalian (e.g., human) host is reduced. They are also useful in pregnancy-induced hypertension and coma (preeclampsia and eclampsia), acute portal hypertension and hypertension secondary to treatment with erythropoietin.
The compounds of the present invention are also useful in the treatment of disorders related to renal, glomerular and mesangial cell function, including acute and chronic renal failure, glomerular injury, renal damage secondary to old age or related to dialysis, nephrosclerosis (especially hypertensive nephrosclerosis), nephrotoxicity (including nephrotoxicity related to imaging and contrast agents and to cyclosporine), renal ischemia, primary vesicoureteral reflux, glomerulosclerosis and the like. The compounds of this invention may also be useful in the treatment of disorders related to paracrine and endocrine function.
The compounds of the present invention are also useful in the treatment of endotoxemia or endotoxin shock as well as hemorrhagic shock.
The compounds of the present invention are also useful in hypoxic and ischemic disease and as anti-ischemic agents for the treatment of, for example, cardiac, renal and cerebral ischemia and reperfusion (such as that occurring following cardiopulmonary bypass surgery), coronary and cerebral vasospasm, and the like.
In addition, the compounds of this invention may also be useful as anti-arrhythmic agents; anti-anginal agents; anti-fibrillatory agents; anti-asthmatic agents; anti-atherosclerotic and anti-arteriosclerotic agents; additives to cardioplegic solutions for cardiopulmonary bypasses; adjuncts to thrombolytic therapy; and anti-diarrheal agents. The compounds of this invention may be useful in therapy for myocardial infarction; therapy for peripheral vascular disease (e.g., Raynaud's disease and Takayashu's disease); treatment of cardiac hypertrophy (e.g., hypertrophic cardiomyopathy); treatment of primary pulmonary hypertension (e.g., plexogenic, embolic) in adults and in the newborn and pulmonary hypertension secondary to heart failure, radiation and chemotherapeutic injury, or other trauma; treatment of central nervous system vascular disorders, such as stroke, migraine and subarachnoid hemorrhage; treatment of central nervous system behavioral disorders; treatment of gastrointestinal diseases such as ulcerative colitis, Crohn's disease, gastric mucosal damage, ulcer and ischemic bowel disease; treatment of gall bladder or bile duct-based diseases such as cholangitis; treatment of pancreatitis; regulation of cell growth; treatment of benign prostatic hypertrophy; restenosis following angioplasty or following any procedures including transplantation; therapy for congestive heart failure including inhibition of fibrosis; inhibition of left ventricular dilatation, remodeling and dysfunction; and treatment of hepatotoxicity and sudden death. The compounds of this invention may be useful in the treatment of sickle cell disease including the initiation and/or evolution of the pain crises of this disease; treatment of the deleterious consequences of ET-producing tumors such as hypertension resulting from hemangiopericytoma; treatment of early and advanced liver disease and injury including attendant complications (e.g., hepatotoxicity, fibrosis and cirrhosis); treatment of spastic diseases of the urinary tract and/or bladder; treatment of hepatorenal syndrome; treatment of immunological diseases involving vasculitis such as lupus, systemic sclerosis, mixed cryoglobulinemia; and treatment of fibrosis associated with renal dysfunction and hepatotoxicity. The compounds of this invention may be useful in therapy for metabolic and neurological disorders; cancer; insulin-dependent and non insulin-dependent diabetes mellitus; neuropathy; retinopathy; maternal respiratory distress syndrome; dysmenorrhea; epilepsy; hemorrhagic and ischemic stroke; bone remodeling; psoriasis; and chronic inflammatory diseases such as rheumatoid arthritis, osteoarthritis, sarcoidosis and eczematous dermatitis (all types of dermatitis).
The compounds of this invention can also be formulated in combination with endothelin converting enzyme (ECE) inhibitors, such as phosphoramidon; thromboxane receptor antagonists; potassium channel openers; thrombin inhibitors (e.g., hirudin and the like); growth factor inhibitors such as modulators of PDGF activity; platelet activating factor (PAF) antagonists; angiotensin II (AII) receptor antagonists; renin inhibitors; angiotensin converting enzyme (ACE) inhibitors such as captopril, zofenopril, fosinopril, ceranapril, alacepril, enalapril, delapril, pentopril, quinapril, ramipril, lisinopril and salts of such compounds; neutral endopeptidase (NEP) inhibitors; dual NEP-ACE inhibitiors; HMG CoA reductase inhibitors such as pravastatin and mevacor; squalene synthetase inhibitors; bile acid sequestrants such as questran; calcium channel blockers; potassium channel activators; beta-adrenergic agents; antiarrhythmic agents; diuretics, such as chlorothiazide, hydrochlorothiazide, flumethiazide, hydroflumethiazide, bendroflumethiazide, methylchlorothiazide, trichloromethiazide, polythiazide or benzothiazide as well as ethacrynic acid, tricrynafen, chlorthalidone, furosemide, musolimine, bumetanide, triamterene, amiloride and spironolactone and salts of such compounds; and thrombolytic agents such as tissue plasminogen activator (tPA), recombinant tPA, streptokinase, urokinase, prourokinase and anisoylated plasminogen streptokinase activator complex (APSAC). If formulated as a fixed dose, such combination products employ the compounds of this invention within the dosage range described below and the other pharmaceutically active agent within its approved dosage range. The compounds of this invention may also be formulated with, or useful in conjunction with, antifungal and immunosuppressive agents such as amphotericin B, cyclosporins and the like to counteract the glomerular contraction and nephrotoxicity secondary to such compounds. The compounds of this invention may also be used in conjunction with hemodialysis.
The compounds of the invention can be administered orally or parenterally to various mammalian species known to be subject to such maladies, e.g., humans, in an effective amount within the dosage range of about 0.1 to about 100 mg/kg, preferably about 0.2 to about 50 mg/kg and more preferably about 0.5 to about 25 mg/kg (or from about 1 to about 2500 mg, preferably from about 5 to about 2000 mg) in single or 2 to 4 divided daily doses.
The active substance can be utilized in a composition such as tablet, capsule, solution or suspension containing about 5 to about 500 mg per unit dosage of a compound or mixture of compounds of formula I or in topical form for wound healing (0.01 to 5% by weight compound of formula I, 1 to 5 treatments per day). They may be compounded in a conventional manner with a physiologically acceptable vehicle or carrier, excipient, binder, preservative, stabilizer, flavor, etc., or with a topical carrier such as Plastibase (mineral oil gelled with polyethylene) as called for by accepted pharmaceutical practice.
The compounds of the invention may also be administered topically to treat peripheral vascular diseases and as such may be formulated as a cream or ointment.
The compounds of formula I can also be formulated in compositions such as sterile solutions or suspensions for parenteral administration. About 0.1 to 500 milligrams of a compound of formula I is compounded with a physiologically acceptable vehicle, carrier, excipient, binder, preservative, stabilizer, etc., in a unit dosage form as called for by accepted pharmaceutical practice. The amount of active substance in these compositions or preparations is such that a suitable dosage in the range indicated is obtained.
The compounds of the present invention may be prepared as follows. ##STR7##
As depicted in Scheme 1, a suitably substituted aryl boronic acid 1 may be coupled with a 2-halo-phenylsulfonamide 2 under Pd(O) catalysis, in the presence of a base, such as aqueous sodium carbonate, and solvent, such as a mixture of toluene and ethanol, to give after deprotection, the title compounds 4. (The 2-halo phenylsulfonamide 2 may be prepared by the methods described in EP Publication Number 0,569,193 (1993)), wherein said European Publication is equivalent to U.S. application Ser. No. 041,583, filed Apr. 13, 1993, and wherein said U.S. application is the parent application of U.S. application Ser. No. 142,262, filed Oct. 29, 1993, which issued as U.S. Pat. No. 5,514,696.
Alternatively, a suitably substituted aryl halide 5, either commercially available or prepared by methods known in the art, may be coupled with a phenylsulfonamide-2-boronic acid 6, under Pd(O) catalyzed conditions analogous to those described above, to give the products 3. These products are deprotected to give the title compounds 4.
A boronic acid intermediate 6 may be prepared from a 2-halo-phenylsulfonamide 2 by lithiation with a suitable alkyl lithium (such as n-butyl lithium), subsequent treatment with a trialkylborate (e.g., triisopropyl borate) and finally adding an aqueous acid such as aqueous hydrochloric acid. ##STR8##
The subsituted aryl boronic acid 1 may be prepared from 5 as shown in Scheme 2(a). Treatment of 5 with an alkyl lithium reagent, such as n-butyl-, s-butyl- or t-butyl lithium, followed by reaction of the intermediate aryl lithium with a trialkylborate, such as trimethylborate, and then hydrolysis, gives the aryl boronic acid 1.
In the case where G 2 =CH 2 OH, 1 may also be prepared as shown in Scheme 2(b) by treatment of compound 7 with an alkyl lithium reagent, such as t-butyl lithium, in the presence of a chelating agent, such as tetramethylethylenediamine (TMEDA), followed by reaction of the intermediate aryl lithium with a trialkylborate and hydrolysis to give the arylboronic acid 8, which may also exist as the arylboronic acid 9. ##STR9##
As depicted in Scheme 3, the G 2 group may also be introduced after formation of the biaryl sulfonamide by a Pd(O)-catalyzed coupling reaction. Specifically, a substituted arylhalide 10, commercially available or prepared by methods known in the art, where R is a straight-chained lower alkyl or --C(O)--R' (where R' is H or lower alkoxy), may be reacted with the arylboronic acid 6 under Pd(O)-catalyzed conditions as described in Scheme 1. When R is a straight-chained lower alkyl, substituted arylhalide 10 may also be first converted into a boronic acid 11, as described in Scheme 2(a), and then reacted with the aryl halide 2 under Pd(O)-catalyzed conditions as described in Scheme 1. The resulting biarylsulfonamide 12 may then be converted to 3 by methods known in the art and deprotected to give the title compounds 4.
In each case, the boronic acid group of compound 1, 6, 3, 9 or 11 may be replaced by a trialkyltin moiety, --SnR", where R" is lower alkyl, and the halo group of compound 2, 5 or 10 may be replaced by a --OSO 2 CF 3 moiety in the Pd-catalyzed coupling reaction. For general strategies in biaryl synthesis, see: Bringmann et al., Angew. Chem. Int., Ed. Engl. 29 (1990) 977-991.
For compounds wherein any of R 1 to R 5 comprise reactive functionalities, the reactants may be treated with protecting agents prior to coupling. The amine portion of the sulfonamide core may also need to be protected when different R 1 , R 2 and R 3 groups are added. Suitable protecting agents and procedures for use thereof are generally known in the art. Exemplary protecting groups are benzyl, halocarbobenzyloxy, tosyl, methyl and the like for hydroxyl; and carbobenzyloxy, halocarbobenzyloxy, t-butoxy carbonyl, acetyl, benzoyl, methoxyethoxymethyl and the like for amino. The sulfonamide nitrogen may be protected with methoxyethoxymethyl, trimethylsilylethoxymethyl, t-butyl and the like. Protecting groups may be removed from the resulting protected analogues of compound I by treatment with one or more deprotecting agents. Suitable deprotecting agents and procedures for use thereof are generally known in the art.
The invention will now be further described by the following working examples, which are preferred embodiments of the invention. These examples are meant to be illustrative rather than limiting.
EXAMPLE 1
N-(3,4-Dimethyl-5-isoxazolyl)-2'-(hydroxymethyl)[1,1'-biphenyl]-2-sulfonamide ##STR10## A. 1,3-Dihydro-1-hydroxy-2,1-benzoxaborole
To a solution of 2-bromobenzyl alcohol (2.8 g, 15 mmol) in 30 ml of tetrahydrofuran (THF) under argon at -40° C., a 2.0 M solution of butyllithium in hexanes (15.5 ml) was added dropwise over 15 minutes. The solution was stirred for an additional 15 minutes and trimethylborate (3.22 g, 31.0 mmol) was added. After 15 minutes at -40° C., the solution was warmed to room temperature and stirred for a further 2 hours. The reaction was quenched by the addition of 10% aqueous hydrochloric acid (HCl) (100 ml), and after 10 minutes, the solution was extracted with ethyl acetate (3×75 ml). The combined ether extracts were then extracted with 2N aqueous sodium hydroxide (NaOH) (3×50 ml). The aqueous extracts were then acidified with dilute hydrochloric acid to pH 2 and extracted with 3×50 ml of ethyl acetate. The combined organic extracts were washed once with water (100 ml), dried and evaporated to afford 0.43 g (21%) of compound A as a white solid (m.p. 138-140° C.).
B. N-(3,4-Dimethyl-5-isoxazolyl)-2-bromobenzenesulfonamide
To a solution of 3.0 g (11.74 mmol) of 2-bromobenzenesulfonyl chloride in 10 ml of pyridine was added 1.32 g (11.74 mmol) of 3,4-dimethyl-5-isoxazolamine. The mixture was stirred at room temperature under argon overnight, added to 150 ml of ice water and filtered. The filtrate was acidified to pH 2 using 6N aqueous hydrochloric acid and the grey solid was filtered and dried. The solid was crystallized from methanol/water to afford 4.0 g (>100%) of compound B as tan crystalline needles (m.p. 125-126° C.).
C. 2-Bromo-N-(3,4-dimethyl-5-isoxazolyl)-N-(methoxyethoxymethyl)benzenesulfonamide
To a solution of 1.1 g (3.33 mmol) of compound B in 15 ml of THF at room temperature under argon was added 0.19 g (4.8 mmol) of sodium hydride (60% suspension in mineral oil) in portions, and the solution was stirred at room temperature for 10 minutes. Methoxyethoxymethyl chloride (0.55 g, 4.4 mmol) was then added and the solution was stirred overnight. The mixture was concentrated and diluted with 30 ml of water, and extracted with 40 ml of ethyl acetate. The combined organic extracts were washed with 50 ml of brine, dried and evaporated to provide 1.2 g (87%) of compound C as a brown gum.
D. N-(3,4-Dimethyl-5-isoxazolyl)-2'-(hydroxymethyl)-N-[(2-methoxyethoxy)methyl][1,1'-biphenyl]-2-sulfonamide
To a solution of 1.02 g (2.43 mmol) of compound C and 0.14 g (0.12 mmol) of tetrakis-(triphenylphosphine)palladium(0) in 30 ml of toluene under argon, 18 ml of 2M aqueous sodium carbonate was added. 0.36 g (2.67 mmol) of compound A was then added in 25 ml of 95% ethanol. The mixture was refluxed for 4 hours, diluted with 100 ml of water, and extracted with 3×50 ml of ethyl acetate. The combined organic extracts were washed once with 100 ml of brine, dried and evaporated. The residue was chromatographed on 50 g of silica gel using 2% methanol in dichloromethane to afford 0.93 g (86%) of compound D as a light brown gum which solidified on standing.
R f =0.11 (Hexanes:ethyl acetate 2:1).
E. N-(3,4-Dimethyl-5-isoxazolyl)-2'-(hydroxymethyl)[1,1'-biphenyl]-2-sulfonamide
To a solution of 0.10 g (0.224 mmol) of compound D in 3 ml of 95% ethanol, 3 ml of 6N aqueous HCl was added and refluxed for 1.5 hours. The mixture was concentrated and diluted with 20 ml of water. The mixture was then extracted with 3×20 ml of ethyl acetate and the combined organic extracts were washed once with 50 ml of brine, dried and evaporated to provide a brown foam. The residue was chromatographed on 10 g of silica gel using 2% methanol in dichloromethane to afford 0.03 g (37%) of the title compound as a white foam (m.p. 70-80° C. (amorphous)).
Analysis calculated for C 22 H 26 N 2 O 4 S 0.26H 2 O: C, 59.55; H, 5.14; N, 7.72; S, 8.83. Found: C, 59.55; H, 5.18; N, 7.72; S, 8.43.
EXAMPLE 2
4'-[(2,3-Dihydro-2-oxo-3-benzoxazolyl)methyl]-N-(3,4-dimethyl-5-isoxazolyl)[1,1'-biphenyl]-2-sulfonamide ##STR11## A. N-(3,4-Dimethyl-5-isoxazolyl)-N-[(2-methoxyethoxy)methyl]-4'-methyl[1,1'-biphenyl]-2-sulfonamide
To a solution of compound C from Example 1, 4-methylbenzeneboronic acid (4.76 g, 35 mmol) in 250 ml of toluene and 200 ml of 95% ethanol under argon, tetrakis(triphenylphosphine)palladium(0) (2.43 g, 2.1 mmol) was added, followed by 150 ml of 2M aqueous sodium carbonate. The reaction mixture was heated at 80° C. for 2.5 hours, cooled and diluted with 300 ml of ethyl acetate. The organic liquid was separated and washed with 200 ml water and 200 ml of brine, dried and concentrated. The residue was chromatographed on silica gel using 5:1 hexane/ethyl acetate to afford compound A (9.0 g, 60%) as a colorless gum.
R f =0.74, silica gel, 1:1 Hexane/ethyl acetate.
B. 4'-(Bromomethyl)-N-(3,4-dimethyl-5-isoxazolyl)-N-[(2-methoxyethoxy)methyl][1.1'-biphenyl]-2-sulfonamide
To compound A (7.7 g, 17.89 mmol) in 180 ml carbon tetrachloride, n-bromosuccinimide (4.14 g, 23.25 mmol) and benzoyl peroxide (385 mg, 1.59 mmol) were added. The reaction was refluxed for 1.5 hours. After cooling, the reaction mixture was diluted with 200 ml dichloromethane, washed with 2×100 ml water and 100 ml brine, dried and concentrated. The residue was chromatographed on silica gel eluting with 4:1 hexane/ethyl acetate to provide compound B (3.64 g, 40%) as a colorless gum.
R f =0.38, silica gel, 2:1 Hexane/ethyl acetate.
C. 4'-[(2,3-Dihydro-2-oxo-3-benzoxazolyl)methyl]-N-(3,4-dimethyl-5-isoxazolyl)-N-[(2-methoxyethoxy)methyl][1,1'-biphenyl]-2-sulfonamide
To compound B (200 mg, 0.39 mmol) and 2-benzoxazolinone (58 mg, 0.43 mmol) in 0.79 ml dimethylformamide (DMF), K 2 CO 3 (109 mg, 0.79 mmol) was added. The reaction was stirred at room temperature for 4 hours and then at 45° C. for 0.5 hours. The mixture was diluted with 30 ml ethyl acetate, washed with 2×10 ml water and 10 ml brine, dried and concentrated. The residue was chromatographed on silica gel using 2.5:1 hexane/ethyl acetate to afford compound A (170 mg, 77%) as a colorless gum.
R f =0.32, silica gel, 1:1 hexane/ethyl acetate.
D. 4'-[(2,3-Dihydro-2-oxo-3-benzoxazolyl)methyl]-N-(3,4-dimethyl-5-isoxazolyl)[1,1'-biphenyl]-2-sulfonamide
To a solution of compound A (170 mg, 0.30 mmol) in 4 ml of 95% ethanol, 4 ml of 6 N aqueous HCl was added. The reaction was refluxed for two hours, cooled and concentrated. The residue was diluted with 25 ml of ethyl acetate, washed with 2×10 ml water and 10 ml of brine, dried and concentrated to provide a white solid (140 mg, 97%), which was crystalized from dichloromethane/hexane to give the title compound as white crystals (m.p. 182-183° C.).
Analysis calcualted for C 25 H 21 N 3 O 5 S.0.58H 2 O Calculated: C, 61.78; H, 4.60; N, 8.65; S, 6.60. Found: C, 61.84; H, 4.33; N, 8.59; S, 6.55.
EXAMPLE 3
4'-[(Dimethylamino)methyl]-N-(3,4-dimethyl-5-isoxazolyl)[1,1'-biphenyl]-2-sulfonamide, hydrochloride ##STR12## A. 4'-[(Dimethylamino)methyl]-N-(3,4-dimethyl-5-isoxazolyl)-N-[(2-methoxyethoxy)methyl][1,1'-biphenyl]-2-sulfonamide, hydrochloride
To compound B from Example 2 (200 mg, 0.39 mmol) in 1 ml methanol, 1.6 ml 40% aqueous dimethylamine was added. The reaction was stirred at room temperature overnight and concentrated. The mixture was diluted with 30 ml ethyl acetate, washed with 10 ml water and 10 ml brine, dried and concentrated. The residue was chromatographed on silica gel using ethyl acetate to afford compound A (145 mg, 78%) as a colorless gum.
R f =0.34, silica gel, 10:1 dichloromethane/methanol.
B. 4'-[(Dimethylamino)methyl]-N-(3,4-dimethyl-5-isoxazolyl)[1,1'-biphenyl]-2-sulfonamide, hydrochloride
To a solution of compound A (145 mg, 0.31 mmol) in 4 ml of 95% ethanol, 4 ml of 6 N aqueous HCl was added. The reaction was refluxed for 2 hours, cooled and concentrated. The mixture was neutralized with saturated aqueous NaHCO 3 , and then acidified to pH˜5 with acetic acid. The solution was extracted with 3×20 ml dichloromethane, and the combined organic extracts were washed with 10 ml brine, dried and concentrated to give a colorless gum (115 mg, 97%), which was dissolved in 1 N HCl and concentrated under vacuum to provide the hydrochloride salt of the title compound as a white solid (m.p. 126-130° C.).
Analysis calcualted for C 20 H 24 N 3 ClO 3 S.1.2H 2 O Calculated: C, 54.16; H, 6.00; N, 9.47; S, 7.23; Cl, 7.99. Found: C, 54.22; H, 6.00; N, 9.39; S, 7.02; Cl 8.39.
EXAMPLE 4
N-(3,4-Dimethyl-5-isoxazolyl)-4'-[(2-hydroxyethoxy)methyl][1,1'-biphenyl]-2-sulfonamide ##STR13## A. N-(3,4-Dimethyl-5-isoxazolyl)-4'-[(2-hydroxyethoxy)methyl]-N-[(2-methoxyethoxy) methyl][1,1'-biphenyl]-2-sulfonamide
To ethylene glycol (98 mg, 1.57 mmol) in 0.5 ml THF and 0.5 ml DMF at 0° C., sodium hydride (NaH) (60% in mineral oil, 31 mg, 0.79 mmol) was added. The mixture was stirred at room temperature for 20 minutes and a solution of compound B from Example 2 (200 mg, 0.39 mmol) in 1.5 ml THF was added. The reaction mixture was heated at 45° C. overnight. Additional ethylene glycol (98 mg, 1.57 mmol) and NaH (60% in mineral oil, 31 mg, 0.79 mmol) were added and the mixture was heated at 50° C. for another 4 hours. The mixture was then added to 15 ml saturated aqueous ammonium chloride (NH 4 Cl) and extracted with 3×20 ml ethyl acetate. The combined organic extracts were washed with 10 ml water and 10 ml of brine, dried and concentrated. The residue was chromatographed on silica gel using 2:3 hexane/ethyl acetate to afford compound A (103 mg, 53%) as a colorless gum.
R f =0.15, silica gel, 1:2 hexane/ethyl acetate.
B. N-(3,4-Dimethyl-5-isoxazolyl)-4'-[(2-hydroxyethoxy)methyl][1,1'-biphenyl]-2-sulfonamide
To a solution of compound A (102 mg, 0.21 mmol) in 2.8 ml of 95% ethanol, 2.8 ml of 6 N aqueous HCl was added. The reaction was refluxed for 1 hour and 45 minutes, cooled and concentrated. The mixture was neutralized with saturated aqueous NaHCO 3 , and then acidified to pH˜5 with acetic acid. The mixture was extracted with 3×20 ml ethyl acetate and the combined organic extracts were washed with 10 ml brine, dried and concentrated. The residue was chromatographed on silica gel using 100:2 dichloromethane/methanol to afford the title compound (58 mg, 69%) as a colorless gum.
Analysis calcualted for C 20 H 22 N 2 O 5 S.0.14H 2 O Calculated: C, 59.31; H, 5.55; N, 6.92; S, 7.92. Found: C, 59.14; H, 5.36; N, 7.09; S, 8.18.
EXAMPLE 5
N-(3,4-Dimethyl-5-isoxazolyl)-2'-(hydroxymethyl)-4'-(2-methylpropyl)[1,1'-biphenyl]-2-sulfonamide ##STR14## A. 3-(2-Methylpropyl)benzenemethanol
To a solution of isobutylene (4.40 g, 78.45 mmol) in 11 ml THF at -78° C., 9-Borabicyclo[3.3.1]nonane (9-BBN) (0.5 M in THF, 157 ml, 78.45 mmol) was added. The mixture was stirred at -78° C. for 3 hours, and then warmed to room temperature and stirred overnight to form 9-(2-Methylpropyl)-9-borabicyclo[3.3.1]nonane (9-isobutyl BBN). In a separate flask, to a solution of 3-bromobenzylalcohol (13.34 g, 71.32 mmol) in 36 ml THF, tetrakis(triphenylphosphine)palladium(0) (2.47 g, 2.14 mmol) and 60 ml 3M NaOH were added. The 9-isobutyl BBN prepared above was then transferred into the flask under argon and the mixture was refluxed for 21 hours. The mixture was cooled with an external ice bath and 18 ml 30% hydrogen peroxide was added. The mixture was stirred for 30 minutes, concentrated to about 100 ml and partitioned between 200 ml each of water and ethyl acetate. The aqueous layer was extracted with ethyl acetate (2×100 ml) and the combined organic extracts were washed with 60 ml brine, dried and concentrated. The residue was chromatographed on silica gel using 9:1 hexane/ethyl acetate to afford compound A (8.16 g, 70%) as a liquid.
B. 1,3-Dihydro-1-hydroxy-5-(2-methylpropyl)-2,1-benzoxaborole
To a solution of compound A (1.00 g, 6.09 mmol) and N,N,N',N'-Tetramethylethylenediamine (TMEDA) (2.48 g, 21.31 mmol) in 12 ml ethyl ether under argon at -78° C., t-butyl lithium (1.7 M in pentane, 12.5 ml, 21.31 mmol) was added over 5 minutes. The mixture was warmed to room temperature, stirred for 4 hours, and cooled to -40° C. Trimethylborate (2.21 g, 21.31 mmol) was added in one portion. The solution was warmed to room temperature, stirred for 1.5 hours and cooled to 0° C., and 15% aqueous HCl (40 ml) was added. The solution was extracted with 3×20 ml ethyl acetate and the combined aqueous extracts were extracted with 6×25 ml 2N NaOH. The combined aqueous extracts were acidified to pH 2 with 6 N aqueous HCl, and the solution was extracted with 3×50 ml ethyl acetate. The combined organic extracts were washed once with 40 ml brine, dried and concentrated to afford compound B as a light yellow solid (384 mg, 33%) (m.p. 96-100° C.).
R f =0.4, silica gel, 3:1 hexane/ethyl acetate.
C. N-(3,4-dimethyl-5-isoxazolyl)-2'-(hydroxymethyl)-N-[(2-methoxyethoxy)methyl]-4'-(2-methylpropyl)[1,1'-biphenyl]-2-sulfonamide
To a solution of compound C from Example 1 (784 mg, 1.87 mmol) and tetrakis(triphenylphosphine)palladium(O) (130 mg, 0.112 mmol) in 14 ml of toluene under argon, 8.0 ml of aqueous sodium carbonate was added followed by compound B (356 mg, 1.87 mmol) in 11 ml of 95% ethanol. The reaction mixture was heated at 80° C. for 4 hours, cooled and diluted with 40 ml of ethyl acetate. The organic layer was separated and washed with 2×20 ml of brine, dried and concentrated. The residue was chromatographed on silica gel using 2.5:1 hexane/ethyl acetate to afford compound C (550 mg, 58%) as a colorless gum.
R f =0.18, silica gel, 2:1 hexane/ethyl acetate.
D. N-(3,4-dimethyl-5-isoxazolyl)-2'-(hydroxymethyl)-4'-(2-methylpropyl)[1,1'-biphenyl]-2-sulfonamide
To a solution of compound C (120 mg, 0.24 mmol) in 8 ml of 95% ethanol, 8 ml of 6 N aqueous HCl was added and refluxed for 2 hours. The reaction mixture was concentrated to about 8 ml and extracted with 3×15 ml of ethyl acetate. The organic extracts were washed with 10 ml of brine, dried and concentrated. The residue was purified by preparative HPLC on a 30×500 mm column using 72% solvent A (90% methanol, 10% water, 0.1% TFA) and 28% solvent B (10% methanol, 90% water, 0.1% TFA) to provide the title compound (50 mg, 50%) as a white solid (m.p. 60-67° C. (amorphous)).
Analysis calcualted for C 22 H 26 N 2 O 4 S.0.18 H 2 O Calculated: C, 63.26; H, 6.36; N, 6.71; S, 7.68. Found: C, 63.39; H, 6.18; N, 6.58; S, 7.90.
EXAMPLE 6
2'-(Aminomethyl)-N-(3,4-dimethyl-5-isoxazolyl)-4'-(2-methylpropyl)[1,1'-biphenyl]-2-sulfonamide ##STR15## A. N-(3,4-Dimethyl-5-isoxazolyl)-2'-formyl-N-[(2-methoxyethoxy)methyl]-4'-(2-methylpropyl)[1,1'-biphenyl]-2-sulfonamide
To oxalyl chloride (2M in dichloromethane, 9 mL, 18.0 mmol) in 26 mL dichloromethane at -78° C., a solution of DMSO (2.8 g, 35.8 mmol) in 39 mL dichloromethane was added and stirred for 10 minutes. Compound C from Example 5 (2.40 g, 4.78 mmol) in 39 mL of dichloromethane was then added and the reaction was stirred at -78° C. for 2 hours. Triethylamine (6.07 g, 60 mmol) was added and stirred at -78° C. for 5 minutes, and the reaction mixture was warmed to room temperature and stirred for 15 minutes. The reaction mixture was partitioned between 300 mL 0.5 N HCl and 200 mL dichloromethane, and the aqueous liquid was extracted with 150 mL dichloromethane. The combined organic extracts were dried and concentrated, and the residue was chromatographed on silica gel using 3.5:1 hexane/ethyl acetate to afford compound A (1.83 g, 77%).
B. N-(3,4-Dimethyl-5-isoxazolyl)-2'-formyl-4'-(2-methylpropyl)[1,1'-biphenyl]-2-sulfonamide
To a solution of compound A (617 mg, 1.23 mmol) in 30 mL of 95% ethanol, 30 mL of 6 N aqueous HCl was added and refluxed for 1.5 hours. The reaction mixture was concentrated to about 30 mL and extracted with 3×30 mL of ethyl acetate. The organic extracts were washed with 20 mL of brine, dried and concentrated. The residue was chromatographed on silic gel using 2.5:1 hexane/ethyl acetate to provide compound B (290 mg, 57%) as a white solid. M.p. 60-66° C. (amorphous).
C. 2'-(Aminomethyl)-N-(3,4-dimethyl-5-isoxazolyl)-4'-(2-methylpropyl)[1,1'-biphenyl]-2-sulfonamide
A mixture of compound B (480 mg, 1.16 mmol), ammonium acetate (15.44 g, 232 mmol) and 3Å molecular sieves (0.5 g) in 58 mL methanol was stirred at room temperature overnight. Sodium triacetoxyborohydride (740 mg, 3.49 mmol) was then added to the reaction mixture and stirred at room temperature for 1 hour. The solution was filtered, concentrated and partitioned between 150 mL methylene chloride and 25 mL water. The organic layer was separated, dried and concentrated. The residue was chromatographed on silica gel using 100:6 dichloromethane/methanol to provide the title compound (250 mg, 52%) as a white solid (m.p. >200° C. dec.).
Analysis calculated for C 22 H 27 N 3 O 3 S.0.26H 2 O Calculated: C, 63.17; H, 6.63; N, 10.05; S, 7.66. Found: C, 63.09; H, 6.56; N, 10.13; S, 7.88.
EXAMPLE 7
N-(3,4-Dimethyl-5-isoxazolyl)-4'-(1-hydroxy-2-methylpropyl)[1,1'-biphenyl]-2-sulfonamide ##STR16## A. N-(3,4-Dimethyl-5-isoxazolyl)-4'-formyl-N-[(2-methoxyethoxy)methyl][1,1'-biphenyl]-2-sulfonamide
To a solution of compound C from Example 1 (1.08 g, 2.58 mmol) and 0.15 g (0.129 mmol) of tetrakis(triphenylphosphine)palladium(0) in 25 ml of toluene under argon, 15 ml of 2 M aqueous sodium carbonate was added followed by 0.43 g (3.22 mmol) of 4-Formyl phenylboronic acid in 18 ml of 95% ethanol. The mixture was refluxed for 3 hours, diluted with 100 ml of water and extracted with 3×50 ml of ethyl acetate. The combined organic extracts were washed once with 100 ml of brine, dried and evaporated. The residue was chromatographed on 50 g of silica gel using hexanes/ethyl acetate 3:2 to afford 0.96 g (84%) of compound A as a colorless gum.
B. N-(3,4-Dimethyl-5-isoxazolyl)-4'-formyl[1,1'-biphenyl]-2-sulfonamide
To a solution of 0.30 g (0.675 mmol) of compound A in 10 ml of 95% ethanol, 10 ml of 6N aqueous HCl was added and refluxed for 2 hours. The mixture was concentrated and diluted with 50 ml of water. The mixture was then extracted with 3×50 ml of ethyl acetate and the combined organic extracts were washed once with 100 ml of brine, dried and evaporated to provide a white foam. The residue was chromatographed on 30 g of silica gel using 3% methanol in dichloromethane to afford 0.20 g (83%) of compound B as a colorless gum.
C. N-(3,4-Dimethyl-5-isoxazolyl)-4'-(1-hydroxy-2-methylpropyl)[1,1'-biphenyl]-2-sulfonamide
To a solution of compound B (0.20 g, 0.56 mmol) in 25 ml of ether at 0° C. under argon, 0.62 ml of 2M isopropyl magnesium chloride in ether was added and stirred for 1 hour. The mixture was slowly warmed up to room temperature and stirred for an additional 3 hours. The mixture was then added to 50 ml of saturated aqueous potassium bisulfate and extracted with 3×50 ml of ethyl acetate. The combined organic extracts were washed once with 100 ml of brine, dried and evaporated. The residue was chromatographed on 20 g of silica gel using hexanes/ethyl acetate 3:2 containing 0.5% glacial acetic acid to afford 0.14 g of a colorless gum. This material was further purified by reverse phase preparative HPLC on a 30×500 mm column using 60% solvent A (90% methanol, 10% water, 0.1% TFA) and 40% solvent B (10% methanol, 90% water, 0.1% TFA) to provide 0.07 g (31%) of the title compound as a white foam (m.p. 60-70° C. (amorphous)).
Analysis calculated for C 22 H 26 N 2 O 4 S.0.27H 2 O Calculated: C, 62.24; H, 6.10; N, 6.91; S, 7.91. Found: C, 62.40; H, 6.01; N, 6.75; S, 8.10.
EXAMPLE 8
N-(3,4-Dimethyl-5-isoxazolyl)-4'-(2-hydroxy-2-methyl-propyl)[1,1'-biphenyl]-2-sulfonamide, monolithium salt ##STR17## A. 4-Bromobenzeneacetic acid, methyl ester
A solution of 2.5 g (11.6 mmoles) of p-bromophenylacetic acid and 0.25 mL of concentrated sulfuric acid in 75 mL of methanol was heated at reflux for 2 hours.
After cooling, the solution was evaporated to dryness and the residue diluted with ethyl acetate. The solution was washed with saturated sodium bicarbonate (twice) and brine (twice), dried (MgSO 4 ), and the solvent removed to give a clear light orange oil.
Distillation (kugelrohr, 125° C., 0.1 mm) afforded 2.6 g (11.3 mmoles, 97%) of compound A as a clear colorless oil.
B. 4-Bromo-α,α-dimethylbenzeneethanol
To 2.2 mL (6.6 mmoles) of 3 M methylmagnesium bromide in tetrahydrofuran (THF), with ice cooling and under argon, was added dropwise a solution of 0.5 g (2.2 mmoles) of compound A in 1 mL of THF. Stirring was continued with cooling for 1 hour, then at room temperature for 2 hours.
The reaction was added to ice-water with vigorous stirring and extracted with ether (three times). The combined ether layers were washed with brine (twice) and dried (MgSO 4 ), and the solvent removed to give 0.5 g of clear colorless oil. Distillation (kugelrohr, 125° C., 0.1 mm) yielded 0.4 g of oil which still contained an impurity by tlc (30% ethyl acetate-hexane).
This material was subjected to flash chromatography on a 75 cc column of silica gel. Elution with 20% ethyl acetate-hexane afforded 0.35 g (1.53 mmoles, 69%) of compound B as a clear colorless oil.
C. 2-Borono-N-(3,4-dimethyl-5-isoxazolyl)-N-[(2-methoxyethoxy)methyl]benzenesulfonamide
To a solution of compound C from Example 1 (5.67 g, 13.52 mmol) in 70 mL of tetrahydrofuran at -78° C., n-butyl lithium (2M solution in cyclohexane, 8.11 mL, 16.23 mmol) was added over 10 minutes. The resulting solution was stirred at -78° C. for 15 minutes and triisopropylborate (1.52 g, 8.06 mmol) was added. The mixture was then warmed to room temperature and stirred for 2 hours. The mixture was cooled to 0° C., 10% aqueous hydrochloric acid (120 mL) was added, and the solution was stirred for 10 minutes. The mixture was concentrated to 120 mL and extracted with 4×60 mL ethyl acetate. The combined organic extracts were washed once with 100 mL brine, dried (MgSO 4 ) and concentrated to give compound B (4.25 g, 82%) as a light yellow gum.
D. N-(3,4-Dimethyl-5-isoxazolyl)-4'-(2-hydroxy-2-methylpropyl)-N-[(2-methoxyethoxy)methyl]-[1,1'-biphenyl]-2-sulfonamide
To a degassed solution of 324 mg (1.4 mmole) of compound B and 506 mg (1.4 mmoles) of compound C in 5 mL of toluene, 4 mL of 95% ethanol and 3.5 mL of 2 M sodium bicarbonate, at room temperature and under argon, was added 116 mg (0.1 mmole) of tetrakis(triphenylphosphine) palladium(0), and the reaction was heated at 80° C. for 3 hours.
After cooling to room temperature, the reaction was diluted with ethyl acetate, washed with brine (three times) and dried (MgSO 4 ), and the solvent was removed to give a clear orange oil.
This material was subjected to flash chromatography on a 75 cc column of silica gel. Elution with 50% ethyl acetate-hexane, followed by 75% ethyl acetate-hexane afforded 189 mg (0.38 mmole, 28%) of compound D as a viscous oil.
E. N-(3,4-Dimethyl-5-isoxazolyl)-4'-(2-hydroxy-2-methyl-propyl)[1,1'-biphenyl]-2-sulfonamide, monolithium salt
A solution of 180 mg (0.37 mmole) of compound D in 4 mL of ethanol and 4 mL of 6 N HCl was heated at reflux for 5 hours. Even though starting material still appeared to be present by tlc, the reaction was worked up.
The reaction was evaporated to near dryness. The residue was rendered alkaline with saturated sodium bicarbonate and extracted with ethyl acetate (three times). The combined extracts were washed with brine and dried (MgSO 4 ), and the solvent was removed to yield unreacted compound D as an orange oil. The combined aqueous layers were acidified with 6 N HCl and extracted with ethyl acetate (three times). The combined extracts were washed with brine and dried (MgSO 4 ), and the solvent was removed to yield 18 mg of the title compound as a viscous oil.
The recovered compound D was taken into 1 mL of ethanol and 1 mL of 6 N HCl and heated at reflux for an additional 5 hours. Starting material still appeared to be present by tlc but the reaction was not heated further.
The reaction was evaporated to complete dryness and the residue subjected to flash chromatography on a 35 cc column of silica gel. Elution with a step-wise gradient from 1 to 5% methanol-chloroform afforded 41 mg of the desired title compound.
The two portions of product were combined and resubjected to flash chromatography on a 35 cc column of silica gel. Elution with 5% methanol-trichloromethane gave 44 mg of compound D of insufficient purity. This material was then subjected to prep. HPLC on a YMC S5 120A ODS column. Elution with a linear gradient of 50-100% methanol-H 2 O (+0.1% TFA) afforded 29 mg of the title compound as a white glass.
This material was taken into methanol and 10 mg of lithium hydroxide.H 2 O was added and the mixture stirred until solution was obtained. The solvent was removed and the residue chromatographed on a 20 cc column of HP-20 resin. After initial elution with 100% water and 10% methanol-water, continued elution with 50% methanol-water afforded 11 mg (0.027 mmole, 7%) of the title compounds as a white powder.
M.p.: 170-172° C. (dried: 50° C., high vac, overnight). MS: (M+Li) + 407 + Calculated for C 21 H 23 N 2 O 4 SLi.1.65H 2 O: C, 57.84; H, 6.08; N, 6.42. Found: C, 58.04; H, 6.19; N, 6.22.
EXAMPLE 9
N-(3,4-Dimethyl-5-isoxazolyl)-4'-(3-hydroxy-2-methylpropyl)[1,1'-biphenyl]-2-sulfonamide, lithium salt ##STR18## A. 4-Bromo-α-methylbenzenepropanoic acid, ethyl ester
A solution of lithium diisopropyl amide (LDA) was prepared at -78° C. under argon, by the addition of 19.2 mL (48 mmoles) of 2.5 M n-butyl lithium to a solution of 7 mL (50 mmoles) of diisopropylamine in 11 mL of dry tetrahydrofuran (THF).
To the LDA solution at -78° C., was added dropwise a solution of 5 mL (44 mmoles) of ethyl propionate in 20 mL of THF. Stirring was continued at -78° C. for 1 hour, after which a solution of 10 g (40 mmoles) of p-bromo benzylbromide in 25 mL of THF was added dropwise. Stirring was continued at -78° C. for 2 hours. Water was then added dropwise and the reaction was allowed to warm to room temperature.
The solution was evaporated to near dryness and the residue diluted with ethyl acetate. The solution was washed with brine, saturated sodium bicarbonate and brine (twice), and dried (MgSO 4 ), and the solvent was removed to give a clear, pale yellow oil.
This material was subjected to flash chromatography on a 500 cc column of silica gel. Elution with 25% dichloromethane-hexane afforded 4.1 g (approx 30%) of a cloudy oil which was used without further purification.
B. 4-Bromo-β-methylbenzenepropanol
To a solution of 4.0 g (assumed 14.7 mmoles) of compound A in 75 mL of toluene, at -78° C. and under argon, was added dropwise 37 mL (37 mmoles) of 1 M diisobutyl aluminum hydride (DIBAL) in toluene. Stirring was continued at -78° C. for 3 hours. To the cold reaction was then added 5.5 mL of methanol, followed by 7.4 mL of water, and the reaction was allowed to warm to room temperature. Stirring was continued for an additional 1 hour. The resulting white precipitate was removed by filtration and the filter cake washed well with ethyl acetate.
The clear colorless filtrate was evaporated to dryness to yield an oil residue which was subjected to flash chromatography on a 500 cc column of silica gel. Elution with 25% ethyl acetate-hexane afforded 2.0 g (59%) of pure compound B as a clear colorless oil.
C. N-(3,4-Dimethyl-5-isoxazolyl)-4'-(3-hydroxy-2-methylpropyl)-N-[(2-methoxyethoxy)methyl]-[1,1'-biphenyl]-2-sulfonamide
To a degassed solution of 230 mg (1 mmole) of compound B and 460 mg (1.2 mmoles) of compound C from Example 8 in 5 mL of toluene, 4 mL of 95% ethanol and 3.5 mL of 2 M sodium bicarbonate, at room temperature and under argon, was added 116 mg (0.1 mmole) of tetrakis(triphenylphosphine) palladium(0) and the reaction was heated at 80° C. for 2.5 hours.
After cooling to room temperature, the reaction was diluted with ethyl acetate, washed with brine (three times) and dried (MgSO 4 ), and the solvent was removed to give a clear orange oil.
This material was subjected to flash chromatography on a 75 cc column of silica gel. Elution with 50% ethyl acetate-hexane, followed by 75% ethyl acetate-hexane afforded 227 mg (0.47 mmole, 47%) of compound C as a viscous oil.
D. N-(3,4-Dimethyl-5-isoxazolyl)-4'-(3-hydroxy-2-methylpropyl)[1,1'-biphenyl]-2-sulfonamide, lithium salt
A solution of 220 mg (0.45 mmole) of compound C in 4 mL of ethanol and 6 mL of 6 N HCl was heated at reflux for 3 hours.
The reaction was evaporated to near dryness and the residue rendered alkaline with saturated sodium bicarbonate and washed with ether (twice). The aqueous layer was acidified with 1 N HCl and extracted with ether (twice). The organic layers were washed with brine (twice) and dried (MgSO 4 ), and the solvent was removed to yield 96 mg of crude title compound.
The ether washes of the alkaline solution remaining from above were washed with brine and dried, and the solvent was removed to give 50 mg of unreacted compound C. This material was taken into 1 mL each of ethanol and 6 N HCl, and refluxed an additional 2 hours. Workup as described afforded an additional 38 mg of crude title compound.
The combined product was subjected to flash chromatography on a 60 cc column of silica gel. Elution with 2% methanol-trichloromethane afforded 113 mg (0.32 mmole) of the title compound as a white foam. This material was dissolved in methanol and 13.5 mg (0.32 mmole) of LiOH.H 2 O added. The resulting solution was evaporated to dryness and the residue chromatographed on a 30 cc column of HP-20 resin. Elution with a step-gradient of 100% water to 50% methanol-water gave 76 mg (0.19 mmole, 42%) of the title compound as its lithium salt.
M.p.: 150-160° d (dried: 60° C., high vac, overnight). MS: (M+H) + 401 + Calculated for C 21 H 23 N 2 O 4 SLi.2.10H 2 O: C, 56.78; H, 6.17. Found: C, 56.98; H, 5.99.
EXAMPLE 10
4'-(1,1-Difluoro-2-methylpropyl)-N-(3,4-dimethyl-5-isoxazolyl)[1,1'-biphenyl]-2-sulfonamide ##STR19## A. 4-Bromo-α-(1-methylethyl)benzenemethanol
To a solution of 9.0 g (0.048 mol) of 4-Bromobenzaldehyde in 150 mL of ether at 0° C. under argon, 2.0 M solution of isopropyl magnesium chloride in ether (29.2 mL) was added and stirred for 30 minutes. The solution was slowly warmed up to room temperature and stirred for an additional 4 hours. The mixture was then added to 150 mL of aqueous saturated sodium bicarbonate and extracted with 200 mL of ether. The organic extract was washed once with water, dried and evaporated to afford 9.8 g (95%) of the product as a gum.
B. 1-(4-Bromophenyl)-2-methyl-1-propanone
To a 2.0 M solution of oxalyl chloride in dichloromethane (58.6 mL) at -78° C. under argon, 100 mL of dry dichloromethane was added followed by dimethylsulfoxide (18.75 g). The mixture was stirred for 10 minutes and then 9.8 g (0.0456 mol) of compound A in 100 mL of dichloromethane was added and stirred for 3 hours. Triethylamine (24 g, 0.23 mol) was then added to the mixture and stirred at -78° C. for 5 minutes. The mixture was slowly warmed to room temperature and stirred for 15 minutes. The mixture was then poured into 500 mL of 1N aqueous HCl and the organic layer was separated. The aqueous layer was back extracted with 2×100 mL of dichloromethane and the combined organic extracts were washed once with water, dried and evaporated. The residue was chromatographed on 500 g of silica gel using hexanes to afford 5.5 g (57%) of the product as a colorless liquid.
C. 1-Bromo-4-(1,1-difluoro-2-methylpropyl)benzene
To a flask containing 2.5 g (11.85 mmol) of compound B, diethylaminosulfur trifluoride (4.2 g, 26.05 mmol) was added and the mixture was stirred at 50° C. for 48 hours. The solution was then warmed up to 70° C. to complete the reaction and then the mixture was poured into 100 mL of ice water and extracted with 2×50 mL dichloromethane. The combined organic extracts were washed once with water, dried and evaporated. The brown liquid thus obtained was distilled in vacuo to provide 1.9 g (64%) of the product as a colorless liquid.
B.p. 124° C. (10-12 mm).
D. 4'-(1,1-Difluoro-2-methylpropyl)-N-(3,4-dimethyl-5-isoxazolyl)-N-[(2-methoxyethoxy)-methyl][1,1'-biphenyl]-2-sulfonamide
To a solution of 0.486 g (1.26 mmol) of compound C from Example 8 and 0.146 g (0.126 mmol) of tetrakis(triphenylphosphine)palladium(0) in 10 mL of toluene under argon, 8 mL of 2M aqueous sodium carbonate was added followed by 0.35 g (1.40 mmol) of compound C above added in 8 mL of 95% ethanol. The mixture was refluxed for 3 hours, diluted with 100 mL of water and extracted with 3×75 mL of ethyl acetate. The combined organic extracts were washed once with 100 mL of brine, dried and evaporated. The residue was chromatographed on 20 g of silica gel using Hexanes/ethyl acetate 3:1 to afford 0.19 g (30%) of compound D as a colorless gum.
E. 4'-(1,1-Difluoro-2-methylpropyl)-N-(3,4-dimethyl-5-isoxazolyl)[1,1'-biphenyl]-2-sulfonamide
To a solution of 0.13 g (0.255 mmol) of compound D in 5 mL of dichloromethane at -78° C. under argon, 1.0 M boron tribromide in dichloromethane (0.3 mL) was added and stirred for 1 hour. The solution was slowly warmed up to room temperature and stirred for an additional 3 hours. The mixture was then diluted with 50 mL of dichloromethane, washed once with water, dried and evaporated to afford 0.16 g of the product as a colorless gum. This material was chromatographed on 25 g of silica gel using 3:1 Hexanes/ethyl acetate to provide 0.06 g (56%) of the title compound as an amorphous light brown foam.
M.p. 52-58° C. Analysis Calculated For C 21 H 22 F 2 N 2 O 3 S.: C,59.99; H,5.27; F,9.04; N,6.66; S,7.62; Found: C,59.73; H,4.97; F,9.26; N,6.42; S,7.70.
EXAMPLE 11
4'-(Difluoromethoxy)-N-(3,4-dimethyl-5-isoxazolyl)[1,1'-biphenyl]-2-sulfonamide ##STR20## A. 1-Bromo-4-(difluoromethoxy)benzene
To 4-bromophenol (10.38 g, 60 mmol) in 36 mL H 2 O, NaOH (2.4 g, 60 mmol) was added and the mixture was stirred at room temperature. When the mixture turned clear, 60 mL acetone was added. The reaction was heated at 50° C. and bubbled with chlorodifluoromethane gas through an inlet tube. The reaction mixture was concentrated and 300 mL hexane and 50 mL ethyl acetate were added. The organic liquid was separated and washed with 3×50 mL 1N NaOH, 50 mL H 2 O and 50 mL brine, dried and concentrated to give compound A (3.6 g, 27%) as a colorless liquid.
B. 4'-(Difluoromethoxy)-N-(3,4-dimethyl-5-isoxazolyl)-N-[(2-methoxyethoxy)-methyl][1,1'-biphenyl]-2-sulfonamide
To a solution of compound C from Example 8 (275 mg, 0.72 mmol), compound A (479 mg, 2.15 mmol) in 6.5 mL of toluene and 5.2 mL of 95% ethanol under argon, tetrakis(triphenyl-phosphine)palladium(0) (83 mg, 0.072 mmol) was added and followed by 3.9 mL of 2M aqueous sodium carbonate. The reaction mixture was heated at 75° C. for 2 hours 40 minutes, cooled and diluted with 40 mL of ethyl acetate. The organic liquid was separated and washed with 10 mL H 2 O and 10 mL brine, dried and concentrated. The residue was chromatographed on silica gel using 4:1 hexane/ethyl acetate to afford compound B (104 mg, 30%) as a colorless gum. R f =0.25, silica gel, 2:1 Hexane/ethyl acetate.
C. 4'-(Difluoromethoxy)-N-(3,4-dimethyl-5-isoxazolyl)[1,1'-biphenyl]-2-sulfonamide
To a solution of compound B (100 mg, 0.21 mmol) in 10 mL of 95% ethanol, 10 mL of 6N aqueous HCl was added and refluxed for 1 hour. The reaction mixture was concentrated and 40 mL ethyl acetate were added. The organic liquid was washed with 10 mL H 2 O and 10 mL of brine, dried and concentrated. The residue was chromatographed on silica gel using 2:1 hexane/ethyl acetate to afford the title compound (51 mg, 62%) as white solid.
M.p. 107-110° C. Analysis calculated for C 18 H 16 N 2 O 4 SF 2 : Calculated: C, 54.82; H, 4.09; N, 7.10; S, 8.13; F, 9.63; Found: C, 54.76; H, 3.86; N, 6.96; S, 8.27; F, 9.98.
EXAMPLE 12
N-(3,4-Dimethyl-5-isoxazolyl)-2'-[(formylamino)methyl]-4'-(2-methylpropyl)[1,1'-biphenyl]-2-sulfonamide ##STR21## A. Acetic formic anhydride
Compound A was prepared as described in Organic Syntheses, Coll. Vol 6, 8-9 (1988).
B. N-(3,4-Dimethyl-5-isoxazolyl)-2'-[(formylamino)methyl]-4'-(2-methylpropyl)[1,1'-biphenyl]-2-sulfonamide
To a solution of the title compound from Example 6 (48 mg, 0.12 mmol) in 0.58 mL dichloromethane, compound A (41 mg, 0.47 mmol) was added and followed by triethylamine (47 mg, 0.47 mmol). The mixture was stirred at room temperature overnight, diluted with 30 mL dichloromethane, washed with 5 mL 0.2N hydrochloride and 0.5 mL H 2 O, dried and concentrated. The residue was chromatographed on silica gel using 100:2.5 dichloromethane/methanol to afford a solid which was further purified by preparative HPLC on a 30×500 mm ODS S10 column using 72% solvent A (90% methanol, 10% H 2 O, 0.1% TFA) and 28% solvent B (10% methanol, 90% H 2 O, 0.1% TFA) to provide the title compound (40 mg, 77%) as a white solid.
M.p. 78-83° C. (amorphous). Analysis calculated for C 23 H 27 N 3 O 4 S.0.36H 2 O: Calculated: C, 61.67; H, 6.24; N, 9.38; S, 7.16; Found: C, 61.81; H, 6.06; N, 9.24; S, 6.88.
EXAMPLE 13
N-(3,4-Dimethyl-5-isoxazolyl)-4'-(trifluoromethyl)[1,1'-biphenyl]-2-sulfonamide ##STR22## A. N-(3,4-Dimethyl-5-isoxazolyl)-N-[(2-methoxyethoxy)methyl]-4'-(trifluoromethyl)-[1,1'-biphenyl]-2-sulfonamide
To a solution of 2-Bromo-N-(3,4-dimethyl-5-isoxazolyl)-N'-(methoxyethoxymethyl)benzenesulfonamide (335 mg, 0.8 mmol, prepared as described for compound A from Example 4 of EP Publication number 0,569,193) 4-trifluoromethylbenzeneboronic acid (228 mg, 1.2 mmol) in 6.5 mL of toluene and 5.2 mL of 95% ethanol under argon, tetrakis(triphenylphosphine)palladium(0) (55 mg, 0.048 mmol) was added and followed by 3.9 mL of 2M aqueous sodium carbonate. The reaction mixture was heated at 80° C. for 4 hours, cooled and diluted with 30 mL of ethyl acetate. The organic liquid was seperated and washed with 10 mL H 2 O and 10 mL of brine, dried and concentrated. The residue was chromatographed on silica gel using 4:1 hexane/ethanol to afford compound A (230 mg, 59%) as a colorless gum. R f =0.42, silica gel, 2:1 Hexane/ethyl acetate.
B. N-(3,4-Dimethyl-5-isoxazolyl)-4'-(trifluoromethyl)[1,1'-biphenyl]-2-sulfonamide
To a solution of compound A (230 mg, 0.48 mmol) in 8 mL of 95% ethanol, 8 mL of 6 N aqueous HCl was added and refluxed for 2 hours. The reaction mixture was concentrated to about 8 mL and extracted with 3×15 mL of ethyl acetate. The organic extracts were washed with 10 mL of brine, dried and concentrated. The residue was chromatographed on silica gel using 2:1 hexane/ethyl acetate to provide the title compound (165 mg, 88%) as a white solid.
M.p. 57-62° C. (amorphous). Analysis calculated for C 18 H 15 N 2 O 3 SF 3 .0.14H 2 O: Calculated: C, 54.21; H, 3.86; N, 7.02; S, 8.04; F, 14.29; Found: C, 54.35; H, 3.58; N, 6.88; S, 7.85; F, 14.65.
EXAMPLE 14
N-(3,4-Dimethyl-5-isoxazolyl)-4'-(1,2,2,2-tetrafluoroethyl)[1,1'-biphenyl]-2-sulfonamide, lithium salt ##STR23## A. 1-(4-Bromophenyl)-2,2,2-trifluoro-1-ethanone
Dibromobenzene (6.0 g, 0.025 mol) was dissolved in 59 mL of anhydrous tetrahydrofuran in a flame-dried flask. The solution was cooled to -78° C. in a dry ice/acetone bath and n-butyllithium (2.56 M in hexanes, 9.8 mL, 0.025 mol) was slowly added dropwise, keeping the reaction temperature less than -60° C. during the course of addition. Upon full addition, the reaction was stirred at -78° C. for 1 hour. The solution was then added dropwise, via cannula, to a solution of ethyl trifluoroacetate (3.56 g, 0.0257 mol) in 36 mL of ethyl ether cooled to -78° C. Upon full addition, the reaction was stirred at -70° C. for 15 minutes, and then allowed to warm gradually to room temperature. The reaction was partitioned between ethyl ether and saturated aqueous ammonium chloride, adjusting the pH of the aqueous phase to approximately pH=2 by the dropwise addition of 1 M HCl. The organic phase was washed with brine and dried over MgSO 4 , filtered and concentrated to provide 10 g (>100%) of crude compound A which was used in the next reaction without further purification.
B. 4-Bromo-α-(trifluoromethyl)benzenemethanol
Compound A (2.5 g, 9.88 mmol) was dissolved in 20 mL of absolute ethanol and the solution was cooled to 0° C. in an ice water bath. Sodium borohydride (375 mg, 9.88 mmol) was suspended in 20 mL of absolute ethanol and the suspension was slowly added to the reaction, keeping the temperature less than 2° C. Upon full addition, the ice bath was removed and the reaction was allowed to warm to room temperature and stirred for 45 minutes. The reaction was quenched by dropwise addition of 1.0 M HCl until the bubbling ceased and the solution had a pH of 2. The reaction was then partitioned between water and ethyl ether. The aqueous phase was extracted again with ethyl ether and the organic phases were dried over MgSO 4 , filtered and concentrated using low vacuum to remove the majority of the excess ether. The remaining solution was distilled at 1 atm to remove excess ethanol and provide 2.679 g of a yellow oil. The oil was azeotroped with pentane several times to remove any residual solvents to provide 2.368 g (94%) of the compound B.
C. 1-Bromo-4-(1,2,2,2-tetrafluoroethyl)benzene
Compound B (700 mg, 2.74 mmol) was dissolved in 6.0 mL of fluorotrichloromethane and the resulting solution was cooled to -78° C. on a dry ice/acetone bath. Diethylaminosulfur trifluoride (444 mg, 2.75 mmol) was then added dropwise to the solution, keeping the temperature less than -65° C. Upon full addition, the reaction was warmed to room temperature and stirred for 3 hours. The reaction was then quenched with water and extracted with ethyl ether. The organic phases were dried over MgSO 4 , filtered and concentrated under low vacuum. The material was then azeotroped with pentane to provide the crude fluoride as a yellow oil which was purified by flash chromatography (silica gel, pentane). The fractions containing product were concentrated under low vacuum and then the residual solvent was distilled off at atmospheric pressure using a short-path still to provide 482 mg (68%) of the purified fluoride as a transparent oil.
D. N-(3,4-Dimethyl-5-isoxazolyl)-N-[(2-methoxyethoxy)methyl]-4'-(1,2,2,2-tetrafluoroethyl)[1,1'-biphenyl]-2-sulfonamide
To compound C from Example 8 (718 mg, 1.87 mmol), suspended in 15 mL of a solution of 3:4:5 saturated sodium carbonate:ethanol:toluene was added compound C above, which was also dissolved in 15-20 mL of the 3:4:5 solution. Tetrakis(triphenylphosphine)palladium (0) (175 mg, 0.150 mmol) was then added and the reaction was heated to 80° C. on an oil bath for 3 hours. The reaction was cooled, diluted in 220 mL of ethyl acetate, and washed with mL each of water and brine. The organic phase was dried over MgSO 4 , filtered and concentrated to yield 1.36 g of a yellow oil which was purified by flash chromatography (silica gel, 75:25 ethyl acetate:hexane) to provide 498 mg (52%) of the purified biphenyl compound D.
E. N-(3,4-Dimethyl-5-isoxazolyl)-4'-(1,2,2,2-tetrafluoroethyl)[1,1'-biphenyl]-2-sulfonamide
The protected amino compound D (475 mg, 0.92 mmol) was dissolved in 12 mL of absolute ethanol and then 12 mL of 6.0 M HCl was added at room temperature. The reaction was heated to 95-100° C. for 2.5 hours, cooled, diluted with water and extracted with ethyl acetate. The organic phases were combined, dried over MgSO 4 , filtered and concentrated to provide 430 mg of the crude amine which was purified by flash chromatography (silica gel, 99:1 dichloromethane, methanol) to provide 252 mg (64%) of free the amine compound E.
F. N-(3,4-Dimethyl-5-isoxazolyl)-4'-(1,2,2,2-tetrafluoroethyl)[1,1'-biphenyl]-2-sulfonamide, lithium salt
Aqueous lithium hydroxide (1.0M, 1.0 mL) was added to compound E (252 mg, 0.588 mmol) and the solution was placed on an HP-20 column, eluting with 200 mL water, followed by 200 mL each of 20% and 30% acetone:water. The fractions containing the product were concentrated to approximately 20 mL in volume, passed through a Millipore filter and lyophilized to provide 110 mg of the desired lithium salt which was further purified by an additional HP-20 column, eluting with 200 mL of water, followed by 200 mL of 30% acetone:water. The fractions containing product were concentrated and lyophilized to provide 75 mg (26%) of the title compound as a white solid.
M.p. 165-180° C. Analysis calculated for C 19 H 15 N 2 O 3 SF 4 .Li.1.7H 2 O: C, 49.07; H, 3.99; N, 6.02; S, 6.89; F, 16.34; Found: C, 48.86; H, 3.82; N, 5.95; S, 6.81; F, 16.05.
EXAMPLE 15
N-(3,4-Dimethyl-5-isoxazolyl)-4'-(1,2,2,3,3,3-hexafluoropropyl)[1,1'-biphenyl]-2-sulfonamide, lithium salt ##STR24## A. 1-(4-Bromophenyl)-2,2,3,3,3-pentafluoro-1-propanone
Compound A was prepared using a process analogous to the process described in Example 14A except that ethyl pentafluoropropionate (2.66 g, 13.86 mmol) was used and the crude ketone was purified by flash chromatography (silica gel, hexane). The fractions containing product were concentrated to provide 1.1 g (29%) of purified compound A as a transparent oil.
B. 4-Bromo-α-(1,1,2,2,2-pentafluoroethyl)-benzenemethanol
Compound A (890 mg, 2.94 mmol) was used in the process described in Example 14B to provide 806 mg (90%) of compound B.
C. 1-Bromo-4-(1,2,2,3,3,3-hexafluoropropyl)-benzene
Compound B (200 mg, 0.656 mmol) was used in the process described in Example 14C to provide 236 mg (>100%) of the purified compound C as a transparent oil which contained 12% by weight pentane as determined by 1 HNMR.
D. N-(3,4-Dimethyl-5-isoxazolyl)-N-[(2-methoxyethoxy)methyl]-4'-(1,2,2,3,3,3-hexafluoropropyl)[1,1'-biphenyl]-2-sulfonamide
Compound C (265 mg, 0.69 mmol) was used in a process analogous to the process of Example 14D to provide 118 mg (36%) of compound D.
E. N-(3,4-Dimethyl-5-isoxazolyl)-4'-(1,2,2,3,3,3-hexafluoropropyl)[1,1'-biphenyl]-2-sulfonamide
Compound D (118 mg, 0.21 mmol) was used in a process analogous to the process of Example 14E to provide 85 mg (85%) of compound E.
F. N-(3,4-Dimethyl-5-isoxazolyl)-4'-(1,2,2,3,3,3-hexafluoropropyl)[1,1'-biphenyl]-2-sulfonamide, lithium salt
Compound E (85 mg, 0.178 mmol) was used in a process analogous to the process of Example 14F to provide 36 mg (42%) of the desired lithium salt as a white solid.
M.p. 245-260° C. 1 H NMR (270 MHz, CD 3 OD) δ 1.5 (d, J=3.5 Hz, 3H, CH 3 ); 2.0 (d, J=3.5 Hz, 3H, CH 3 ); 6.1 (ddd, J=43, 19, 3 Hz, 1H, CHCF 2 CF 3 ); 7.2 (d, J=8 Hz, 1H, ArH); 7.5 (m, 6H, ArH); 8.2 (d, J=8 Hz, 1H, ArH).
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Compounds of the formula ##STR1## inhibit the activity of endothelin. The symbols are defined as follows: ##STR2## R 2 and R 3 are each independently (a) hydrogen;
(b) alkyl, alkenyl, alkynyl, alkoxy, cycloalkyl, cycloalkylalkyl, cycloalkenyl, cycloalkenylalkyl, aryl, aryloxy, aralkyl or aralkoxy, any of which may be substituted with Z 1 , Z 2 and Z 3 ;
(c) halo;
(d) hydroxyl;
(e) cyano;
(f) nitro;
(g) --C(O)H or --C(O)R 6 ;
(h) --CO 2 H or --CO 2 R 6 ;
(i) --SH, --S(O) n R 6 , --S(O) m --OH, --S(O) m --OR 6 , --O--S(O) m --R 6 , --O--S(O) m OH or --O--S(O) m --OR 6 ;
(j) --Z 4 --NR 7 R 8 ; or
(k) --Z 4 --N(R 11 )--Z 5 --NR 9 R 10 ;
and the remaining symbols are as defined in the specification.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a National Stage application under 35 U.S.C. §371 of PCT Application No. PCT/US2007/006457, filed Mar. 15, 2007, entitled “Instrument For Making Optical Measurements On Multiple Samples Retained By Surface Tension”, which claims the priority benefit of U.S. Provisional Application No. 60/785,208, filed Mar. 23, 2006, entitled “Eight-Channel Instrument”, which applications are incorporated herein by reference in their entireties.
FIELD OF THE INVENTION
This invention relates to the field of optical measurements and particularly to spectrophotometry and more particularly to such measurements made upon liquid drops on the order of 2 microliters or less.
BACKGROUND OF THE INVENTION
Robertson, in U.S. Pat. Nos. 6,628,382 and 6,809,826, teaches containment of small droplets by surface tension. These patents are incorporated in their entirety by reference. In addition the method and apparatus disclosed may be applied to fluorometry with apparatus and method as taught in Robertson et al.'s application PCT/US 2006/04406 with inclusion of the special optical requirements in fluorometry to keep the signal from being overwhelmed by incident light. The disclosure of that application is incorporated herein in its entirety by reference.
In making these measurements, the need for high productivity in the work of the laboratory involved is plain. Instrumentation and method that permit simultaneous, or near simultaneous, operation on multiple samples is most desirable. It is to this end that this invention is directed.
SUMMARY OF THE INVENTION
In brief, the invention is directed to processing in an optical measuring device a plurality of small droplets of liquid (“nanodrops” of micro-liter volume) simultaneously or nearly so. The preferred embodiment of the invention has eight fibers, which preferably are 100 micron, individually picking up light from a flash lamp and feeding the upper fiber bushings of an array of eight paired measurement fiber optic (FO) bushings. Light from the eight receiving fibers, which preferably are 400 micron, is fed to a fiber optic switch or multiplexer where a precision linear actuator scans a single 400-micron fiber across the spaced ends of the eight sample-signal-receiving fibers. The fibers are spaced in the multiplexer by interleaving dead fibers (in the expanded view seen in FIG. 2 b these dead fibers are shown as black circles which is a long used industry practice) or can be spaced with the use of a micro machined V-groove block or by packing custom coated fibers into a cavity machined to be an exact fit.
Unlike the prior art apparatus disclosed in U.S. Pat. Nos. 6,628,382 and 6,809,826, the upper arm is moved by a stepper motor or servo motor linear actuator to accommodate the weight of the arm. Like the prior art apparatus, the moveable, upper arm after sample loading is moved to a substantially closed position to spread the samples and wet the opposing anvil surfaces and then to a selected more open position to pull the samples into columns to establish optical paths for optical measurements.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 a is a view in perspective of the apparatus in the open position.
FIG. 1 b is a view in perspective of the apparatus in a closed position.
FIG. 2 a is a somewhat schematic partial view in perspective of the scanning apparatus enlarged from FIGS. 1 a and b.
FIG. 2 b is a somewhat schematic view in perspective of the fiber array with the scanning means removed and shows a further enlargement to show the spacing of the fibers.
FIG. 3 shows the perspective view of the apparatus where more than one fiber is scanned across the sample measurement fiber each feeding a separate spectral analysis system.
FIGS. 4 a and b show an alternate arrangement for holding the source fibers to the moving arm of the apparatus with 4 a showing the apparatus open without the source fibers and 4 b showing the apparatus closed with the source fibers.
FIGS. 5 a, b , and c show alternate fiber spacing arrangements with 5 a also schematically indicating rotary scanning means.
DETAILED DESCRIPTION OF THE INVENTION
Consider FIG. 1 a showing the apparatus of the invention 10 in the open position which is used for loading and FIG. 1 b showing it closed either in the first instance where the surfaces are proximate to spread the samples and wet the surfaces or in the measuring position where the surfaces are moved sufficiently apart to pull the samples into liquid columns for measuring. Light is generated in flash-lamp 12 . We use a lamp from Hamamatsu of Hamamatsu City, Japan. The light is carried by eight supply fibers 14 , preferably 100 micron, to upper arm 16 of the 8-channel measuring instrument 10 . The fibers pass through upper arm 16 and are finished proud of the surface 20 of upper arm 16 . These form the eight upper anvils 22 of the apparatus. Upper arm 16 is pivotally mounted at 18 to fixed arm 24 which serves as a base for the instrument or can be mounted to a base. Eight receiving/detection fibers 26 pass through fixed arm 24 and are finished so as to stand slightly proud of the surface 28 thereof to form eight lower anvils 30 . Preferably the receiving/detecting fibers are 400 micron. These lead to optical switch 32 in which a single fiber 34 is scanned across the eight fibers 26 with apparatus which will be described in detail below—The single scanning fiber 34 leads the signals in turn to measuring means 36 , preferably a spectrometer or fluorometer (see FIG. 3 ).
Consider FIGS. 2 a and 2 b . Here the scanning mechanism of optical switch 32 is shown in greater detail. In FIG. 2 a it is seen that optical switch 32 comprises feed block 38 , scanning block 40 , base/guide slide assembly 42 , and linear actuating mechanism 44 .
Feed block 38 holds the ends of fibers 26 in spaced linear array. The fiber ends 48 are finished flush with face 46 of feed block 38 . This is seen in more detail in FIG. 2 b with both a view in the same scale as FIG. 2 a where scanning block 40 is removed and, in greater detail, in the enlarged view. Spacing is provided by inter-leaving active fiber ends 48 with dead fiber ends 50 as seen in the enlargement. “Dead fibers” are simply suitable lengths of fiber not connected to a source. Spacing is important in limiting any cross-talk in reading the signals output by the individual fibers 26 . For convenience, the known convention is used showing the ends of the dead fibers as black circles. Feed block 38 in the physical embodiment is an assembly custom made by Romack of Williamsburg, Va.
Scanning block 40 mounted on base/guide slide assembly 42 , is constrained by means not shown in detail in base/guide slide assembly 42 to move linearly along the face of feed block 38 so that one end of fiber 34 moves across the eight ends 48 of spaced fibers 26 . It is moved by linear actuating mechanism 44 . In the physical embodiment of the invention, single opposing fiber 34 is a custom SMA terminated fiber optic patch cord also from Romack.
Base guide slide assembly 42 functions to linearly guide scanning block 40 in orthogonal relationship with fiber ends 48 . In the physical embodiment it is a ball bearing slide from Deltron of Bethel, Conn. p/n E-1. An end stop detector 54 is provided to establish a reference point for the motion of the scanning block. Linear actuating mechanism 44 is a stepper motor linear actuator. We use one fabricated by Haydon Switch of Waterbury Conn. p/n 28H43-05-036. It is plain to one skilled in the art that the linear array of the embodiment and the linear scanning means 32 described and shown, for example, in FIG. 2 b could be replaced by a toroidal array scanned by rotary means 32 carrying scanning fiber 34 as schematically indicated in FIG. 5 a . Alternatively the fibers can be spaced by location in V-shaped grooves in the assembly (see FIG. 5 c ). Still another embodiment would be to use fibers custom coated to yield suitable spacing in a suitable cavity or to enclose each fiber end in a sleeve 27 as indicated schematically in FIG. 5 b.
In a physical embodiment we use a spectrometer fabricated by Ocean Optics of Dunedin, Fla. p/n USB2000 UV/Vis.
Not shown is the control means of a suitably programmed computer that controls illumination and scanning. Such means and the programming thereof are within the skill of the skilled instrument designer and require no further explication here.
In use, with the instrument open as shown in FIG. 1 a , the eight lower anvils 30 are loaded each with a sample of fluid preferably using a pipette permitting simultaneous loading of all 8 samples. Then the instrument 10 is closed as shown in FIG. 1 b , first to a close sample compression position (as taught in the prior Robertson patents). This spreads the samples and wets both the lower set of anvils 30 and the upper set of anvils 22 . Then, as described in the prior Robertson patents, the two arms 16 and 24 are spaced apart a controlled distance in a substantially parallel relationship to draw each sample into a measuring column between the opposing ends of fibers 14 and 26 . This establishes a substantially parallel relationship between the fiber ends forming the opposing anvils establishing an optical path between the wetted areas on each of the fiber ends The flash-lamp 12 is actuated as the light source, a measurement signal is formed in each measuring column, and fiber 34 is scanned across the eight ends 48 of fibers 26 . Fiber 34 transmits each signal in turn to spectrometer 36 which in practice is connected to means such as a computer for information processing and output display as well as instrument sequencing.
Because upper arm 16 is much heavier than those in prior instruments described in the prior Robertson patents and application, improved means for actuating the relative motion between pivotally-mounted upper arm 16 and fixed arm 24 have been developed. One such implementation uses a DC servo motor 60 to activate a screw 61 that when turned controls the level of the upper arm when closed. The end of screw 61 bears on a suitable bushing 64 in surface 20 of upper arm 16 .
In applications needing more complex spectral analysis, a second collecting fiber can be used to collect data simultaneously with the primary fiber as is shown in FIG. 3 . Here the second fiber 74 is spaced one or more intervals away from the primary scanning fiber 34 and may be associated with a second spectrometer 37 , or other optical measuring instrument as will be seen, as shown in the figure. If the spacing is one interval, then only a single spectrometer will be employed for measurement on either end of the scan. Such measurements could be used to extend the measurement wavelength range beyond that covered by a single spectrometer or the second instrument could be used for entirely different sorts of measurements like fluorescence, the latter requiring additional light sources if the measurement is to be made in the orthogonal illumination fashion of the fluorescence instrument of application PCT/US2006?00406. Multiple fiber measurements can also be used to decrease the time needed to make measurements on the multiple samples. More than 2 spectrometers can be similarly employed by using additional scanning fibers spaced at the same interval as the fiber end group 48 .
Additionally the supply fibers 14 connecting the moving upper arm 16 to the lamp 12 can be mounted entirely on the arm as is shown in FIG. 4 a with the lamp 12 mounted directly to the lower arm 24 . The fibers are coupled by passing through ports 13 in both the lower 24 and upper arm 16 .
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The invention is an installment for making multi-channel spectroscopic measurements on a plurality of nanodrop samples held by surface tension between opposing optical fibers wherein a single fiber is scanned across a linear spaced array of receiving, detecting fibers.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to device control methods and device control apparatuses for connecting a device conforming to the universal serial bus (USB) standard to a computer, and more particularly, to a device control method and a device control apparatus which simplify a procedure required for connection to the device.
2. Description of the Related Art
A new standard for personal computers, called a universal serial bus (USB), has been recently formed and units conforming to this standard have been made commercially available. In this new standard, each of various types of peripheral units (hereinafter called devices), such as a keyboard, a mouse, and a game controller, has a connector with the same shape, and is connected to a USB port of a computer by the use of this connector.
The USB port has four pins in its inside and the pins are used for D+ and D− data lines, a power line, and the ground. Either the D+ pin or the D− pin is used to indicate that the device is connected or not connected. Whichever pin is used is pulled up (switched on) to indicate that a device is being connected, or the pin is pulled down (switched off) to indicate that a device is not connected.
Usually, one computer is provided with two USB ports of the same type. If three or more devices conforming to the USB standard are to be connected, then one or more ports may be lacking.
To handle such a case, a unit called a USB hub 9 shown in FIG. 3 has been developed, which is provided with a plurality of ports 2 b having the same shape as a USB port 2 a formed in a personal computer. When the USB hub 9 is connected to the USB port 2 a of the personal computer, a plurality of devices can be connected to the USB port 2 a of the personal computer.
The USB hub 9 shown in FIG. 3 is connected to the personal computer (PC) 2 by the use of a USB interface cable 6 . A device 1 , a device 2 , and a device X are connected to USB ports 2 b formed in the USB hub 9 with USB interface cables 7 .
However, device connection with the use of a usual USB port or device connection with the use of the USB hub 9 , described above, has the following inconveniences.
When a new device (device X in this case) is added to the PC 2 after devices (device 1 and device 2 in this case) have already been connected, the PC 2 does not identify the new device X and a driver for the device X does not run unless a USB connector formed at a end of the interface cable 6 is disconnected from the USB port 2 a of the PC 2 then and connected again. When a connected device is removed, a device driver for the device cannot be deleted without disconnecting the USB connector and connecting it again in the same way as above.
If a USB port is formed at the back of a personal computer, it is very troublesome to disconnect a USB connector and connect it again at the back of the personal computer.
As described above, when a device is added or is removed, the D+ pin (or the D− pin) of the USB port, which has been pulled up, is pulled down and then pulled up again to send the information of each device being connected at the time before the pin is pulled down, to the personal computer through data lines 6 a and 6 b. In this way, the personal computer can reidentify device connections.
Without disconnecting the USB connector and connecting it again, device connections can be identified again by resetting the personal computer. In this case, it takes a long time to make the personal computer ready and the operation therefor is troublesome. In addition, if the personal computer is reset, any application programs being currently used have to be ended.
The USB hub 9 described above just allows an increase in the number of devices to be connected. When a device is added or removed, the USB connector needs to be disconnected and connected again at the USB port 2 a, or the personal computer has to be reset, in the same way as in a case in which the USB hub 9 is not used.
A wireless device is easier to handle because it does not have a cable. Even for such a device, a connector needs to be disconnected and connected again, or an operation corresponding thereto is required to identify device connection again. A further operability improvement cannot be expected, which uses the advantages of a wireless device.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide a device control method and a device control apparatus which automatically identify device connection and allow a connected device to be used, without initializing the device by resetting a system or by disconnecting a connector and then connecting it again.
The foregoing object is achieved in one aspect of the present invention through the provision of a device control method in which a device driver is switched when a computer provided with a USB port is connected to a device which conforms to the USB standard and is used by being connected to the computer, wherein a control section which can switch the device driver is provided for the computer, and when a new device is added to the computer or a connected device is removed from the computer, the control section allows the device driver to be automatically switched to a driver dedicated to the device without switching a data-line connection pin provided for the USB port or without performing the corresponding switching operation.
With the foregoing means, the computer perceives that a device has been connected and can immediately make the connected device ready just by connecting the device to the computer, without disconnecting a connector from the USB port and then connecting it again after the device is added or removed or without resetting the system.
In this case, the control section can be introduced into the computer by software.
By installing the software into the computer in advance, when a new device is connected, a device driver dedicated to the device immediately starts running and is readily used.
Even an unfamiliar device (a device whose device driver is not installed in advance) can be used by upgrading the software to a version which handles the unfamiliar device. If the operating system of the computer is updated to a new version, the program only needs to be changed so that the software corresponds to the operating system. The user does not need to buy new hardware.
It is preferred that the device be a wireless device connected to the computer through a controller which transmits and receives device data.
As described above, when a wireless device is used, the device is made ready just by disposing it at a predetermined location specified by the controller. By moving the device from the predetermined location, the device driver which corresponds to the device and which has started running in the computer is released.
In this case, when a new device is disposed at a predetermined location, the controller receives information from the device and sends the received device information to the computer. The control section perceives the device information, identifies the type of the connected device, and activates a device driver dedicated to the device.
The foregoing object is achieved in another aspect of the present invention through the provision of a device control apparatus including a computer provided with a USB port, a device which conforms to the USB standard and is used by being connected to the computer, and a control section which can switch the driver of the device, wherein the control section is introduced into the computer by software. Thereby, when a new device is added to the computer or a connected device is removed from the computer, the device driver is automatically switched to a driver dedicated to the device without switching a data-line connection pin provided for the USB port or without performing the corresponding switching operation.
Since the control section provided for the computer is implemented by the software in the control apparatus, a device is made ready just by disposing it at a predetermined location without adding new hardware.
As described above, according to the present invention, when a new device is connected, the device can be used immediately after the connection without switching either the D+ pin or the D− pin provided for the USB port of the personal computer, or without resetting the system. Since software can handle the processing, even if a not-installed driver is to be used or the operating system is updated, the processing is accomplished by only changing the program, thereby providing improved cost-effectiveness.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an outlined view of connections between a personal computer and devices.
FIG. 2 is a block diagram showing device-data flows.
FIG. 3 is an outlined view of conventional connections between a personal computer and devices.
DESCRIPTION OF THE PREFERRED EMBODIMENT
A device control method and a device control apparatus according to the present invention will be described below by referring to the drawings.
FIG. 1 is an outlined view of connections between a personal computer (PC 2 ), a USB controller 1 , and various types of devices. The devices are of a wireless type. Not all of them need to be wireless.
The PC 2 is connected to the USB controller 1 with a USB interface cable 6 through a USB port 2 a. A plurality of wireless devices are connected to the USB controller 1 .
The USB port 2 a has four pins in its inside. The pines are used for D+ and D− data lines, a power line, and the ground. Either the D+ pin or the D− pin is pulled up when a connector is inserted to the port, and thereby the PC 2 perceives that a device has been connected. When a connector is not inserted into the port, either the D+ pin or the D− pin is pulled down (switched off) to the ground, and thereby the PC 2 perceives that a device is not connected. In the USB standard, transmission rates of 1.5 MB/bps and 12 MB/bps are supported and either transmission rate is applied according to the type of a connected device.
The USB controller 1 can manage various types of devices in a centralized manner. For example, as shown in FIG. 1, three wireless devices (i.e., device 1 , device 2 and device X) are disposed.
The USB controller 1 is provided with receiving sections for various types of devices. When a device is connected, the USB controller 1 identifies the type of the device and sends the data of the device to the PC 2 . When the USB controller 1 perceives for some reason such as battery run-down that the device is not connected, the USB controller 1 sends data to the PC 2 for removing the device.
When the data of the device is sent to the PC 2 as described above, a device driver built into the PC 2 in advance starts running. When a keyboard is connected, the type of a pressed key is sent, or when a mouse is connected, the coordinate data of the cursor is sent, and the PC 2 performs predetermined processing.
FIG. 2 is a block diagram used for describing data flows of devices and those inside the PC 2 .
The PC 2 is provided with a USB host controller 10 , a control section 11 , mini-port drivers 12 a, 12 b, and 12 c dedicated to devices, and processing sections 13 a and 13 b for processing data from each device.
The USB host controller 10 receives device data sent from the USB controller 1 in a centralized manner and sends it to the control section 11 . The control section 11 transmits the received device data to the corresponding drivers dedicated to devices.
As shown in FIG. 2, it is assumed that the three types of wireless devices, the device 1 , the device 2 , and the device X, are a keyboard A, a keyboard B, and a mouse, respectively, and a case in which these devices are installed will be described below.
When each device is installed in a predetermined area (an area in which it can be detected) of the USB controller 1 , the USB controller 1 gives identification information indicating the type of each device and sends device information through a USB interface cable 6 as data 20 a, data 20 b, and data 20 c. The information is not transmitted one by one but transmitted (A) by a bulk transmission method so that a plurality of data items are sent as a group.
When the USB interface cable 6 is connected to the USB port 2 a, either the D+ pin or the D− pin in the port 2 a is pulled up (switched on) and a transmission rate of 1.5 MB/bps or 12 MB/bps is determined. In the USB interface cable 6 , data is transferred through the two D+ and D− data lines.
The USB host controller 10 transmits (B) the data 20 a, the data 20 b, the data 20 c sent from the devices to the control section 11 . The control section 11 activates the mini-port drivers 12 a, 12 b, and 12 c according to the identification information in the device data 20 a, 20 b, and 20 c, and sends the device data through the mini-port drivers 12 a, 12 b, and 12 c. In this case, the control section 11 automatically divides (C, D, E) the data such that the data 20 a, 20 b, and 20 c are sent to the drivers of the keyboard A ( 12 a ), the keyboard B ( 12 b ), and the mouse ( 12 c ), respectively.
The mini-port drivers 12 a and 12 b for the keyboards A and B send an input signal from the keyboards to an integrated device driver 13 a which converts the signal to data to be processed by the CPU. In this case, the two keyboards A and B can be connected together and used at the same time. The mini-port driver 12 c for the mouse sends an input signal from the mouse indicating click information or coordinate information to a device driver 13 b which converts the signal to data to be processed by the CPU.
When a new wireless device, for example, a game controller (device Y), is connected, the USB controller 1 identifies the device data of the game controller and determines identification information. The identification information and other data are sent through the interface cable 6 to the USB host controller 10 and then to the control section 11 . A mini-port driver 12 d dedicated to the game controller starts running and data information for the game controller is sent to a device driver 13 c.
The control section 11 periodically sends a confirmation signal to the USB controller 1 . According to the confirmation signal, the USB controller 1 always identifies the devices being used. If the device 1 is removed, for example, the USB controller 1 sends information indicating that the device 1 has been removed to the control section 11 and the control section 11 identifies the condition.
When a device whose device driver is not installed in the PC 2 is used, the device driver is installed into the PC 2 first, and then the control section 11 is updated by upgrading the software.
The CPU applies predetermined processing through the device driver 13 a to the input data sent from the keyboards A and B as described above, and input characters and other data are displayed on a display unit of the PC. The CPU also applies predetermined processing through the device driver 13 b to the input data sent from the mouse, and the cursor is moved or selection or determination is performed on a screen on the display unit of the PC.
The USB controller 1 may be disposed at any place within an area where it can detect a device, such as on a display unit, when the USB controller 1 is connected to a desktop personal computer and used.
The USB controller 1 may be provided with a USB port so that not only a wireless device but also a cable-connection-type device can be connected thereto. Instead of the USB controller 1 , a USB hub may be connected so that all devices are connected with cables and used. Also in this case, a device can be simply added or removed just by disconnecting the connector and connecting it again.
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With a control section implemented by software, which is provided for a personal computer, when a device is added, a device driver dedicated to the device starts running. When a device is removed, the corresponding device driver is released. Since a control apparatus is used which includes the personal computer provided with the control section, a wireless device, and a universal serial bus (USB) controller for transferring data to and from the device, the device can be used immediately after it is disposed at a predetermined location.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is the US National Stage of International Application No. PCT/EP2005/053157, filed Jul. 4, 2005 and claims the benefit thereof. The International Application claims the benefits of European Patent application No. 04016357.8 filed Jul. 12, 2004. All of the applications are incorporated by reference herein in their entirety.
FIELD OF INVENTION
[0002] The invention relates to a method and an apparatus for determination of the gap size of a radial gap between rotating and rotationally fixed components, in particular between those of a continuous-flow machine. The invention also relates to a continuous-flow machine having an apparatus such as this.
BACKGROUND OF THE INVENTION
[0003] Continuous-flow machines, such as compressors or turbines, have rotationally fixed stator blades arranged in rings and rotor blades, which are firmly connected to the rotor, which can rotate, of the continuous-flow machine, in each case alternately in the flow channel. The radial gaps are formed between the radially outer tips of the rotor blades and the boundary surface, which is located radially on the outside, of the flow channel. Radial gaps are likewise formed between the tips of the stator blades and the inner boundary surface of the flow channel, which is formed by the outer surface of the rotor. Various methods are known for measurement of these radial gaps during operation.
[0004] U.S. Pat. No. 4,326,804 describes a method for radial gap measurement between the guide ring and the rotor blades of a turbine. A means which reflects light and reflects a measurement light beam, preferably laser light, is provided at each rotor-blade tip. The respectively reflected light beam is directed at a light spot position detector via a lens system. Its focus appears, as a function of the radial gap, at a position in the detector from which the radial gap is determined. In this case, one measurement is carried out per revolution for each rotor blade.
[0005] Furthermore, DE 27 30 508 discloses an optical method for determination of the distance between a stationary and a rotating component. A light source emits a conical light beam which is projected as a light spot of different size onto a light-intensive receiver as a function of the gap size, and this light spot is evaluated for distance measurement.
[0006] Furthermore, patent specification DE 196 01 225 C1 discloses an apparatus for radial-gap monitoring for a turbine, in which a measurement reference point for reflection of light is provided on a turbine blade, with the light being directed at the measurement reference point from a glass-fiber probe which is passed through the turbine casing. During operation of the turbine, the currently detected intensity differences between the transmitted light and received light are compared with the intensity differences determined in a reference measurement, and the size of the radial gap is calculated from the discrepancy in the intensity difference between real measurement and the reference.
[0007] Furthermore, EP 492 381 A2 discloses a method for tip clearance measurement on turbine blades using an optical transmitter and receiver, with the receiver receiving the light that has been reflected from the turbine blades and, in this case, evaluating the time reflection-intensity profile.
[0008] This method is based on a transmitter and a receiver in the form of a sensor being placed in the stationary system, that is to say in the outer boundary wall or in the casing, in order to use optical effects to identify the rotating component, which is thus moving past the receiver or the sensor tip, and to determine the distance to it at this instant.
[0009] In general, these methods are characterized in that the receivers or sensors that are used cannot be miniaturized below a specific limit and thus have a mass which cannot be ignored. Furthermore, some of the methods require complex feed and transmission electronics.
[0010] These sensors cannot be mounted at the tip of a free-standing stator blade in a continuous-flow machine since a sensor such as this would have a negative influence on the natural oscillation behavior of the stator blades. These stator blades could be caused to oscillate during operation, thus reducing the life of the blades.
[0011] It is often impossible to arrange sensors in the rotating system, or this requires an unjustified high degree of complexity in order to supply the generally complex electronics. If sensors, or in particular receivers, are provided in the rotating system, a costly telemetry installation, which is susceptible to defects, may be required in order to pass information out of the rotating system, and this increases the general complexity.
SUMMARY OF INVENTION
[0012] One object of the invention is to specify a cost-effective and reliable method and an apparatus for determination of the gap size of a radial gap between rotating and rotationally fixed components, which has sensors with a comparatively small mass and small volume.
[0013] A further object is for the apparatus and the method to satisfy general requirements such as insensitivity to pressure and temperature, a wide operating range, that is to say dynamic range, with respect to the temperature of use and the rotation speed, and/or not to require any adjustment or calibration. A further object of the invention is to specify the use of an apparatus such as this for monitoring of the radial gap.
[0014] The object relating to the method is achieved by the features of the claims. Furthermore, the object relating to the apparatus is achieved by the features of the claims. Advantageous refinements are specified in each of the dependent claims.
[0015] One solution to the object relating to the method provides that, in order to determine the gap size of a radial gap between rotating and rotationally fixed components, in particular between those in a continuous-flow machine, in which a source signal which is emitted as a radio wave from a transmitting device that is arranged on the surface of the rotating component is received by a receiving device, which is arranged on the rotationally fixed component, and is passed on to an evaluation device, which evaluation device uses the received signal to determine the gap size of the radial gap, and to display this, by determination of the parameters of the path curve (trajectory determination) of the rotating transmitting device.
[0016] Another solution to the object relating to the method provides that, in order to determine the gap size of a radial gap between rotating and rotationally fixed components, in particular between those of a continuous-flow machine, a source signal which is emitted as a radio wave from a transmitting device which is arranged on the rotationally fixed component is reflected in a modified form by a reflection structure which is arranged on the rotating component, which is received, as a received signal, by a receiving device which is arranged on the rotationally fixed component and is passed on to an evaluation device, and which evaluation device uses the received signal to evaluate the change in comparison to the source signal in order to determine the parameters of the path curve (trajectory determination) of the rotating reflection structure, in order to determine and to display the gap size of the radial gap.
[0017] Both solutions are based on the inventive idea that the gap size of the radial gap can be determined by determination of the parameters of the path curve of a defined point which is arranged on the rotating component, that is to say by determination of its trajectory. The position of the receiving device is used as a stationary reference point for this purpose.
[0018] The distance, which changes all the time, between the rotating defined point (which may on the one hand be a transmitting device which is arranged on the rotating component or may on the other hand be the reflection structure) and the position of the receiving device as a stationary reference point is recorded, at least at times, as a function of the rotation angle of the rotating component. A function graph of the magnitude of the distance as a function of the rotation angle is derived by the evaluation device (trajectory determination), from which the desired parameter, specifically the minimum distance between the rotating transmitting device and the receiving device that is arranged in a rotationally fixed manner, is determined, and corresponds to the radial gap between the rotating component and the rotationally fixed component.
[0019] Radio waves have the advantage over optical waves that they can be produced, passed on, transmitted, received and processed further using comparatively simple electronic components. Furthermore, the use of radio waves results in a particularly wide operating range, that is to say dynamic range.
[0020] In one advantageous refinement, the signals are radio-frequency (RF) electromagnetic waves at a frequency in the range between 0.5 MHz and 100 GHz, in particular at a frequency in the range from 100 MHz to 10 GHz. The use of electromagnetic radio waves results in general independence from the medium that is located in the radial gap. Furthermore, comparatively small and low-mass transmitting/receiving components with high resolution, a wide dynamic range and which cost little are available for electromagnetic radio waves, and these allow a differentiating measurement of the radial gap at high rotation speeds, such as those which occur during operation of a continuous-flow machine.
[0021] According to a further advantageous refinement, in order to determine the distance between the rotating point and the reference point, the evaluation device evaluates the field strength and/or the intensity of the received signal. The revolving, that is to say rotating, transmitting device cyclically moves towards and away from the stationary receiving device on its circular path, so that a continuously varying field strength or intensity of the received signal is recorded by the receiving device, as a function of the distance between the two devices. In this case, the field strength and the intensity of the received signal are strongest at the point where the transmitting and receiving devices are opposite, forming the shortest possible distance between them. When electromagnetic waves are used as signals, the field strength is evaluated.
[0022] Instead of the transmitting device, a reflection structure can be provided on the rotating component, which reflects a source signal (which is transmitted as a radio wave from the transmitting device which is now mounted in a rotationally fixed manner) to the receiving device (which is mounted in a rotationally fixed manner) and in this case results in manipulation, that is to say variation, of the source signal, and this is identified by the evaluation device. Apart from this, the evaluation device is equipped analogously to the first solution.
[0023] The trajectory determination, that is to say the parameters of the path curve of a defined point on a rotating circular path, can alternatively be determined by evaluating the frequency shift in the received signal caused by the Doppler effect, instead of by measurement of the intensity and/or field strength. If the transmitting device is moving, the source signal that is transmitted from it as a radio wave is modulated by the Doppler effect.
[0024] According to one advantageous proposal, the evaluation device filters out the Doppler frequency, that is to say the difference frequency of the received signal, by frequency demodulation from the received signal. The gap size of the radial gap can be determined from this on the basis of the time duration of the change in the difference frequency.
[0025] The first solution to the object relating to the apparatus provides that, in order to carry out the method as claimed in the claims, for determination of the radial gap between rotating and rotationally fixed components, in particular between those in a continuous-flow machine, a transmitting device which transmits radio-frequency waves is arranged on the rotating component and a receiving device which receives radio-frequency waves is arranged on the rotationally fixed component, and is connected to an evaluation device for communication purposes.
[0026] In one advantageous refinement of the apparatus, the transmitting device can be supplied with energy by means of an inductive coupling from the rotationally fixed component. As an alternative to this, the transmitting device can be supplied with energy by a battery, which is likewise arranged on the rotating component. This allows the transmitting device to be supplied with energy without any contact and thus without wear. The design of the economic transmitting device results in the capacity of a battery being sufficient to supply the transmitting device with energy over a plurality of years until, for example, the servicing of the continuous-flow machine allows the rotor to be exposed, and thus allows the battery to be replaced.
[0027] A second solution to the object relating to the apparatus provides that, in order to carry out the method as claimed in for determination of the radial gap between rotating and rotationally fixed components, in particular between those in a continuous-flow machine, a reflection structure, which can receive and transmit radio-frequency waves is arranged on the rotating component, and a transmitting and receiving device which processes radio-frequency waves is arranged on the rotationally fixed component, which receiving device is connected to an evaluation device, for communication purposes.
[0028] The reflection structure is expediently formed by a dipole which is arranged on an insulated mount layer and has an RF diode, with the dipole preferably being in the form of a non-linear, passive dipole. The dipole receives the source signal transmitted from the transmitting device and uses the RF diode to transmit an electromagnetic wave at approximately twice the frequency back, with this electromagnetic wave furthermore being modulated by the Doppler effect, as a result of the rotation. The receiving device filters the electromagnetic wave at twice the transmission frequency out of the received signal, and passes this to the evaluation device. The electromagnetic waves which are reflected in any case from a metallic or planar surface of the rotating component, and which are at the same frequency as the source signal, are therefore ignored. The devices operate using radio waves whose frequencies are in the range between 0.5 MHz and 100 GHz, preferably 100 MHz and 10 GHz.
[0029] The transmitting and receiving devices can be arranged as co-axially as possible with respect to one another if the transmitting device and the receiving device respectively have a transmitting antenna and a receiving antenna-which respectively have a point-beam or a linear-beam characteristic.
[0030] The solution to the object of the invention relating to use proposes that a continuous-flow machine is equipped with an apparatus as claimed in the claims, in which a method as claimed in the claims can be carried out. This allows radial gaps to be monitored in the continuous-flow machine, which is preferably in the form of a stationary gas turbine, in which these radial gaps can assume critical values in particular during hot starting of the continuous-flow machine. Furthermore, an axial shift, which is carried out in order to improve efficiency, of the rotor in a continuous-flow machine which has a conical flow channel can be carried out particularly exactly. This results in the flow medium in the continuous-flow machine being carried correctly past the rotor blades in the continuous-flow machine, allowing the flow losses caused by the radial gap above the blade tips in the flow medium to be minimized.
BRIEF DESCRIPTION OF THE DRAWINGS
[0031] The invention will be explained with reference to a drawing, in which:
[0032] FIG. 1 shows schematically, a measurement arrangement for determination of the parameters of the relative path curve of a rotating point,
[0033] FIG. 2 shows a diagram of the distance function s=f(φ),
[0034] FIG. 3 shows a diagram of the velocity function ds/d(φ),
[0035] FIG. 4 shows the difference frequency of a sound-wave signal, which has been modulated by the Doppler effect, from a moving transmitting device,
[0036] FIG. 5 shows the difference frequency of an electromagnetic RF signal, which has been modulated by the Doppler effect, from a moving transmitting device,
[0037] FIG. 6 shows a schematic illustration of a continuous-flow machine in the form of a gas turbine,
[0038] FIG. 7 shows an apparatus according to the invention for determination of the gap size of the radial gap, and
[0039] FIG. 8 shows an alternative design for an apparatus according to the invention for determination of the radial gap.
DETAILED DESCRIPTION OF INVENTION
[0040] FIG. 6 shows a continuous-flow machine 1 according to the invention, in the form of a gas turbine with a compressor 3 , a combustion chamber 5 and a turbine unit 7 . Rotor blades 13 are arranged on the rotor 9 of the gas turbine in the compressor 3 and, together with stator blades 11 which are attached to the casing 10 , compress the inlet air flow 15 in the flow channel 6 . The compressed air flow 15 is burnt in the combustion chamber 5 with the addition of a fuel to form a hot gas 17 , which is expanded on the stator blades 11 and on the rotor blades 13 in the turbine unit 7 , producing work. During the process, the rotor 9 is driven, and drives not only the compressor 3 but also a process machine, for example an electrical generator.
[0041] FIG. 1 shows a detail of the measurement arrangement for the proposed trajectory method. A transmitting device 22 rotates on a circular path K about the coordinate origin P(0, 0) of the Cartesian coordinate system P(x, y), through which the rotation axis 2 of the rotor 9 of the gas turbine runs. By way of example, the transmitting device 22 may be arranged on the surface of the rotor 9 , which forms the inner boundary surface for the flow channel 6 of the gas turbine.
[0042] A receiving device 24 which is arranged in a rotationally fixed manner is in this case located outside the circular path K, for example at the free end of a free-standing stator blade 11 in the gas turbine, which is opposite the inner boundary surface, forming a radial gap 18 ( FIG. 6 ).
[0043] The distance s between the continuously varying position of the transmitting device 22 and of the receiving device 24 is determined at least at times. The minimum magnitude of the distance s is the distance s 0 to be monitored and to be determined, and which is to be determined for the gas turbine as the gap size of the radial gap 18 between the rotationally fixed and rotating components.
[0044] The rotation of the rotor 9 at a constant angular velocity results in the time-resolved and position-resolved distance s being functionally related to the rotation angle φ of the rotor 9 and the distance s 0 , as follows:
[0000] s=f (φ, s 0 ) (1)
[0045] which is illustrated at least partially in the diagram in FIG. 2 . The section of the rotation angle φ under consideration extends from 86° to 94°, on the assumption that the position of the receiving device 24 , which is attached to the free-standing stator blade, is at the point P(0, y E ), that is to say the receiving device 24 is arranged on the ordinate.
[0046] FIG. 2 shows the relationship between the distance s and the rotation angle φ for three different distances s 0 for a measurement arrangement in which the rotor 9 has a radius of r=0.5 m, thus resulting in three different relative path curves. The three distance function graphs 26 which result from this are illustrated in FIG. 2 . Each distance function graph 26 has a relative minimum 27 in the determined path curve of the transmitting device 24 at an angle of φ=90°.
[0047] Since the aim is to measure the distance s 0 during operation, it is expedient not to measure the distance s, but to measure the velocity of the transmitting device 24 by means of the first derivative ds/d(φ) of the distance s.
[0048] The first derivative of the distance function illustrated in FIG. 2 is illustrated as a velocity function in FIG. 3 . The rises in the velocity function graphs 28 have different gradients, depending on the particular minimum distance s 0 . The velocity function graphs 28 flatten out to a greater extent, the greater the minimum distance s 0 is between the transmitting device 22 and the receiving device 24 at an angle of φ=90°.
[0049] The gap size can be determined by determination of a necessary rotation angle Δφ for which the velocity function graph 28 is located within an interval [G u , G o ] which is defined by a lower velocity limit G u and an upper velocity limit G o . The rotation angle Δφ determined in this way is proportional to the gap size of the radial gap 18 , corresponding to the distance s 0 . Because of the constant angular velocity of the rotor 9 , as is necessarily required for flow generation when using stationary continuous-flow machines, the rotation angle Δφ can be converted to a time period by means of a linear conversion.
[0050] Various signal forms, that is to say carrier media, and various detection methods can be used for distance measurement. Sound waves, ultrasound waves or electromagnetic radio waves are used as carrier media. Intensity measurement in the case of sound waves on the one hand or field-strength measurement in the case of electromagnetic radio waves on the other hand can be used as detection methods. Furthermore, the Doppler effect can be used as a detection method for both carrier media.
[0051] The detection method will be described in the following text with reference to the Doppler effect.
[0052] FIG. 4 shows the difference frequencies, which have been filtered out of the received signal, when using ultrasound-based transmitting and receiving devices 22 , 24 . If the radial gap is determined, for example, using a transmission frequency of f 0 =40 kHz, a radius of r=0.5 m and a rotation speed of n=3600 rpm, using ultrasound-based transmitting and receiving devices, then it can be seen that a useful received signal, which can be differentiated, can be expected only in the rotation angle range of Δφ≈±2°. However, only about 4-6 oscillations occur in this interval when using a transmission frequency of f 0 =40 kHz, so that sufficiently accurate differentiation of the Doppler frequency function graphs 30 for use in a continuous-flow machine at a rotation speed of n=3600 rpm is possible only to a limited extent. If radial gaps 18 have to be monitored at relatively low rotation speeds, then the cost-effective use of ultrasound-based transmitting and receiving devices 22 , 24 may be adequate.
[0053] On the assumption of a constant wave propagation speed, analysis of the Doppler equation
[0000]
f
=
f
O
(
1
-
v
c
)
(
2
)
[0054] when approaching, and
[0000]
f
=
f
o
(
1
+
v
c
)
(
3
)
[0055] when moving away,
[0056] shows that the frequency shift to be expected, that is to say the frequency interval in which the difference frequencies to be expected are located, is proportional to the transmission frequency. A transmission frequency that is as high as possible is thus advantageous in order to obtain a received signal which can be evaluated particularly well.
[0057] If a radio-frequency (RF) transmitting and receiving device is used instead of the ultrasound-based transmitting and receiving device, for example with a transmission frequency of f 0 =435 MHz, this allows sufficiently accurate differentiation of the Doppler-frequency function graph 30 determined by the evaluation device. In consequence, Doppler frequencies which can be evaluated particularly well can in this case be filtered out of the received signal. For the chosen example, they have a frequency shift of [−280 Hz, 280 Hz].
[0058] In this context, FIG. 5 shows the Doppler-frequency function graphs 30 with identical parameters from FIG. 4 . The associated
[0059] gap size and thus the distance s 0 can be determined from the gradient of the respective Doppler-frequency function graphs 30 ′, 30 ″, 30 ″′, and from their gradients.
[0060] The transmission frequency of f 0 =435 MHz chosen in the example is licensed for telemetry. Furthermore low-cost, functionally optimized and miniaturized transmitting/receiving components are commercially available as surface mounted devices (SMDs), and their masses are negligible in comparison to a free-standing stator blade. Higher frequencies are in this case desirable, and are also achievable.
[0061] The difference frequency can be obtained by frequency demodulation from the received signal. The determination of the desired gap size can be derived from the determination of the rotation angle Δφ, which can be determined from the time period in which the difference frequency function graph 30 is located in the frequency interval of [−200 Hz, +200 Hz]. By way of example, a signal processor can be used for signal evaluation.
[0062] A range of approximately 20 cm is expediently adequate for the transmitting and receiving devices 22 , 24 , so that only extremely low transmission powers in the sub-mW range are required. This means that the transmitting device 22 can be expected to have a very low power consumption, thus allowing installation in the rotating system. The required feed energy can be injected into the rotating system without contact being made (inductively). Alternatively, a battery supply using commercially available lithium cells is also feasible and allows adequate operating times to be achieved. Furthermore, as a result of the limited range, the radial gap is determined only at times.
[0063] It should be noted that, instead of the difference frequency, the field strength of an electromagnetic signal or the intensity of a sound wave can also be used in a similar manner to determine the distance function s=f(φ, s 0 ).
[0064] The technical implementation for determination of the distance function will be described in the following text on the basis of the Doppler effect, since this occurs independently of the chosen signal form. The trajectory method is used for determination of the gap size for all of the technical implementations, based on the determination of the field-strength profile, of the intensity profile or of the frequency shift.
[0065] FIGS. 7 and 8 show, schematically, a plurality of configurations of a measurement chain for determination of the gap size of a radial gap between a rotating and a stationary system, that is to say between rotating and stationary components.
[0066] FIG. 7 shows a refinement of the invention in which the transmitting device 22 including its energy supply is arranged on the rotating system, that is to say the rotor. The transmitting device 22 has an energy source 32 , a frequency generator 34 and a transmitting antenna 36 .
[0067] The stationary system itself has a receiving antenna 40 . Based on the Doppler effect, the receiving device 24 ″ has an FM demodulator 41 and an RF oscillator 42 . If the field strength or the intensity of the received signal is evaluated rather than the Doppler effect, the receiving device 24 ′ has a field-strength detector 43 in addition to the receiving antenna 40 .
[0068] The receiving device 24 is coupled to an evaluation device 48 , in which the trajectory is determined.
[0069] FIG. 8 shows an alternative refinement. A combined transmitting and receiving device 50 is arranged in a fixed position, and is connected to an evaluation device 48 .
[0070] If the aim is to evaluate the difference frequency caused by the Doppler effect to determine the gap size, the combined transmitting and receiving device 50 ″ has an RF oscillator 42 , a frequency generator 34 and an FM demodulator 41 in addition to the transmitting and receiving antenna 51 . If the detection method used comprises a field-strength or intensity measurement, the combined transmitting and receiving device 50 ′ has a frequency generator 34 and a field-strength detector 43 .
[0071] In order to vary the source signal, which is transmitted by the transmitting and receiving device 50 , at a frequency f s by means of the rotating system, a reflection structure 52 , for example a non-linear, passive dipole with an RF diode, is arranged on it and is arranged on an insulating layer or carrier layer which does not reflect electromagnetic radio waves. The dipole receives the source signal, provided that it is in range of the transmitting and receiving antenna 51 . The non-linear dipole uses the RF diode to double the frequency f S of the received source signal, and transmits a signal at twice the frequency f E back to the receiving device as the received signal. The movement of the dipole, on the circular path K modulates the signal that is thrown back, so that the transmitting and receiving antenna 51 can receive the received signal at twice the frequency and modulated by the Doppler effect. The receiving device 50 just extracts, that is to say filters out of the received frequency spectrum, the signal at twice the frequency f E , and passes this to the evaluation device 48 . The evaluation device 48 uses the varying field strength or the varying Doppler frequency of the received signal to determine the parameters of the path curve (trajectory determination), from which the gap size of the radial gap between the rotating and the stationary system or component can be determined.
[0072] The reflections of the source signal which occur as a result of smooth surfaces or in any other way and are essentially at the same frequency as the source signal are filtered out or ignored by the receiving device.
[0073] The apparatuses according to the invention have the advantage that they can be used in a temperature range from 0° C. to 450° C. Furthermore, the detection method is not dependent on the surface character, on the geometric character or on the physical characteristics of the rotating component. In addition, the apparatuses do not require adjustment, and require calibration only after initial installation, with this then being sufficient for the entire life of the apparatus.
[0074] The radial gap which exists between the tip of a free-standing stator blade and the rotor hub can thus be measured because of the comparatively low-mass and small sensors. They can, of course, also be used when a reflection structure or a transmitting device is provided at the tip of a rotor blade, free-standing or with a covering strip, and when at least the receiving antenna of the receiving device is provided on the outer boundary surface.
[0075] If, for example, each rotor blade in a rotor blade ring has a transmitting device, and/or a plurality of receiving antennas are distributed over the circumference, this allows the gap size to be determined in an even better manner, and at the same time at a plurality of locations.
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The invention relates to a method for determining the size of a radial gap between rotating and torsion-proof parts, particularly the parts of a turbomachine. According to said method, an original signal emitted by a transmitter device located on the surface of the rotating part is received in a modified manner by a receiver device disposed on the torsion-proof part and is redirected to an evaluation unit. Said evaluation device determines and displays the size of the radial gap from the received signal by determining the parameters of the trajectory of the rotating transmitter device.
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CROSS REFERENCE TO RELATED APPLICATION
This application is a division of application Ser. No. 08/163,566, filed Dec. 8, 1993, now abandoned.
BACKGROUND OF THE INVENTION
1. Field Of The Invention
The present invention relates generally to rear view mirrors for automotive vehicles and more particularly to an adjustable rear view mirror providing improved visibility through the use of flat and convex mirrored surfaces.
2. Description Of The Prior Art
Since the advent of the automotive vehicle, rear view mirrors for use in the vehicle have been of primary importance as the vehicles moved much more quickly and responsively than prior horse-drawn carriages. It has become increasingly important due to increased traffic and vehicle speeds to have an optimum view of what is behind and to the sides of a vehicle in addition to what is readily viewable in front of the vehicle.
While many cars are intentionally designed to provide good peripheral and rear vision by optimizing window space around the perimeter of the cab of a vehicle, aesthetic design considerations often override utilitarian considerations thereby leaving some vehicles less than desirable from a vision standpoint.
Further, conventional rear view mirrors typically have a flat mirrored surface providing a fixed range of vision for an operator of the vehicle even though the positioning of that range is adjustable through a universal mounting of the mirror on the windshield of the vehicle. When the mirror is set in a predetermined position, however, the angle of vision is no greater than a predetermined angle as determined primarily by the horizontal width of the mirror.
Attempts have been made to broaden the angle of rear vision provided to the operator of an automotive vehicle. Some such attempts have included a plurality of laterally spaced flat mirrored surfaces which form an angle relative to each other and thus various angles relative to the operator of the vehicle so that a broader spectrum of rear vision is provided. Other attempts have been in the form of attachments to mirrors which have been devised such that a convex mirror may be removably attached to a conventional flat automotive mirror with the curvature of the convex mirror being such that the angle of rear viewing is greater than that provided by the flat mirror of the same size. Further, convex mirrors have been provided for adhesive attachment over conventional flat mirrors again to broaden the range of vision. In these instances, however, the driver is usually predominantly limited to use of the convex mirror as opposed to the flat mirror as the convex mirror overlies a significant portion of the flat mirror and as will be appreciated, convex mirrors do in fact distort vision to some degree leaving the operator of the vehicle with a predominantly distorted rear view.
It is against this background of prior art that the present invention has been developed.
SUMMARY OF THE INVENTION
The rear view automotive mirror of the present invention has been uniquely designed in several embodiments to incorporate a pair of mirrored surfaces with one of the surfaces being flat and the other convex. The mirrored surfaces are interconnected such that the operator of an automotive vehicle can selectively use either or both of the mirrored surfaces for obtaining optimal rear vision.
In one embodiment of the invention, a convex mirror is hingedly connected to a flat mirror so that the surfaces can be individually selected for viewing separately and independently. In another embodiment, a flat horizontally elongated mirror has a horizontal extension with a convex surface so that the flat mirror can be used for vision directly behind the vehicle while the convex mirror provides an enlarged view to the right side of the vehicle. In still another embodiment of the invention, a convex mirror is adjustably mounted adjacent to the right side of an elongated flat mirror so that the flat mirror can again be used to view an area behind the vehicle and the adjustable convex mirror used to adjustably and selectively view an enlarged area to the side and rearwardly of the vehicle.
The rear view mirror of the present invention thereby permits the operator of a vehicle to have enhanced rear view vision while operating the vehicle and provides the enhancement in a way that is selectively adjustable.
Other aspects, features and details of the present invention can be more completely understood by reference to the following detailed description of a preferred embodiment, taken in conjunction with the drawings, and from the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagrammatic plan view of an automotive vehicle having a conventional flat rear view mirror.
FIG. 2 is a diagrammatic plan view similar to FIG. 1 illustrating the vision available with a first embodiment of the present invention as shown in FIGS. 5-10.
FIG. 3 is a diagrammatic plan view similar to FIG. 1 illustrating the vision obtainable from a second embodiment of the present invention as seen in FIGS. 11-14.
FIG. 4 is a diagrammatic plan view similar to FIG. 1 illustrating the vision available with a third embodiment of the present invention as illustrated in FIGS. 15-17.
FIG. 5 is an isometric view of a first embodiment of the rear view mirror of the present invention.
FIG. 6 is an enlarged section taken along line 6--6 of FIG. 5.
FIG. 7 is an enlarged section taken along line 7--7 of FIG. 5.
FIG. 8 is an isometric view of the mirror shown in FIG. 5 with the mirror moved into an alternate position.
FIG. 9 is an enlarged section taken along line 9--9 of FIG. 8.
FIG. 10 is a diagrammatic illustration showing the range of view available with the mirror of FIG. 5 in the position illustrated in FIG. 5.
FIG. 11 is an isometric view of a second embodiment of the rear view mirror of the present invention.
FIG. 12 is an enlarged fragmentary section taken along line 12--12 of FIG. 11.
FIG. 13 is a fragmentary section taken along line 13--13 of FIG. 11.
FIG. 14 is a diagrammatic top plan view illustrating the field of vision available with the embodiment of the invention shown in FIG. 11.
FIG. 15 is an isometric view of a third embodiment of the rear view mirror of the present invention.
FIG. 16 is a fragmentary section taken along line 16--16 of FIG. 15.
FIG. 17 is a diagrammatic top plan view of an automotive vehicle illustrating the field of vision available with the embodiment of the invention shown in FIG. 15.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 illustrates the angle A of rear vision available to the operator 20 of an automotive vehicle 22 utilizing a conventional standard flat rear view mirror 24 mounted interiorly on the windshield 26 of the vehicle. As will be appreciated, a considerable area to the sides of the vehicle are not in view of the operator without taking his eyes off the road in front of the vehicle which is a particularly acute problem on the right side of the vehicle more than the left due to the fact that typically the vehicle will have an outside rear view mirror 28 on the left side of the vehicle.
A first embodiment 30 of the rear view mirror of the present invention is shown in FIG. 5 to include a mounting base 32 that typically has an adhesive on a front face thereof so that the mounting base can be securely adhered to the windshield 26 or other such mounting surface within the automotive vehicle 22. Reference herein to front and rear is to be interpreted with reference to the front end and rear end of the vehicle 22 on which the mirror is mounted. A rearwardly projecting mounting arm 34 is rigidly secured or mounted on the mounting base 32. The mounting arm is slightly arcuate in configuration and angles slightly downwardly in a rearward direction. The distal or rearwardmost end of the arm has a substantially spherical head 36 forming a male connection element of a universal connector interconnecting the mounting arm 34 with a mirror system 38.
The mirror system 38 includes a backing plate 40 of substantially rectangular configuration having a recessed rear face in which is disposed a conventional mirror 42 having a flat mirrored surface 44. A pivotal plate 46 is hingedly connected to the backing plate 40 along upper horizontal edges of each plate by conventional hinges 48 and 50 so that the pivotal plate 46 can be selectively moved about the horizontal top edge of the backing plate. The pivotal plate has a convex mirrored surface 52 which is curved in both horizontal and vertical directions as best illustrated in FIG. 9. The convex mirrored surface faces rearwardly when the backing plate 40 and pivotal plate 46 are in confronting overlapped relationship as seen in FIG. 5.
The front face 54 of the backing plate has a socket 56 formed at its geometric center with the socket defining the female element of the universal connector. The socket 56 is configured between a hemispherical shape and a spherical shape and made of a somewhat resilient material so that the spherical head 36 on the mounting arm 34 can be snapped into the socket to retain the mirror system in a universally pivotal relationship relative to the mounting arm. Such mounting systems are well-known in the art and a more detailed description thereof is not felt necessary.
As can be appreciated, both the convex and flat mirrored surfaces 52 and 44 respectively of the mirror system 38 are horizontally elongated and of generally rectangular configuration. The hinges 48 and 50 interconnecting the backing plate 40 with the pivotal plate 46 have one leg 58 attached to a top surface 60 of the backing plate at horizontally spaced locations. The hinge 50 disposed on the right side of the mirror system as viewed in FIG. 5 has a second leg 62 attached to a front surface 64 of the pivotal plate 46 in a loose manner for a reason to be described hereafter. A second leg 62 of the hinge 48 on the left side of the mirror system as viewed in FIG. 5 hangs downwardly between the backing plate and the pivotal plate and has secured thereto a threaded nut 66 aligned with a cavity 68 formed in the backing plate.
An adjustment screw or pin 70 extends through an aperture 72 in the pivotal plate 46 and has a threaded forwardmost end 74 and a thumb screw head 76 on the rearward most end. The threaded end 74 is received in a threaded opening through the nut 66 while a shoulder 78 adjacent to the thumb screw head abuts the convex mirrored surface 52 of the pivotal plate. A recess or pocket 80 is formed in the front surface 64 of the pivotal plate in alignment with the aperture 72 through the pivotal plate and a snap ring 82 is fixedly positioned on the pin 70 within the recess 80. It will therefore be appreciated that rotative movement of the adjustment pin 70 will selectively move the left end of the pivotal plate 46 relative to the flat mirrored surface 44 of the backing plate so that the spacing between the pivotal plate and the backing plate at the left side of the mirror can be regulated to adjust the angle of vision of the operator of the vehicle when looking at the convex mirrored surface. The loose connection of the right hinge 50 to the pivotal plate allows for the small amount of pivotal movement created by axial adjustment of the adjustment pin.
As will be appreciated from the above description and from FIGS. 5 and 8, the first embodiment of the rear view mirror is moveable between two positions with one position illustrated in FIG. 5 that allows the operator of the vehicle to utilize the convex mirror 52 to obtain a broader rear angle view. Pivotal movement of the pivotal plate upwardly about the hinges exposes the flat mirrored surface 44 of the backing plate as shown in FIG. 8 which allows the operator of the vehicle to obtain a rear angle view similar to that found with conventional automotive rear view mirrors. As mentioned previously, when the mirror is in the position illustrated in FIG. 5, the mirror can be pivoted in a horizontal plane about the right hinge 50 through rotative movement of the adjustment pin to select a desired position for optimal rear vision.
FIG. 10 diagrammatically shows by way of illustration the first embodiment 30 of the mirror wherein the convex mirror 52 provides a rear angle of vision of seventy degrees. This is substantially greater than the angle of vision obtainable from the flat mirror 44 which might be by way of example thirty-five degrees. FIG. 2 also diagrammatically illustrates the angles of vision available with the embodiment of FIGS. 5 through 10, and it can be seen that when using the flat mirror 44 on the backing plate, the operator has the same angle of vision represented by the letter A as found with a conventional mirror 24 (as shown in FIG. 1) while use of the convex mirror 52 when folded down into an overlapping relationship with the flat mirrored surface permits vision through angle A'. In other words, with the convex mirror, the operator of the vehicle obtains a better view of the right side of the vehicle when looking rearwardly through the mirror.
A second embodiment 84 of the present invention is illustrated in FIGS. 11 through 14 wherein it will be appreciated that a mounting plate 86 having an adhesive front face for adhering the mirror to the windshield 26 of an automotive vehicle 22 or the like is provided and includes a rearwardly and downwardly projecting curved mounting arm 88 having a substantially spherical head 90 on its free end. A mirror system 92 is universally mounted on the spherical head 90 and includes a backing plate 94 with a mirrored surface 96 along a rear edge 98. The front wall 100 of the backing plate has a socket 102 formed therein which is between hemispherical and spherical in configuration and made of a somewhat resilient material so that the spherical head 90 on the mounting arm can be snapped into the socket to retain the mirror system 92 on the mounting arm in a universally pivotal manner.
As best viewed in FIG. 11, the backing plate 94 is horizontally elongated and of generally rectangular configuration. The rear edge 98 of the backing plate at its right end tapers forwardly and to the right as viewed in FIG. 11. The mirrored surface 96 is flat across an area 110 covering approximately three-fourths of the mirror commencing from the left edge of the mirror with the right hand quarter 112 of the mirror being convex. The convex portion 112 of the mirror is curved in both a horizontal and vertical plane as seen in FIGS. 12 and 13 to broaden the range of vision which would be available with a flat mirror. Of course, the mirror is adjustable relative to the operator of the vehicle and by reference to FIG. 14, the various angles of vision available with the mirror are diagrammatically illustrated.
As will be appreciated by reference to FIG. 14, the operator of the vehicle by way of example can look into the flat portion 110 of the mirrored surface and obtain an angle of vision, for example thirty-five degrees, and by viewing the convex right hand quarter 112 of the mirrored surface can obtain another approximately thirty-five degrees of vision to the right side of the vehicle. This is further illustrated diagrammatically in FIG. 3 wherein angle A shows the vision obtainable through the flat portion 110 of the mirrored surface while angle B illustrates the vision through the convex portion 112 of the mirrored surface.
A third embodiment 114 of the present invention in shown in FIGS. 15 through 17 and it will be therein appreciated that again the mirror has a mounting base 116 of generally rectangular configuration having a front face with an adhesive surface for bonding the mirror to a windshield of an automotive vehicle. A rearwardly and downwardly curved mounting arm 118 is formed on the mounting plate and has a substantially spherical head 120 on its rearwardmost or distal end. A mirror system 122 is universally connected to the mounting arm through the use of a socket 124 formed in a backing plate 126 of the mirror system with the socket having a configuration between a hemisphere and sphere and made of a somewhat resilient material so that the spherical head 120 on the mounting arm can be snapped into the socket 124 to universally mount the mirror system on the arm.
The backing plate 126 is of substantially rectangular configuration defining a first rearwardly opening recess 128 on the left hand side of the mirror system extending approximately three quarters of the horizontal length of the mirror system and a second rearwardly opening recess 130 on the right hand quarter of the backing plate. The left and right side recesses are divided by an internal divider 131 projecting rearwardly from the backing plate. A right side portion 134 of the backing plate is flared slightly forwardly and to the right. A mirror 136 having a flat mirrored surface is fixidly mounted in the first recess 128 of the backing plate for unitary movement therewith adjacent to the rearwardmost edge thereof and a second mirror 138 having a convex mirrored surface is mounted in the second recess 130. The second mirror has a pocket 140 formed in its front face of a configuration between a hemisphere and a sphere and is made of a somewhat resilient material so as to universally receive and retain a substantially spherical head 142 mounted on a secondary mounting arm 143 projecting rearwardly from the backing plate. The secondary mounting arm 143 is supported by a support plate 144 securely attached to the rear face of the backing plate and disposed within the second recess.
It will be appreciated that the second mirror 138 is universally pivotal and further has a convex surface to broaden the range of vision available to the operator of the vehicle through a lateral extension of the operator's view to the right of the vehicle. The rear view available to the operator of the vehicle is probably best illustrated in FIGS. 4 and 17. With reference first to FIG. 4, it will be appreciated that the angle of view from the flat mirror 136 is represented by the letter A with the angle of view available from the convex mirror 138 being represented by an angle B' which is adjustable, not in width, but in position so that it can be made to abut angle A or overlap angle A.
By way of illustrative example, FIG. 17 shows the angle of vision from the flat mirror 136 as being thirty-five degrees while the angle of vision from the smaller convex mirror 138 is also thirty-five degrees but movable within a five degree arc so as to be either contiguous with the range of vision from the flat portion of the mirror or overlapping slightly.
It will be appreciated from the above description that the mirror of the present invention provides a distinct advantage over conventional car mirrors of either the flat or convex configuration by combining into one mirror selectively adjustable viewing capabilities to enhance and increase vision to the rear and to the right of the vehicle.
Although the present invention has been described with a certain degree of particularity, it is understood that the present disclosure has been made by way of example, and changes in detail or structure may be made without departing from the spirit of the invention, as defined in the appended claims.
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A rear view mirror for an automotive vehicle includes a universally mounted mirror system having a flat mirror component and a convex mirror component which are uniquely combined in several embodiments to enhance the rear view vision of an operator of the vehicle. In one embodiment, the convex mirror is pivotally positioned in overlying relationship with the flat mirror portion and adjustable laterally relative to the flat mirror portion. In another embodiment, the flat and convex mirror portions are contiguous in a horizontal direction while in a third embodiment the flat and convex mirror portions are horizontally aligned with the convex portion being universally mounted for adjustment relative to the flat mirrored portion.
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FIELD OF THE INVENTION
This invention relates to a process for preparing cephem and isooxacephem cephalosporin derivatives, and intermediates therefor.
BACKGROUND OF THE INVENTION
U.S. Pat. No. 5,523,400, issued Jun. 4, 1996 (Wei, et al) discloses certain cephalosporin antibiotics having a lactam moiety at the 3 position of the cephalosporin.
U.S. Pat. No. 4,409,214, issued Oct. 11, 1983 (Takaya, et al) discloses 7-acylamino-3-vinyl-cephalosporanic acid derivatives having antimicrobial activity.
Kamachi, et al, J. Antibiotics (December 1990) Vol. 43, pages 1564-1572 discloses the synthesis of 1-Acetoxyethyl 7- (Z)-2-(2-aminothiazol-4-yl)-2-hydroxyiminoacetamido!-3- (Z)-1-propenyl!-3-cephem-4-carboxylate by acylation of the cephem unit with an activated aminothiazole derivative in which the activating group is a benzothiazolyl ester.
European Patent Publication No. EP 620228, published Oct. 19, 1994 (Lucky, Ltd.) discloses thiophosphate derivatives of thia(dia)zole acetic acid for use in the preparation of β-lactam antibiotics. In this case the cephem unit is acylated using an activated aminothiazole derivative in which the activating group is a mixed anhydride of thiophosphoric acid.
Other acyl groups which can be used to acylate β-lactam antibiotics may be found in Cephalosporins and Penicillins, Flynn, ed, Academic Press (1972); Belgian Patent No. 866,038, published Oct. 17, 1978; Belgian Patent No. 867,994, published Dec. 11, 1978; and U.S. Pat. No. 3,971,778, issued Jul. 27, 1976.
SUMMARY OF THE INVENTION
The present invention is concerned with a process for the preparation of cephem- and isooxacephem derivatives of formula ##STR4## wherein R 1 is trityl, acetyl, tetrahydropyranyl or cyclopentyl;
R 2 is hydrogen, hydroxy, lower alkyl, cycloalkyl, lower alkoxy, lower alkenyl, lower alkynyl, aryl, aryloxy, aryl-lower alkyl, aryl-lower alkoxy, heterocyclyl or heterocyclyl-lower alkyl; the lower alkyl, cycloalkyl, lower alkoxy, lower alkenyl, cycloalkenyl, lower alkynyl, aryl-lower alkyl, aryl, aryloxy, aryl-lower alkoxy, the heterocyclyl moieties being unsubstituted or substituted with at least one group selected from carboxy, amino, nitro, cyano, lower alkyl, lower alkoxy, hydroxy, halogen, --CONR 21 R 22 , --N(R 22 )COOR 23 , R 22 CO--, R 22 OCO-- or R 22 COO--, wherein R 21 is hydrogen, lower alkyl, or cycloalkyl; R 22 is hydrogen or lower alkyl; R 23 is lower alkyl, lower alkenyl or a carboxylic acid protecting group;
Y is --S-- and Z is --CH 2 -- or
Y is --CH 2 -- and Z is --O--,
by acylation of a compound of formula ##STR5## with an activated carboxylic acid derivative of formula ##STR6## wherein R 3 is lower alkyl, and R 1 , R 2 , Y, Z have the significance given above.
The compounds of formula I are useful as antibiotics having potent and broad antibacterial activity.
This invention provides compounds of formula III.
As used herein, the term "lower alkyl" refers to both straight and branched chain saturated hydrocarbon groups having 1 to 8, preferably 1 to 4 carbon atoms, for example, methyl, ethyl, n-propyl, isopropyl, tertiary butyl and the like.
By the term "cycloalkyl" is meant a 3-7 membered saturated carbocyclic ring e.g., cyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl and the like.
The term "lower alkoxy" refers to an oxygen radical having an alkyl group as defined above, examples include methoxy, ethoxy, n-propyloxy and the like.
As used herein, "lower alkenyl" refers to an unsubstituted or substituted hydrocarbon chain radical having from 2 to 8 carbon atoms, preferably from 2 to 4 carbon atoms, and having at least one olefinic double bond, e.g. vinyl, allyl and the like.
As used herein, "lower alkynyl" refers to an unsubstituted or substituted hydrocarbon chain radical having from 2 to 8 carbon atoms, preferably 2 to 4 carbon atoms, and having at least one triple bond.
The term "halogen" used herein refers to all four forms, that is chlorine or chloro; bromine or bromo; iodine or iodo; and fluorine or fluoro.
By the term "aryl" is meant a radical derived from an aromatic hydrocarbon by the elimination of one atom of hydrogen and can be substituted or unsubstituted. The aromatic hydrocarbon can be mononuclear or polynuclear. Examples of aryl radicals of the mononuclear type include phenyl, tolyl, xylyl, mesityl, cumenyl, and the like. Examples of aryl radicals of the polynuclear type include naphthyl, anthryl, phenanthryl, and the like. The aryl group can have at least one substituent selected from, as for example, halogen, hydroxy, cyano, carboxy, carbamoyl, nitro, amino, aminomethyl, lower alkyl, lower alkoxy or trifluoromethyl. Examples include 2-fluorophenyl, 3-nitrophenyl, 4-nitrophenyl, 4-methoxyphenyl, 4-hydroxyphenyl and the like.
By the term "aryl-lower alkyl" is meant a lower alkyl group containing an aryl group as defined above, for example benzyl.
As used herein, "aryloxy" is an oxygen radical having an aryl substituent as defined above (i.e., --O-aryl).
As used herein, "aryl-lower alkoxy" is an oxygen radical having an aryl-lower alkyl substituent. (i.e., --O-lower-alkyl-aryl).
As used herein, "heterocyclyl ring" refers to the residue of an unsaturated or saturated, unsubstituted or substituted 5-, 6-, or 7-membered heterocyclic ring containing at least one hetero atom selected from the group consisting of oxygen, nitrogen, or sulfur. Exemplary heterocyclyl groups include, but are not limited to, e.g., the following groups: pyridyl, pyridiniumyl, pyrazinyl, piperidyl, piperidino, N-oxido-pyridyl, pyrimidyl, piperazinyl, pyrrolidinyl, pyridazinyl, N-oxide-pyridazinyl, pyrazolyl, triazinyl, imidazolyl, thiazolyl, 1,2,3-thiadiazolyl, 1,2,4-thiadiazolyl, 1,3,4-thiadiazolyl, 1,2,5-thiadiazolyl, 1,2,3-oxadiazolyl, 1,2,4-oxadiazolyl, 1,3,4-oxadiazolyl, 1,2,5-oxadiazolyl, 1,2,3-triazolyl, 1,2,4-triazolyl, 1H-tetrazolyl, 2H-tetrazolyl, thienyl, furyl, hexamethyleneiminyl, oxepanyl, 1H-azepinyl, thiophenyl, tetrahydrothiophenyl, 3H-1,2,3-oxathiazolyl, 1,2,3-oxadiazolyl, 1,2,5-oxadithiolyl, isoxazolyl, isothiazolyl, 4H-1,2,4-oxadiazinyl, 1,2,5-oxathiazinyl, 1,2,3,5-oxathiadiazinyl, 1,3,4-thiadiazepinyl, 1,2,5,6-oxatriazepinyl, oxazolidinyl, tetrahydrothienyl, and others. Substituents for the heterocyclic ring include lower-alkyl, lower-alkoxy, halogen, trifluoromethyl, trichloro-ethyl, amino, mercapto, hydroxy, carboxy or carbamoyl. Preferred examples of substituted heterocyclyl groups are mono-substituted and include 5-methyl-isoxazol-3-yl, N-methyl-pyridinium-2yl, 1-methyl-tetrazolyl and the like.
As used herein, "heterocyclyl-lower alkyl" refers to a lower alkyl group containing a heterocyclic group as defined above, e.g. tetrazolyl-methyl, tetrahydrofuranyl-methyl, thiophenyl-methyl or benzimidazolyl-methyl.
The heterocyclic ring can also be substituted by an optionally substituted phenyl ring such as 2,6-dichlorophenyl. Preferred is 2,6-dichlorophenyl-5-methyl-isoxazolyl.
A further substituent of the heterocyclic ring is oxo, such as in 2-oxo-oxazolidin-3-yl, 1,1-dioxo-tetrahydrothien-3-yl.
The heterocyclic ring can also be fused together with a benzene ring.
By the term "substituted phenyl" is meant phenyl mono or di-substituted.
The term "carboxylic acid protecting group" refers to protecting groups conventionally used to replace the acidic proton of a carboxylic acid. Examples of such groups are described in Greene, T., Protective Groups in Organic Synthesis, Chapter 5, pp. 152-192 (John Wiley and Sons, Inc. 1981), incorporated herein by reference. These examples include methoxymethyl, methylthiomethyl, tetrahydropyranyl, tetrahydrofuranyl, methoxyethoxymethyl, benzyloxymethyl, phenacyl, p-bromophenacyl, α-methylphenacyl, p-methoxyphenacyl, diacylmethyl, N-phthalimidomethyl, ethyl, 2,2,2-trichloroethyl, 2-haloethyl, ω-chloroalkyl, 2-(trimethylsilyl)ethyl, 2-methylthioethyl, 2-(p-nitrophenyl-sulfenyl)ethyl, 2-(p-toluenesulfonyl)ethyl, 1-methyl-1-phenylethyl, t-butyl, cyclopentyl, cyclohexyl, allyl, cinnamyl, phenyl, p-methylthiophenyl, benzyl, triphenylmethyl, diphenylmethyl, bis(o-nitrophenyl)methyl, 9-anthrylmethyl, 2-(9,10-dioxo)anthrylmethyl, 5-dibenzosuberyl, 2,4,6-trimethylbenzyl, p-bromobenzyl, o-nitrobenzyl, p-nitrobenzyl, p-methoxybenzyl, piperonyl, 4-picolyl, trimethylsilyl, triethylsilyl, t-butyldimethylsilyl, i-propyl-dimethylsilyl, phenyldimethylsilyl, S-t-butyl, S-phenyl, S-2-pyridyl, N-hydroxypiperidinyl, N-hydroxysuccinimidoyl, N-hydroxyphthalimidoyl, N-hydroxybenzo-triazolyl, O-acyl oximes, 2,4-dinitrophenylsulfenyl, 2-alkyl-1,3-oxazolines, 4-alkyl-5-oxo-1,3-oxazolidines, 5-alkyl-4-oxo-1,3-dioxolanes, triethylstannyl, tri-n-butylstannyl; the amides or hydrazides of N,N-dimethylamino, pyrrolidinyl, piperidinyl, o-nitrophenyl, 7-nitroindolyl, 8-nitrotetra-hydroquinolyl, p-benzenesulfonamide, hydrazides, N-phenylhydrazide, N,N'-diisopropylhydrazide. Preferred are benzyhydryl, t-butyl, p-nitrobenzyl, p-methoxybenzyl and allyl.
DETAILED DESCRIPTION OF THE INVENTION
The process according to the invention is especially suited for the preparation of cephem and isooxacephem derivatives respectively of formula I wherein R 1 is hydrogen, i.e. with an hydroxyimino group, which has to be protected during the acylation step. It is essential that the protecting groups are cheap, easily removeable, recycleable and that no additional purification steps are involved due to contamination of a catalyst used during the protecting and deprotecting process. Furthermore the protecting group should not interfere with the acylation step.
It has been found that the acylation process according to invention is especially suited for the acylation of cephem- and isooxacephem derivatives of formula II with an aminothiazol derivative of formula III which is activated as mixed anhydride of thiophosphoric acid and R 1 is protected by a trityl, acetyl or tetrahydropyranyl group, preferably a trityl group. The yield of this reaction as well as the purity of the product are excellent and the protecting groups are easily removed to yield hydroxyimino compounds, i.e. compounds of formula I wherein R 1 is hydrogen.
The acylation of a compound of formula II with the activated compound of formula III is preferably carried out in a polar solvent as dimethyl formamide (DMF), dichloromethane, or a mixture of DMF/i-pronanol/water in presence of a base as e.g. triethylamine, at a temperature of about -10° C. to about 60°, preferably from about 0° C. to about 30° C.
The compounds of formula III are part of the present invention. They can be prepared as follows.
To obtain (Z)-(2-aminothiazol4-yl)-trityl (or acetoxy, tetrahydropyranyl or cyclopentyl)oxyimino acetic acid, their precursor the unprotected (Z)-(2-aminothiazol-4-yl)oxyimino acetic acid ethylester (compound A), is commercially available. This compound is then protected as follows:
a) For the preparation of the trityl derivative (as used in example 1) the compound A is deprotonated and treated with tritylchloride to form (Z)-2-(aminothiazol-4-yl)trityl-oxyimino acetic acid ethylester which is then hydrolysed to yield the free acid.
b) For the preparation of the acetyl derivative (as used in example 2) compound A is hydrolysed to form the free acid (Z)-2-(aminothiazol-4-yl)oxyimino acetic acid and subsequently treated with acetanhydride in the presence of potassium carbonate to form the acetyl derivative.
c) The tetrahydropyranyl derivative (as used in Example 3) is prepared by treating the glyoxylic acid derivative described below with O-(tetrahydro-pyran-2-yl)-hydroxyl-amine in the presence of triethylamine in ethanol as depicted below: ##STR7## d) For the preparation of the cyclopentyl derivative the compound A is deprotonated and treated with cyclopentylbromide to form (Z)-2-(aminothiazol-4-yl)cyclopentyl-oxyimino acetic acid ethylester which is then hydrolysed to yield the free acid. The free acid is then reacted in analogy to example 1 to yield the activated acid.
The compounds of formula III are prepared by reaction of (Z)-(2-aminothiazol-4-yl)-trityl (or acetoxy, or tetrahydropyranyl, or cyclopentyl) oxyimino acetic acid with di-lower alkyl-chloro thio phosphate in an organic solvent in the presence of a tert.amine. The compounds of formula III precipitate directly from the reaction mixture. Preferred tert.amine compounds are DABCO, tributylamine and mixtures thereof. The organic solvent is preferably dichloromethane or dimethylacetamide.
Compounds of formula II in which Y is S may be obtained from 3-cephem aldehyde as described in U.S. Pat. No. 5,523,400, issued Jun. 4, 1996 (Wei et al).
Compounds of formula II in which Z is O may be obtained from 3-isooxacephem aldehyde as shown in Scheme 1. ##STR8##
Scheme 1
Wittig reaction 1 to 3
The reaction of known 3-isooxacephem aldehyde (1) wherein the 7-amino-protecting group is allyloxycarbonyl and the carboxy protecting group is allyl with a Wittig reagent (2) yields the coupling product (3). The reaction is carried out in the presence of a base which is either an inorganic base (sodium or potassium hydroxide, sodium or potassium carbonate etc.), an organic base (tertiary amines), an organolithium compound such as butyl lithium or phenyl lithium or an epoxide such as 1,2-butyleneoxide. The preferred solvents are in the case of inorganic base being used, water and water-miscible solvents (acetone, tetrahydrofuran, or alcohols etc.); in the case of organic base being used, an inert solvent such as methylene chloride, chloroform, benzene, tetrahydrofuran; in the case of organolithium being used, benzene or tetrahydrofuran; and in the case an epoxide being used, the epoxide itself (e.g. 1,2-butyleneoxide). The temperature for the reaction ranges from -20° C. to 80° C.
In the normal Wittig Reaction according to scheme 1, the E isomer is the predominant product. Invariably, less than 10% Z-isomer is formed, the amount depending on the reagents and conditions.
The making of the Wittig reagent (2) can be carried out in a manner known per se; for example, by cyclization of a N-substituted dibromide using a catalyst like Dowex as described in the European Patent Application EPA 0 620 255.
Deprotection 3 to 4
The carboxylic acid protecting group R h and the amino protecting group R f are removed and the reaction conditions used are depending on the nature of the protecting groups.
In the case of the amino protecting group being allyloxycarbonyl and the carboxy protecting group being the allyl ester, Pd(0) generated in situ is employed. In the case of the amino protecting group being t-butoxycarbonyl and the carboxy protecting group being benzhydryl, trifluoroacetic acid is employed, at temperature of about -20 ° C. to about room temperature.
Conventional carboxylic acid protecting groups and amino protecting groups are described in Greene, T., Protective Groups in Organic Synthesis, Chapter 5, pp. 152-192 (John Wiley and Sons, Inc. 1981).
The products in accordance with the invention can be used as medicaments, for example, in the form of pharmaceutical preparations for enteral (oral) administration. The products in accordance with the invention can be administered, for example, perorally, such as in the form of tablets, coated tablets, dragees, hard and soft gelatine capsules, solutions, emulsions or suspensions, or rectally, such as in the form of suppositories.
Pharmaceutical compositions containing these compounds can be prepared using conventional procedures familiar to those skilled in the art, such as by combining the ingredients into a dosage form together with suitable, nontoxic, inert, therapeutically compatible solid or liquid carrier materials and, if desired, the usual pharmaceutical adjuvants.
It is contemplated that the compounds are ultimately embodied into compositions of suitable oral or parenteral dosage forms. The compositions of this invention can contain, as optional ingredients, any of the various adjuvants which are used ordinarily in the production of pharmaceutical preparations. Thus, for example, in formulating the present compositions into the desired oral dosage forms, one may use, as optional ingredients, fillers, such as coprecipitated aluminum hydroxide-calcium carbonate, dicalcium phosphate or lactose; disintegrating agents, such as maize starch; and lubricating agents, such as talc, calcium stearate, and the like. It should be fully understood, however, that the optional ingredients herein named are given by way of example only and that the invention is not restricted to the use hereof. Other such adjuvants, which are well known in the art, can be employed in carrying out this invention.
Suitable as such carrier materials are not only inorganic, but also organic carrier materials. Thus, for tablets, coated tablets, dragees and hard gelatine capsules there can be used, for example, lactose, maize starch or derivatives thereof, talc, stearic acid or its salts. Suitable carriers for soft gelatine capsules are, for example, vegetable oils, waxes, fats and semi-solid and liquid polyols (depending on the nature of the active substance; no carriers are, however, required in the case of soft gelatine capsules). Suitable carrier materials for the preparation of solutions and syrups are, for example, water, polyols, saccharose, invert sugar and glucose. Suitable carrier materials for suppositories are, for example, natural or hardened oils, waxes, fats and semi-liquid or liquid polyols.
As pharmaceutical adjuvants there are contemplated the usual preservatives, solubilizers, stabilizers, wetting agents, emulisifiers, sweeteners, colorants, flavorants, salts for varying the osmotic pressure, buffers, coating agents and antioxidants.
The compounds of formula I and their salts, or hydrates, can preferably be used for parenteral administration, and for this purpose are preferably made into preparations as lyophilisates or dry powders for dilution with customary agents, such as water or isotonic common salt solution.
Depending on the nature of the pharmacologically active compound the pharmaceutical preparations can contain the compound for the prevention and treatment of infectious diseases in mammals, human and non-human, a daily dosage of about 10 mg to about 4000 mg, especially about 50 mg to about 3000 mg, is usual, with those of ordinary skill in the art appreciating that the dosage will depend also upon the age, conditions of the mammals, and the kind of diseases being prevented or treated. The daily dosage can be administered in a single dose or can be divided over several doses. An average single dose of about 50 mg, 100 mg, 250 mg, 500 mg, 1000 mg, and 2000 mg can be contemplated.
The following examples illustrate the invention in more detail and are not intended to be a limitation in any manner.
The following abbreviations were used:
______________________________________mp melting pointHPLC high performance liquid chromatography______________________________________
HPLC-analysis were performed as follows:
Sample preparation: The heterogeneous reaction mixture was dissolved with a little DMSO and diluted with CH 3 CN.
Instrument: HP-1050 HPLC System.
Column: Machery-Nagel Nucleosil 100-5 C18 AB, 250×4 mm.
Column temperature: 50° C.
Mobile Phase: A water+5% CH 3 CN; C CH 3 CN; D 0.03M potassium phosphate buffer pH 3+10% CH 3 CN.
Gradient (t min!, A:C:D): (0, 85:0:15); (8, 15:70:15); (19, 15:70:15); (19.5, 85:0:15).
Flow: 1.2 ml/min.
Detection: UV 225 nm.
EXAMPLE 1
a) Preparation of (Z)-(2-Aminothiazol-4-yl)-trityloxyiminoacetic acid diethoxythiophosphoryl ester ##STR9##
To a stirred suspension of 50 g (Z)-(2-aminothiazol-4-yl)-trityloxyiminoacetic acid (116.4 mmol) and 130 mg 1,4-diazabicyclo 2.2.2!octane (DABCO) (1.164 mmol) in 500 ml dichloromethane was added under argon atmosphere 36 ml tributylamine (151 mmol). After 5 min, the red solution was cooled to 2° C. With the aid of a syringe pump was added over 30 min 24.5 ml diethyl chlorothiophosphate (151 mmol). Stirring was continued at 2° C. for 1.5 h. After approximately 30 min, the activated ester (Z)-(2-Aminothiazol-4-yl)-trityloxyiminoacetic acid diethoxythiophosphoryl ester started to crystallize from the brown reaction mixture. The reaction was followed by HPLC. After 1 h, the starting material was consumed. To the heterogeneous reaction mixture was added dropwise over 1.5 h 750 ml water (to remove water soluble by-products) and over 40 min 500 ml n-hexane (to drive the precipitation of the product to completion). The suspension was stirred for 1 h at 2° C. and then filtered. The crystalline product was washed with 3×100 ml water and 3×100 ml n-hexane/dichloromethane 3:1 dried to constant weight. Activated ester (Z)-(2-Aminothiazol-4-yl)-trityloxyiminoacetic acid diethoxythiophosphoryl ester was obtained as a tan solid (64.24 g, yield=94.9%, HPLC=97.5 area %, mp=146 ° C.) and was stored under Ar at 4° C. No further purification was necessary and the product was used as isolated for the next step.
IR (KBr) 3444, 3092, 2983, 1770, 1618, 1541, 1490, 1024, 720.
1 H-NMR (250 MHz, CDCl 3 ) δ1.29 (dt,J 1 =7,J 2 =0.8,6H); 4.19 (dq,J 1 =8.0, J 2 =7.0,4H); 6.01 (s,br,2H); 6.59 (s,1H); 7.26-7.34 (m,15H).
31 P-NMR (100 MHz, CDCl 3 ) δ59,05.
ISP-MS 582.4 (100, M+H! + ).
MA calculated for C 28 H 28 N 3 O 5 PS 2 C 57.82, H 4.85, N 7.22, S 11.02, P 5.33 found C 58.09, H 4.96, N 7.21, S 10.92, P 5.35 and 0.35% water.
b) (6R, 7R)-7- (Z)-2-(2-Aminothiazol-4-yl)-2-trityloxyimino-acetylamino)!-3- (E)-1-cyclopropylmethyl-2-oxo-pyrrolidin-3-ylidenemethyl!-8-oxo-5-thia-1-aza-bicyclo 4.2.0!oct-2-ene-2-carboxylic acid triethylammonium salt ##STR10##
To a stirred suspension of 22.78 g (E)-(6R,7R)-7-amino-3-(1-cyclopropylmethyl-2-oxo-pyrrolidin-3-ylidenemethyl)-8-oxo-5-thia-1 -azabicyclo 4.2.0!oct-2-ene-2-carboxylic acid (65.2 mmol) in 160 ml dimethylformamide was added under argon 9.1 ml triethylamine (65.2 mmol) at 10° C. After 30 min, to the solution was added 48 ml 2-propanol and 3.9 ml water causing the starting material to precipitate partially. The suspension was cooled to 2° C. and over 5 min was added in portions 36.68 g activated ester (Z)-(2-Aminothiazol-4-yl)-trityloxyiminoacetic acid diethoxythiophosphoryl ester (66.5 mmol). Stirring was continued at room temperature with exclusion of light for 17 h. The reaction was followed by HPLC. To the slightly turbid reaction mixture was added over 2 min 9.2 ml triethylamine (65.2 mmol, 1.0 eq) resulting in a clear, yellow solution. Reference material was added and after ca. 15 min, the reaction mixture became turbid, indicating the onset of crystallization. Stirring at room temperature was continued for 60 min and then 330 ml ethylacetate was added dropwise over 90 min. To drive crystallization to completion the suspension was cooled to 2° C. and stirred for 3 h at this temperature. The suspension was filtered. The crystalline product was washed with 3×100 ml ice-cold ethylacetate and dried to constant weight. The cephalosporin (6R, 7R)-7- (Z)-2-(2-Aminothiazol-4-yl)-2-trityloxyimino-acetylamino)!-3- (E)-1-cyclopropylmethyl-2-oxo-pyrrolidin-3-ylidenemethyl!-8-oxo-5-thia-1-aza-bicyclo 4.2.0!oct-2-ene-2-carboxylic acid triethylammonium salt was obtained as an off-white solid (51.56 g, yield=77%, HPLC=100 area %) and was stored under Ar at 4° C. No further purification was necessary and the product was used as isolated for the next step.
Anal.
1 H-NMR (250 MHz, DMSO) δ0.20 (m,2H); 0.46 (m,2H); 0.92 (m,1H); 3.14 (d,J=7.0,2H); 3.22-4.09 (mm,7H); 3.78, 3.82 (2d,J=16.0,2H); 5.16 (d,J=5.0,1H); 5.87 (dd,J 1 =13.2,J 2 =8.3,1H); 6.61 (s,1H); 7.23-7.33 (mm,16H); 9.90 (d,J=8.3,1H)+signals for NEt 3 and DMF. calculated for C 40 H 36 N 6 O 6 S 2 : C 6 H 15 N: C 3 H 7 NO=1:1:2 and 0.36% H 2 O C 61.94, H 6.50, N 12.50, S 6.36 found C 61.49, H 6.29, N 12.17, S 6.69.
EXAMPLE 2
a) Preparation of (Z)-(2-Aminothiazol-4-yl)-acetoxyiminoacetic acid diethoxythiophosphoryl ester ##STR11##
To a stirred solution of 134.9 g (Z)-(2-aminothiazol-4-yl)-acetoxyiminoacetic acid dihydrate (508.6 mmol) and 570 mg 1,4-diazabicyclo 2.2.2!octane (DABCO) (5.09 mmol) in 1500 ml dimethylacetamide was added under argon 158 ml tributylamine (661 mmol). The yellowish solution was cooled to -20° C. and over 30 min was added dropwise 104 ml diethyl chlorothiophosphate (661 mmol). Stirring was continued at -20° C. for 3.5 h. The reaction was followed by HPLC. After 3 h, all starting material was consumed. The reaction mixture was allowed to warm up to 0° C. and over 1.0 h was added dropwise 2200 ml water. The precipitated product was filtered, washed with water and dissolved in 800 ml dichloromethane. The aqueous layer was back-extracted with 300 ml dichloromethane. The combined organic layers were dried over 70 g sodium sulfate and concentrated under reduced pressure until the product started to crystallize. The residual solution was cooled to 2° C. and 1200 ml n-hexane was added dropwise over 1 h. The resulting suspension was stirred for 1 h at 2° C. and then filtered. The crystalline product was washed with n-hexane and dried to constant weight. (Z)-(2-aminothiazol-4-yl)-acetoxyiminoacetic acid diethoxythiophosphoryl ester was obtained as a white solid (166.9 g, yield=86%, mp 128°-130° C. and was stored under argon at -20° C. No further purification was necessary and the product was used as isolated for the next step.
IR (KBr) 3429, 3260, 3172, 3135, 1795, 1770, 1619, 1538, 1174, 1020.
1 H-NMR (250 MHz, CDCl 3 ) δ1.38 (dt,J 1 =7.0,J 2 =0.9,6H); 2.26 (s,3H); 4.34 (dq,J 1 =8.0,J 2 =7.0,4H); 6.94 (s,1H); 7.50 (s,br,2H).
31 P-NMR (100 MHz, CDCl 3 ) δ59.27.
ISP-MS 404.1 (31, M+Na! + ), 382.1 (100, M+H! + ).
MA calculated for C 11 H 16 O 6 N 3 PS 2 C 34.64, H4.23, N 11.02, S 16.81, P 8.12 found C 34.64, H 4.18, N 11.07, S 16.67, P 8.02.
b) Preparation of (6R,7R)-7- (Z)-2-(2-aminothiazol-4-yl)-2-acetoxyimino-acetylamino)!-3- (E)-1-cyclopropylmethyl-2-oxo-pyrrolidin-3-ylidenemethyl!-8-oxo-5-thia-1-azabicyclo 4.2.0!oct-2-ene-2-carboxylic acid ##STR12##
Under an argon atmosphere to a stirred suspension of 25.6 g (E)-(6R,7R)-7-Amino-3-(1-cyclopropylmethyl-2-oxo-pyrrolidin-3-ylidenemethyl)-8-oxo-5-thia-1-azabicyclo 4.2.0!oct-2-ene-2-carboxylic acid (73.3 mmol) in 120 ml dimethylformamide was added 20 ml triethylamine (143 mmol) at 10° C. After 15 min, the solution was cooled to 0° C. and 28.5 g (Z)-(2-aminothiazol-4-yl)-acetoxyiminoacetic acid diethoxy thiophosphonyl ester (74.8 mmol) was added in portions over 5 min. Stirring was continued at 0° C. with exclusion of light for 5 h. The reaction was followed by HPLC. The brown reaction mixture was poured at once into 550 ml water of 10° C. Over 30 min, 50 ml HCl 1N was added. The pH dropped from 4.6 to 3.2 and the product precipitated from the reaction mixture. Stirring was continued for 1 h at 0° C. The suspension was filtered. The product was washed with ice-cold water, re-suspended in water, stirred for 20 min at room temperature, filtered and again washed with water. (6R,7R)-7- (Z)-2-(2-aminothiazol-4-yl)-2-acetoxyimino-acetylamino)!-3- (E)-1-cyclopropylmethyl-2-oxo-pyrrolidin-3-ylidenemethyl!-8-oxo-5-thia-1-azabicyclo 4.2.0!oct-2-ene-2-carboxylic acid was obtained as a beige, wet solid. The product was used immediately and without drying for the next step.
EXAMPLE 3
a) Preparation of (Z)-(RS)-(2-aminothiazol-4-yl)- (tetrahydropyran-2-yloxyimino)!-acetic acid diethoxythio-phosphoryl ester ##STR13## wherein THP is tetrahydropyranyl
To a stirred suspension of 30 g (Z)-(RS)-(2-aminothiazol-4-yl)- (tetrahydropyran-2-yloxyimino)!-acetic acid (80.5 mmol) and 90 mg 1,4-diazabicyclo 2.2.2!octane (DABCO) (0.80 mmol) in 300 ml dimethylacetamide was added under argon over 45 min 17 ml diethyl chlorothiophosphate (104.9 mmol). Stirring was continued at 0° C. for 1 h. The reaction was followed by HPLC. To the slightly turbid reaction mixture was added dropwise over 50 min 450 ml water. The precipitated product was filtered, washed with water and dissolved in dichloromethane. The aqueous layer was back-extracted with dichloromethane. The combined organic layers were dried over sodium sulfate and concentrated under reduced pressure until the product started to crystallize. To the residual solution was added dropwise over 30 min n-hexane. The resulting suspension was cooled to 2° C., stirred for 1 h and then filtered. The crystalline product was washed with n-hexane and dried to constant weight. (Z)-(RS)-(2-aminothiazol-4-yl)- (tetrahydropyran-2-yloxyimino)!-acetic acid diethoxythio-phosphoryl ester was obtained as a white solid (28.01 g, yield=82%) and was stored under argon at -20° C. No further purification was necessary and the product was used as isolated for the next step.
IR (KBr) 3423, 3261, 3169, 3145, 2946, 1772, 1614, 1541, 1388, 1241, 1204, 1156, 1110, 1020, 973, 944, 908, 888, 857, 827, 727, 692.
1 H-NMR (250 MHz, CDCl 3 ) δ1.37 (t,J=7.1,6H); 1.50-1.95 (m,6H); 3.65 (dm,J=11.4,1H); 3.86 (tm,J=11.4,1H); 4.33 (dq,J 1 =8.0,J 2 =7.0,4H); 5.47 (s,br,1H); 6.56 (s,br,2H); 6.79 (s,1H).
31 P-NMR (100 MHz, CDCl 3 ) δ59.33.
ISP-MS 446.4 (19, M+Na! + ), 424.5 (26, M+H! + ), 340.2 (100).
MA calculated for C 14 H 22 N 3 O 6 PS 2 C 39.71, H 5.24, N 9.92, S 15.14, P 7.31 found C 39.87, H 5.20, N 10.08, S 14.99, P 7.53.
b) (6R,7R)-7- (Z)-2-(2-Aminothiazol-4-yl)-2- (R,S)-tetrahydropyran-2-yloxyimino-acetylamino)!-3- (E)-1-cyclopropylmethyl-2-oxo-pyrrolidin-3-ylidenemethyl!-8-oxo-5-thia-1-aza-bicyclo 4.2.0!oct-2-ene-2-carboxylic acid ##STR14##
Under argon atmosphere to a stirred suspension of 20 g (E)-(6R,7R)-7-Amino-3-(1-cyclopropylmethyl-2-oxo-pyrrolidin-3-ylidenemethyl)-8-oxo-5-thia-1-azabicyclo 4.2.0!oct-2-ene-2-carboxylic acid (57.2 mmol) in 140 ml dimethylformamide was added 16 ml triethylamine (114.8 mmol) at 10° C. After 10 min, to the solution was cooled to 0° C. and 24.72 g (Z)-(RS)-(2-aminothiazol-4-yl)- (tetrahydropyran-2-yloxyimino)!-acetic acid diethoxythio-phosphoryl ester (58.4 mmol) was added in portions over 1 min. Stirring was continued at 10° C. with the exclusion of light for 6 h. The reaction was followed by HPLC. The reaction mixture was poured at once into a 10° C. mixture of 220 ml water and 50 ml acetone. Over 30 min, 55 ml HCl 1N was added. The pH dropped from 9.6 to 3.2 and the product precipitated from the reaction mixture. Stirring was continued for 30 min at 0° C. The suspension was filtered. The product was washed with ice-cold water and dried to constant weight. (6R,7R)-7- (Z)-2-(2-Aminothiazol-4-yl)-2- (R,S)-tetrahydropyran-2-yloxyimino-acetylamino)!-3- (E)-1-cyclopropylmethyl-2-oxo-pyrrolidin-3-ylidenemethyl!-8-oxo-5-thia-1-aza-bicyclo 4.2.0!oct-2-ene-2-carboxylic acid was obtained as an off-white solid (27.7 g). The product was used as isolated for the next step.
1 H-NMR (250 MHz, DMSO) δ0.21 (m,2H); 0.46 (m,2H); 0.93 (m,1H); 1.40-1.90 (m,6H); 2.90-3.10 (m,2H); 3.16 (d,J=7.1,2H); 3.48 (m,2H); 3.50 (m,1H), 3.85 (m,1H); 3.90 (s,2H); 5.21 (d,J=5.0,1H); 5.26 (s,br,1H); 5.90 (dd,J 1 =8.2,J 2 =5.0,1H); 6.75 (s,1H); 7.23 (s,br,3H); 9.69 (d,J=8.2,1H); 13.95 (s,br,1H).
EXAMPLE 4
Cleavage of the Protective Groups
Preparation of (6R,7R)-7- (Z)-2-(2-aminothiazol-4-yl)-2-hydroxyimino-acetylamino!-3- (E)-1-cyclopropylmethyl-2-oxo-pyrrolidin-3-ylidenemethyl!-8-oxo-5-thia-1-aza-bicyclo 4.2.0!oct-2-ene-2-carboxylic acid ##STR15## a) By cleavage of the trityl group
To a stirred solution of 30 g (6R, 7R)-7- (Z)-2-(2-Aminothiazol-4-yl)-2-trityloxyimino-acetylamino)!-3- (E)-1-cyclopropylmethyl-2-oxo-pyrrolidin-3-ylidenemethyl!-8-oxo-5-thia-1-aza-bicyclo 4.2.0!oct-2-ene-2-carboxylic acid triethylammonium salt (29.2 mmol) in 60 ml dichloromethane was added over 15 min 7.5 ml triethylsilane (45.9 mmol) and over 90 min 23.9 ml trifluoroacetic acid (306 mmol) at 2° C. Stirring was continued at 10° C. for 2 h. The reaction was followed by HPLC. To the reaction mixture was added over 90 min 300 ml diethylether, causing the product to precipitate. Stirring was continued for 1h at room temperature. The suspension was filtered. The product was washed with 2×60 ml diethylether, again suspended in 100 ml diethylether, stirred for 15 min, filtered, washed with 2×40 ml diethylether and dried to constant weight. The trifluoroacetate of (6R,7R)-7- (Z)-2-(2-aminothiazol-4-yl)-2-hydroxyimino-acetylamino!-3- (E)-1-cyclopropylmethyl-2-oxo-pyrrolidin-3-ylidenemethyl!-8-oxo-5-thia-1-aza-bicyclo 4.2.0!oct-2-ene-2-carboxylic acid was obtained as an off-white solid (19.92 g, 99%, HPLC=100 area %) and suspended in 400 ml water. Over 15 min 20 ml NaOH 1N (20 mmol) were added at 2° C. The pH rose from 1.51 to 3.30. The suspension was stirred at 2° C. for 10 min and then filtered. For the filtration a mild vacuum of about 400 mbar was applied. The product was washed with 2×50 ml water, suspended in 250 ml water, stirred for 15 min at 2° C., filtered, washed with 2×50 ml water and re-suspended in 400 ml water. Over 40 min 30 ml NaOH 1N was added at 2° C. The pH rose from 2.38 to 5.6 and most of the product dissolved. The turbid solution was filtered and two membrane filters of 0.45 μm and 0.22 μm. To the resulting, clear solution was added over 20 min 26 ml HCl 1N (26 mmol) at 2° C. The pH dropped from 5.42 to 3.30 and the product precipitated. The suspension was stirred for 60 min at 2° C., filtered and washed with 100 ml water. The product was dried (15 mbar, 24 h, 35° C.) to constant weight. (6R,7R)-7- (Z)-2-(2-Aminothiazol-4-yl)-2-hydroxyimino-acetylamino!-3- (E)-1-cyclopropylmethyl-2-oxo-pyrrolidin-3-ylidenemethyl!-8-oxo-5-thia-1-aza-bicyclo 4.2.0!oct-2-ene-2-carboxylic acid was isolated as an off white solid (12.1 g, yield 81%, HPLC 94 area %).
1 H-NMR (250 MHz, DMSO) δ0.21 (m,2H); 0.46 (m,2H); 0.93 (m,1H); 2.90 (m,1H); 3.10 (m,1H); 3.15 (d,J=7.0,2H); 3.48 (t,J=6.0,2H); 3.88 (s,2H); 5.18 (d,J=4.9,1H); 5.82 (dd,J 1 =8.7,J 2 =4.9,1H); 6.66 (s,1H); 7.14 (s,br,2H); 7.22 (s,1H); 9.51 (d,J=8.7,1H); 11.33 (s,br,1H).
Anal. calculated for C 21 H 22 N 6 O 6 S 2 : C 48.64, H 4.28, N 16.21, S 12.36 found C 47.88, H 4.36, N 15.85, S 12.17 and 2.47% H 2 O.
b) By cleavage of the acetyl group
To a stirred suspension of (6R,7R)-7- (Z)-2-(2-aminothiazol-4-yl)-2-acetoxyimino-acetylamino)!-3- (E)-1-cyclopropylmethyl-2-oxo-pyrrolidin-3-ylidenemethyl!-8-oxo-5-thia-1-azabicyclo 4.2.0!oct-2-ene-2-carboxylic acid (used in wet form, assumed ˜73.3 mmol) in 300 ml methanol was added under an argon atmosphere over 10 min 30 ml HCl conc. (304 mmol) at 2° C. After 5 h stirring at 2° C., another 10 ml HCl conc. (101 mmol) were added to the suspension. The reaction mixture was allowed to warm up to room temperature over night. The reaction was followed by HPLC. After 21 h total reaction time, all starting material was consumed and a brown solution had resulted. The reaction mixture was poured at once into 800 ml ice cold water. To the resulting suspension was added over 60 min 500 ml NaOH 1N. The pH rose from 0.6 to 3.3. Stirring at 2° C. was continued for 15 min. The suspension was filtered. The product was washed with water and dried to constant weight. (6R,7R)-7- (Z)-2-(2-Aminothiazol-4-yl)-2-hydroxyimino-acetylamino!-3- (E)-1-cyclopropylmethyl-2-oxo-pyrrolidin-3-ylidenemethyl!-8-oxo-5-thia-1-aza-bicyclo 4.2.0!oct-2-ene-2-carboxylic acid was obtained as a yellowish solid (29.8 g, yield 78%, HPLC 90 area %).
c) By cleavage of the tetrahydropyranyl (THP) group
To a stirred suspension of 20 g (6R,7R)-7- (Z)-2-(2-aminothiazol-4-yl)-2- (R,S)-tetrahydropyran-2-yloxyimino-acetylamino)!-3- (E)-1-cyclopropylmethyl-2-oxo-pyrrolidin-3-ylidenemethyl!-8-oxo-5-thia-1-aza-bicyclo 4.2.0!oct-2-ene-2-carboxylic acid (33.3 mmol) in 150 ml methanol was added over 10 min 15 ml HCl conc. (180 mmol) at room temperature. The yellow solution was stirred at 45° C. for 4.5 h. The reaction was followed by HPLC. After 4 h all starting material was consumed. The reaction mixture was allowed to cool to room temperature and poured at once into 500 ml water. To the solution was added over 40 min 170 ml NaOH 1N. The pH rose from 0.43 to 3.1. The resulting suspension was cooled to 2° C., stirred for 1 h and filtered. The product was washed with ice cold water and dried to constant weight. (6R,7R)-7- (Z)-2-(2-amino-thiazol-4-yl)-2-hydroxyimino-acetylamino!-3- (E)-1-cyclopropylmethyl-2-oxo-pyrrolidin-3-ylidenemethyl!-8-oxo-5-thia-1-aza-bicyclo 4.2.0!oct-2-ene-2-carboxylic acid was obtained as a yellowish solid (12.8 g, yield 74%, HPLC 85 area %).
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The invention is concerned with a new process for the preparation of compounds of formula ##STR1## wherein R 1 is trityl, acetyl, tetrahydropyranyl or cyclopentyl;
R 2 is hydrogen, hydroxy, lower alkyl, cycloalkyl, lower alkoxy, lower alkenyl, lower alkynyl, aryl, aryloxy, aryl-lower alkyl, aryl-lower alkoxy or heterocyclyl or heterocyclyl-lower alkyl; the lower alkyl, cycloalkyl, lower alkoxy, lower alkenyl, cycloalkenyl, lower alkynyl, aryl-lower alkyl, aryl, aryloxy, aryl-lower alkoxy, the heterocyclyl moieties being unsubstituted or substituted with at least one group selected from carboxy, amino, nitro, cyano, lower alkyl, lower alkoxy, hydroxy, halogen, --CONR 21 R 22 , --N(R 22 )COOR 23 , R 22 CO--, R 22 OCO-- or R 22 COO--, wherein R 21 is hydrogen, lower alkyl, or cycloalkyl; R 22 is hydrogen or lower alkyl; R 23 is lower alkyl, lower alkenyl or a carboxylic acid protecting group;
Y is --S-- and Z is --CH 2 -- or
Y is --CH 2 -- and Z is --O--,
by acylation of a compound of formula ##STR2## with an activated carboxylic acid derivative of formula ##STR3## wherein R 3 is lower alkyl, and R 1 , R 2 , X, Y, Z have the significance given above; and it is further concerned with compounds of formula III.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to semiconductor memory devices, and in particular to semiconductor memory devices such as DRAMs (dynamic random access memories) provided with a bit line precharge voltage generating device that is capable of quickly performing a precharge operation if the precharge potential of the bit lines differs from a middle potential of the bit line pair.
[0003] 2. Description of the Related Art
[0004] The circuit configuration and the operation of a semiconductor memory device in which a conventional bit line precharge voltage generating device is mounted are described below with reference to the drawings.
[0005] [0005]FIG. 19 shows a function block diagram of an ordinary DRAM 5000 . Numeral 4000 denotes a memory array, 4001 denotes memory array blocks, 4002 denotes a power source block, 4003 denotes a row controller, 4004 denotes a column controller, 4005 denotes a control circuit, and 4006 denotes an I/O buffer.
[0006] The memory array 4000 includes a plurality of memory array blocks 4001 . The power source block 4002 supplies the voltage necessary for the memory array 4000 , such as the bit line precharge voltage VBP and the memory cell plate voltage VCP, to each memory array block 4001 . Each memory array block 4001 is controlled by a bit line precharge signal NEQ, sense amplifier activation signals SAN and SAP, and a word line drive signal WL [63:0], which are input from the row controller 4003 . Further, the memory array blocks 4001 are each connected to the column controller 4004 .
[0007] The row controller 4003 receives the access control signal SE and the row address signal RAD from the control circuit 4005 . The column controller 4004 receives the write enable signal WEN and the column address signal CAD from the control circuit 4005 .
[0008] The control circuit 4005 receives an outside clock signal CLK, a row address strobe signal NRAS, a column address strobe signal NCAS, a write control signal NWE, an address ADDR, and a refresh control signal REF.
[0009] The column controller 4004 is connected to the I/O buffer 4006 . The I/O buffer 4006 receives data input signals DI and outputs data output signals DO.
[0010] [0010]FIG. 20 is a circuit diagram of the memory array blocks 4001 . Numeral 4100 is a memory cell, 4101 is a sense amplifier, 4102 is a precharge circuit, BL[n](n=0,1, . . . ) are bit lines, and /BL[n](n=0,1, . . . ) are bit lines paired with the bit lines BL[n]. The memory cell 4100 is made of a capacitor 4104 and an access transistor 4103 , which is a p-channel transistor. The source of the access transistor 4103 is connected to the bit line BL[n] or /BL[n], the drain of the access transistor 4103 is connected to one node of the capacitor 4104 , and the gate of the access transistor 4103 is connected to a word line drive signal WL[n] line. The other node of the capacitor 4104 is connected to the memory cell plate voltage VCP.
[0011] The sense amplifier 4101 is an ordinary cross-coupled sense amplifier, and is connected to the pair of bit lines BL[n] and /BL[n]. The sense amplifier 4101 is controlled by the sense amplifier activation signals SAN and SAP. The precharge circuit 4102 is made of three p-channel transistors. These are a transistor whose source is connected to the bit line BL[n], whose drain is connected to the bit line /BL[n], and whose gate is connected to the bit line precharge signal NEQ line, a transistor whose source is connected to the bit line BL[n], whose drain is connected to the bit line precharge voltage VBP, and whose gate is connected to the bit line precharge signal NEQ line, and a transistor whose source is connected to the bit line precharge voltage VBP, whose drain is connected to the bit line /BL[n], and whose gate is connected to the bit line precharge signal NEQ line.
[0012] [0012]FIG. 21 shows the power source wiring network of the bit line precharge voltage VBP. Bit line precharge power lines VBP[n] are arranged on the memory cell array 4000 so as to supply the bit line precharge voltage VBP from the precharge voltage generating circuit 4200 to the precharge circuits 4102 that are arranged in each memory array block 4001 (see FIG. 20). The bit line precharge power lines VBP[n] are expressed as VBP[0], VBP[1], . . . VBP[n] in order from the side near the precharge voltage generating circuit 4200 . The bit line precharge power lines VBP[n] are disposed in the column direction as the wiring layer of the upper layer of each memory array block 4001 (in FIG. 21, shown by the solid lines). The bit line precharge power lines VBP[n] are connected to one another in the row direction by metal wiring (in FIG. 21, shown by the dashed lines) so as to lower the impedance. In this manner, the bit line precharge power lines VBP[n] are arranged in a matrix, and the thickest possible wiring is used. The bit line precharge power line VBP[0] is connected to the precharge voltage generating circuit 4200 .
[0013] [0013]FIG. 22 shows a conventional precharge voltage generating circuit 4200 . Numeral 4300 denotes a reference voltage generating circuit, 4301 denotes an operational amplifier, and 4302 denotes a p-channel transistor. VBPREF is the bit line precharge reference voltage, VOUT is the bit line precharge hold voltage, and PEN is the driver enable signal. The reference voltage generating circuit 4300 generates the bit line precharge reference voltage VBPREF and the bit line precharge hold voltage VOUT. The bit line precharge reference voltage VBPREF is connected to the −input of the operational amplifier 4301 and the bit line precharge hold voltage VOUT is connected to the bit line precharge power line VBP[0]. The +input of the operational amplifier 4301 is connected to the bit line precharge power line VBP[0]. The output of the operational amplifier 4301 is the driver enable signal PEN, and is input to the gate of the p-channel transistor 4302 . The source of the p-channel transistor 4302 is connected to the VDD, and the drain of the p-channel transistor 4302 is connected to the bit line precharge power line VBP[0]. Thus the operational amplifier 4301 and the p-channel transistor 4302 compose a comparing and driving circuit.
[0014] [0014]FIG. 23 shows a circuit diagram of the reference voltage generating circuit 4300 . Numeral 4400 denotes a resistor (resistor R1) and 4401 denotes a resistor (resistor R2). The circuit configuration is that of an ordinary ½ VDD generating circuit, which is described in detail in “Super LSI Memories” (authored by Kiyoo Itoh, Baifukan), and thus a detailed description thereof is omitted. The output stages are for generating the bit line precharge reference voltage VBPEREF and the bit line precharge hold voltage VOUT. The voltage that is output is VOUT=VBPREF=R2/(R1+R2)×VDD. Resistance values that are sufficiently larger than the on resistance of the transistors making up this circuit can be used as the values for R1 and R2.
[0015] The operational amplifier 4301 is an ordinary, current mirror load-type differential operational circuit such as that shown in FIG. 24. AMPEN is a differential amplifier control signal. As the differential input, the bit line precharge reference voltage VBPREF is connected to the −input and the bit line precharge power line VBP[0] is connected to the +input. The output is the driver enable signal PEN. When the differential amplifier control signal AMPEN is the VDD level, then the operational amplifier 4301 is in an operational state, and when it is the VSS level, the operational amplifier 4301 is in a stopped state, and current consumption can be reduced. As this circuit is well known, a more detailed explanation of its operation will be omitted.
[0016] [0016]FIG. 25 shows the operation timing and the internal voltage timing of a DRAM having the above configuration. Here, only the read operation is shown. In a non-operational state (stand-by), all word lines WL[n] are at a high level, all access transistors 4103 are off, and an arbitrary voltage is held in the capacitor 4104 . Also, the bit line precharge signal NEQ is at a low level, all precharge circuits 4102 are in an operating state, and all bit lines BL[n] and /BL[n] are charged to the bit line precharge voltage VBP.
[0017] At the rising edge of the outside clock signal, the word line selection operation is started by setting the row address strobe signal NRAS to a low level and receiving a row address as the address ADDR. When the word line selection operation is started, the bit line precharge signal NEQ that is input to the arbitrary memory array block 4001 determined by the row address that is input is set to a high level. When the bit line precharge signal NEQ is set to a high level, the corresponding precharge circuit 4102 is stopped. Also, the differential amplifier control signal AMPEN is set to a high level and the operational amplifier is activated in order to prepare for the precharge operation.
[0018] Then, the word line WL[n] that is determined by the input row address is set to a low level (VSS), the plurality of memory cells 4100 that are connected thereto are turned on, and the voltage that is held in the capacitor 4104 is read to the connected bit line BL[n] or /BL[n]. Next, the sense amplifier activation signal SAN is set to a low level (VSS) and the sense amplifier activation signal SAP is set to a high level (VDD) so that the sense amplifier 4101 is activated. When the sense amplifier 4101 is activated, the bit line BL[n] or /BL[n] is charged to a low level (VSS) or a high level (VSS) based on the potential that is read to the bit line BL[n] or /BL[n].
[0019] Here, the word line WL[n] to which the memory cell 4100 that is read out is connected is set to a low level (VSS), so that the potential of the connected bit lines BL[n], /BL[n] is once again written into the capacitor 4104 . The access transistor 4103 is a p-channel transistor, and therefore a potential of Vtp (the threshold voltage of a p-channel transistor) is written as the low level and VDD is written as the high level. That is, the voltage that is written to the capacitor 4104 is VDD if high level and Vtp if low level. In order to read out both the high level read potential and the low level read potential with an optimal margin, the bit line precharge voltage VBP is ideally ½(VDD+Vtp), which is the mean value between them.
[0020] Then, by setting the column address strobe signal NCAS to a low level and inputting a column address as the address ADDR in synchronization with the rising edge of the outside clock signal CLK, the column controller 4004 is activated and data are output as data output signals DO.
[0021] Next, by setting the row address strobe signal NRAS and the column address strobe signal NCAS to a high level in synchronization with the rising edge of the outside clock signal CLK, the precharge operation is started. When the precharge operation is started, the word line WL[n] is set from a low level to a high level, the access transistor 4103 is turned off, and a charge is held in the capacitor 4104 . To prepare for the next read operation, the bit line precharge signal NEQ is set to a low level and the precharge circuit 4102 is activated.
[0022] When the precharge circuit 4102 is activated, the potentials of the bit lines BL[n], /BL[n], which are set to the potentials VDD and VSS, are equalized by the sense amplifier 4101 and charged to a potential of ½ VDD. The precharge circuit 4102 simultaneously is connected to the bit line precharge power line VBP[n] corresponding to the bit lines BL[n], /BL[n] so as to charge to it the bit line precharge voltage VBP.
[0023] [0023]FIG. 26 shows the operation of the bit line precharge power line VBP[n] according to this conventional configuration during activation of the precharge circuit 4102 . As mentioned previously, when the bit line precharge signal NEQ is set to a low level and the precharge circuit 4102 is activated, the activated bit lines BL[n], /BL[n], which are connected to the bit line precharge power line VBP[n], current is consumed and a drop in voltage occurs. The bit line precharge power line VBP[n] and the bit line precharge power line VBP[0] are connected in a lattice so as to lower the impedance, and transmission of the voltage is delayed by about several ns.
[0024] The bit line precharge power line VBP[0] is connected to the precharge voltage generating circuit 4200 . At the point that the bit line precharge power line VBP[0] becomes a lower voltage than the bit line precharge reference voltage VBPREF, the driver enable signal PEN, which is output by the operational amplifier 4301 , becomes lower toward the low level and the p-channel transistor 4302 is turned on, so that a high level voltage is supplied to the bit line precharge power line VBP[0]. At the point that the high level voltage supplied to the bit line precharge power line VBP[0] has increased the voltage to a higher voltage than the bit line precharge reference voltage VBPREF, the driver enable signal PEN, which is output by the operational amplifier 4301 , rises toward the high level and the p-channel transistor 4302 is turned off.
[0025] Because the p-channel transistor 4302 requires current capabilities and is relatively large in size (W=50 μm or more), the drive enabler signal PEN is delayed with respect to the relationship between the bit line precharge power line VBP[0] and the bit line precharge reference voltage VBPREF, and as shown in FIG. 26, the current ia that flows through the p-channel transistor 4302 is delayed.
[0026] To achieve a stable read during the next read operation, the voltage of the bit lines BL[n], /BL[n] must be kept within a predetermined range. However, with the conventional bit line precharge voltage generating device 4200 , the operation of the operational amplifier 4301 is slow and it is difficult to increase the speed of the precharge operation, and this was a problem. Although the speed of the precharge operation can be raised by increasing the current consumption of the operational amplifier 4301 , the increase in power consumption becomes a problem.
SUMMARY OF THE INVENTION
[0027] It is an object of the present invention to provide a semiconductor memory device that is capable of very quickly and accurately precharging the bit lines.
[0028] A semiconductor memory device according to the present invention is provided with a plurality of memory cells, bit line pairs to which the memory cells are connected, a plurality of precharge circuits for precharging the bit line pairs to a first voltage that is different from a mean value between a high level and a low level in accordance with a first control signal, a bit line precharge power line for supplying the first voltage for precharging to the precharge circuits, a first capacitor, a charging circuit for charging the first capacitor, a transfer gate circuit for controlling connection and disconnection between the first capacitor and the bit line precharge power line, and a first control circuit for controlling the charging circuit and the transfer gate circuit. The first control circuit, in accordance with a second control signal, controls the transfer gate circuit so that the first capacitor and the bit line precharge power line are connected during precharging of the bit line pairs.
[0029] According to this configuration, the charge on the first capacitor is released during the precharge operation, so that the bit lines can be precharged at high speeds.
[0030] In the above configuration, it is possible to further provide a reference voltage generating circuit for generating a second voltage, and a comparing and driving circuit for driving the bit line precharge power line at the first voltage in accordance with reference to the second voltage.
[0031] In the above configuration, it is preferable that the first capacitor is made of a first MOS transistor whose source and drain are grounded, that the charging circuit is made of a first p-channel MOS transistor whose gate is connected to the second control signal, whose source is connected to a first outside power source, and whose drain is connected to the gate of the first MOS transistor, and that the transfer gate circuit is made of a first n-channel MOS transistor into whose gate the second control signal is input, whose source is connected to the gate of the first MOS transistor, and whose drain is connected to the precharge circuit, a first inverter into whose input the second control signal is supplied, and a second p-channel MOS transistor into whose gate an output of the first inverter is input, whose source is connected to the gate of the first MOS transistor, and whose drain is connected to the precharge circuit.
[0032] Thus, the bit lines can be precharged at high speeds with the smallest circuit configuration.
[0033] Further, the device may have a configuration in which the first control circuit, after a first delay time that starts when the first control signal has become a voltage that activates the precharge circuit, controls the second control signal to a first voltage level so that the first capacitor and the bit line precharge power line are connected, and after a further second delay time, the first control circuit controls the second control signal to a voltage of a phase opposite the first voltage level.
[0034] With this configuration, current is supplied from the first capacitor after the comparing and driving circuit has been activated, and thus the bit lines can be precharged at high speeds.
[0035] Additionally, the device may have a configuration in which, when a difference between a first outside power source voltage and the second voltage is taken as a first voltage difference, a difference between the second voltage and the mean voltage of the voltages of the bit line pairs is taken as a second voltage difference, and a total capacitance of simultaneously precharged bit line pairs is taken as a first capacitance, then a capacitance of the first capacitor is equivalent to a second capacitance obtained by multiplying the first capacitance with the ratio of the second voltage difference to the first voltage difference.
[0036] Also, it is preferable that when a difference between a first outside power source voltage and the second voltage is taken as a first voltage difference, a difference between the second voltage and the mean voltage of the voltages of the bit line pairs is taken as a second voltage difference, and a total capacitance of simultaneously precharged bit line pairs is taken as a first capacitance, then a capacitance of the first capacitor is a value of approximately 50% to 80% that of a second capacitance obtained by multiplying the first capacitance with the ratio of the second voltage difference to the first voltage difference.
[0037] Thus, an excess rise in voltage caused by a rise in the first voltage due to discharge of the first capacitor and a rise in the voltage from the comparing and driving circuit is prevented, and the bit lines can be precharged at high speeds with high accuracy.
[0038] Furthermore, the above configuration may be revised to such that the plurality of memory cells are refreshed in correspondence with a refresh control signal, wherein during a refresh operation, a greater number of bit line pairs are activated than in normal operation, and wherein the first control circuit enables a connection of the transfer gate circuit in correspondence with the first control signal only when the level of the refresh control signal indicates the refresh operation.
[0039] According to this configuration, the operation for precharging the bit lines can be performed at high speeds during the refresh operation. Also, the capacitance of the first capacitor can be set to a required size only during the refresh operation, the circuit area can be reduced, and the circuit configuration can be simplified.
[0040] Also, the above configuration may be revised to such that, responsive to a test signal, when not in test mode, the transfer gate circuit becomes connecting state in correspondence with the first control signal, and when in test mode, the first control circuit is stopped and the output of the first control circuit becomes high impedance, and the transfer gate circuit becomes disconnecting state.
[0041] According to this configuration, during testing, for example, the operation for precharging the bit lines is applied from the outside, and thus when confirming the operation margin, for example, a desired voltage can be achieved easily.
[0042] Further, the device may have a configuration in which the comparing and driving circuit compares the second voltage to a voltage of a portion of the bit line precharge power line coupled to a precharge circuit, of the plurality of precharge circuits, that is disposed around the portion farthest from the comparing and driving circuit, and based on a result of this comparison, drives a portion of the bit line precharge power line that is closest or near to the comparing and driving circuit.
[0043] According to this configuration, with respect to the entire memory array that is supplied, the operation for precharging the bit lines can be performed at relatively high speeds even with respect to memory array blocks that are far from the supply source of the voltage for precharging.
[0044] In a further configuration, the plurality of memory cells are divided into a plurality of memory array blocks and each memory array block includes a plurality of memory cells connected to the plurality of precharge circuits that are simultaneously driven by the first control signal, and a noise canceller is disposed at each memory array block, wherein the noise canceller is made of a second inverter and a second capacitor, the first control signal is input to the second inverter, an output of the second inverter is input to a terminal of the second capacitor, and the bit line precharge power line is coupled to another terminal of the second capacitor.
[0045] According to this configuration, the impact of coupling noise to the precharge voltage for the bit lines due to the first control signal can be cancelled out, so that the operation for precharging the bit lines can be performed at high speeds with high accuracy.
[0046] Another semiconductor memory device according to the present invention includes a plurality of memory cells, bit line pairs to which the memory cells are connected, a plurality of precharge circuits for precharging the bit line pairs to a first voltage that is different from a mean value between a high level and a low level, in accordance with a first control signal, a bit line precharge power line for supplying the first voltage for precharging to the precharge circuits, a plurality of capacitor circuits; and a first control circuit for controlling the capacitor circuits. Each capacitor circuit includes a first capacitor, a charging circuit for charging the first capacitor, and a transfer gate circuit for controlling connection and disconnection between the first capacitor and the bit line precharge power lines. The first control circuit, in accordance with a third control signal for controlling the number of bit line pairs that are simultaneously activated, changes the number of the plurality of capacitor circuits that are activated, and only in a capacitor circuit that is activated, the transfer gate circuit is controlled in accordance with a second control signal so that the first capacitor and the bit line precharge power line are connected during precharging of the bit line pairs.
[0047] According to this configuration, in a semiconductor memory device in which the active block can be changed by the second control signal, the bit lines can be precharged quickly regardless of the size of the active block, and a source for supplying an optimal voltage for precharging can be provided.
BRIEF DESCRIPTION OF THE DRAWINGS
[0048] [0048]FIG. 1 is a circuit block diagram of a semiconductor memory device according to Embodiment 1 of the present invention.
[0049] [0049]FIG. 2 is a circuit diagram of a precharge voltage generating circuit and a charge tank circuit according to Embodiment 1.
[0050] [0050]FIG. 3 is a circuit diagram of a charge/discharge control circuit according to Embodiment 1.
[0051] [0051]FIG. 4 shows an operation timing and a voltage of a primary node during precharge operation according to Embodiment 1.
[0052] [0052]FIG. 5 is a function block diagram of a semiconductor memory device according to Embodiment 2.
[0053] [0053]FIGS. 6A and 6B are structural diagrams showing memory array blocks that are activated during normal operation and during refresh operation of the semiconductor memory device according to Embodiment 2.
[0054] [0054]FIG. 7 is a circuit block diagram of the semiconductor memory device according to Embodiment 2.
[0055] [0055]FIG. 8 is a circuit diagram of a charge/discharge control circuit according to Embodiment 2.
[0056] [0056]FIG. 9 is a diagram showing the timing of the normal operation and the timing of the refresh operation of the semiconductor memory device according to Embodiment 2.
[0057] [0057]FIG. 10 is a circuit block diagram of a semiconductor memory device according to Embodiment 3.
[0058] [0058]FIG. 11 is a circuit diagram of a charge/discharge control circuit according to Embodiment 3.
[0059] [0059]FIG. 12 is a circuit block diagram of a semiconductor memory device according to Embodiment 4.
[0060] [0060]FIG. 13 is a circuit diagram of a precharge voltage generating circuit and a charge tank circuit according to Embodiment 4.
[0061] [0061]FIG. 14 is a circuit block diagram of a semiconductor memory device according to Embodiment 5.
[0062] [0062]FIG. 15 is a circuit diagram of a noise canceling circuit and a memory array block according to Embodiment 5.
[0063] [0063]FIG. 16 is a circuit block diagram of a semiconductor memory device according to Embodiment 6.
[0064] [0064]FIGS. 17A and 17B are diagrams for explaining the selection of an active block of the semiconductor memory device according to Embodiment 6.
[0065] [0065]FIG. 18 is a block diagram of a bit line precharge voltage generating device according to Embodiment 6.
[0066] [0066]FIG. 19 is a function block diagram of a conventional, ordinary DRAM.
[0067] [0067]FIG. 20 is a circuit diagram of a conventional memory array block.
[0068] [0068]FIG. 21 is a diagram showing a conventional power source wiring network for the bit line precharge voltage.
[0069] [0069]FIG. 22 is a circuit diagram of a conventional precharge voltage generating circuit.
[0070] [0070]FIG. 23 is a circuit diagram of a conventional reference voltage generating circuit.
[0071] [0071]FIG. 24 is a circuit diagram of a conventional operational amplifier.
[0072] [0072]FIG. 25 is a timing diagram of an operation timing and an internal voltage timing of a conventional DRAM.
[0073] [0073]FIG. 26 is a diagram showing a conventional voltage of bit line precharge power lines and current during activation of a precharge circuit.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0074] Embodiment 1
[0075] [0075]FIG. 1 shows a circuit block diagram of a semiconductor memory device in which a bit line precharge voltage generating device according to Embodiment 1 of the present invention is installed. The memory array 4000 , the power source block 4002 , the precharge voltage generating circuit 4200 , and the bit line precharge power lines VBP[n] have the same configuration as in the conventional example. The function block configuration of the semiconductor memory device is the same as in the conventional configuration shown in FIG. 19. The circuit configuration of the memory array blocks 4001 (see FIG. 19) making up the memory array 4000 is the same as in the conventional configuration shown in FIG. 20.
[0076] The element that has been improved is a bit line precharge voltage generating device (a bit line precharge voltage generator circuit block) 100 . The bit line precharge voltage generating device 100 includes a charge tank circuit 101 and a charge/discharge control circuit 102 in addition to the precharge voltage generating circuit 4200 , which has the same configuration as in the conventional example. The bit line precharge voltage generating device 100 is connected to the bit line precharge power line VBP[0], which is the closest of the bit line precharge power lines VBP[n].
[0077] [0077]FIG. 2 shows circuit diagrams of the precharge voltage generating circuit 4200 and the charge tank circuit 101 . The charge tank circuit 101 is made of a first capacitor 200 , a first p-channel transistor 201 , a second p-channel transistor 202 , a first n-channel transistor 203 , a first inverter 204 , and a buffer inverter 205 . CPND denotes a charge accumulation node, and AP, NAP, and ACP denote transfer gate connection signals. The circuit configuration of the precharge voltage generating circuit 4200 is like that of the conventional example.
[0078] The first terminal of the first capacitor 200 is connected to the drains of the first p-channel transistor 201 , the second p-channel transistor 202 , and the first n-channel transistor 203 , and the other terminal of the first capacitor 200 is grounded. The capacitance Ccap of the first capacitor 200 should be large enough to store (VBPREF−½VDD)×Cb1, which is equivalent to the charge necessary for charging the potential of the bit lines BL[n], /BL[n] to the bit line precharge reference voltage VBPREF, when the total capacitance of the simultaneously precharged bit lines BL[n], /BL[n] is set to Cb1. Taking into account the amount of charge that is supplied by the operational amplifier 4301 during operation, a capacitance Ccap<(VBPREF−½VDD)/(VDD−VBPREF)×Cb1 is used.
[0079] The transfer gate connection signal AP is input at the gate of the first p-channel transistor 201 , whose source is connected to an outside power source VDD. The second p-channel transistor 202 receives the transfer gate connection signal NAP at its gate, and the source of the second p-channel transistor 202 is connected to the bit line precharge power line VBP[0]. The transfer gate connection signal AP is received at the gate of the first n-channel transistor 203 , and the source of the first n-channel transistor 203 is connected to the bit line precharge power line VBP[0]. The transfer gate connection signal AP is supplied to the input of the first inverter 204 , and the output of the first inverter 204 constitutes the transfer gate connection signal AP. The buffer inverter 205 is made of an even number of inverter stages connected in series. The transfer gate connection signal ACP is supplied to the input of the buffer inverter 205 , and the output of the buffer inverter 205 constitutes the transfer gate connection signal AP.
[0080] [0080]FIG. 3 is a circuit diagram of the charge/discharge control circuit 102 . Numeral 300 denotes a first delay element, 301 denotes a second delay element, 302 denotes a second inverter, and 303 denotes a first NOR element. The delay time of the first delay element 300 is τ1. The input of the first delay element 300 is the bit line precharge signal NEQ, and the output of the first delay element 300 is received as input by the second delay element 301 and the first NOR element 303 . The delay time of the second delay element 301 is τ2, and its output is connected to the input of the second inverter 302 . The output of the second inverter 302 is received as input by the first NOR element 303 , and the output of the first NOR element 303 is the transfer gate connection signal ACP.
[0081] [0081]FIG. 4 shows the operation timing and the voltage of the primary node during the precharge operation of the bit line precharge voltage generating device 100 . The operation is described below with reference to this drawing. The operation timing of the semiconductor memory device in which the bit line precharge voltage generating device according to the present invention is mounted is the same as that shown in FIG. 25.
[0082] When the bit line precharge signal NEQ is set to a low level and the precharge circuit 4102 (see FIG. 20) is activated, the potentials of the bit lines BL[n], /BL[n], which are set to potentials of VDD and VSS, are equalized by the sense amplifier 4101 and are charged to a potential of ½ VDD. The precharge circuit 4102 at the same time connects the bit lines BL[n], /BL[n] to the corresponding bit line precharge power line VBP[n] and charges the bit lines to the bit line precharge voltage VBP. At this time, current is consumed and a voltage drop occurs.
[0083] When a voltage drop occurs in the bit line precharge power line VBP[n], the voltage drop is transmitted to the bit line precharge power line VBP[0] via wiring connected in a lattice. This is detected and the operational amplifier 4301 is activated, and it takes time before the current ia flowing through the p-channel transistor 4302 becomes large.
[0084] If the bit line precharge signal NEQ is at a high level, then the transfer gate connection signal AP is at a low level and the second p-channel transistor 202 and the first n-channel transistor 203 are off, the first p-channel transistor 201 is on, and the charge accumulation node CPND is charged to a high level so that a charge builds up in the first capacitor 200 .
[0085] When the bit line precharge signal NEQ become low level, after the delay time τ1 determined by the first delay element 300 , the transfer gate connection signal AP become high level, the first p-channel transistor 201 is turned off, and the second p-channel transistor 202 and the first n-channel transistor 203 are turned on. Thus, the first capacitor 200 and the bit line precharge power line VBP[0] are electrically connected to one another and the current ib is allowed to flow. The current accumulation node CPND is connected to the high level, and due to the current ib, the voltage level of the bit line precharge power line VBP[0] is increased rapidly.
[0086] In response to the rise in the voltage level, the operational amplifier 4301 changes the operation of the p-channel transistor 4302 toward off, and it takes time before the flowing current ia becomes small.
[0087] Then, after the delay time τ2 that is determined by the second delay element 301 , the transfer gate connection signal AP is at a low level, the second p-channel transistor 202 and the first n-channel transistor 203 are off, and the first p-channel transistor 201 is on so that the charge accumulation node CPND is charged to a high level in preparation for the next precharge operation.
[0088] As explained hereinabove, according to this embodiment, a function has been added for releasing the charge stored in the first capacitor 200 to the operational amplifier 4301 , which experiences a delay in operation, when the bit lines BL[n], /BL[n] are precharged to the high level, so that the precharge operation can be ended quickly and the semiconductor memory device can operate at high speed.
[0089] Embodiment 2
[0090] [0090]FIG. 5 shows a function block diagram of a semiconductor memory device 500 in which a bit line precharge voltage generating device is installed according to Embodiment 2 of the present invention. Elements similar to those of the conventional semiconductor memory device that already have been explained are assigned identical reference numerals and a further description thereof is omitted. The elements to which changes have been made are a control circuit 501 , a row controller 502 , and a power source block 503 . REFEN is a refresh operation enable signal. In the following description, primary emphasis is given to items that are different from those appearing in the conventional configuration.
[0091] The control circuit 501 receives as input the outside clock signal CLK, the row address strobe signal NRAS, the column address strobe signal NCAS, the write control signal NWE, the address ADDR, and the refresh control signal REF. The refresh operation enable signal REFEN that is output from the control circuit 501 is input to the row controller 502 and the power source block 503 .
[0092] [0092]FIGS. 6A and 6B show the conditions of the active memory array blocks 4001 during normal operation and during the refresh operation, respectively, of a semiconductor memory device to which the bit line precharge voltage generating device according to this embodiment has been installed. When the refresh operation enable signal REFEN is at a low level, the semiconductor memory device is in normal operation, and as shown in FIG. 6A, the bit line precharge signal NEQ, the sense amplifier activation signals SAN and SAP, and the word line drive signal WL[63:0] are output from the row controller 502 to a single memory array block 4001 . When the refresh operation enable signal REFEN is at a high level, the semiconductor memory device is in refresh operation, and as shown in FIG. 6B, the bit line precharge signal NEQ, the sense amplifier activation signals SAN and SAP, and the word line drive signal WL[63:0] are output from the row controller 502 to a plurality of memory array blocks 4001 .
[0093] [0093]FIG. 7 shows a circuit block diagram of the semiconductor memory device according to this embodiment. The memory array 4000 , the power source block 4002 , the precharge voltage generating circuit 4200 , and the bit line precharge power lines VBP[n] have the same configurations as in the conventional example. Also, the circuit configuration of the memory array block 4001 is the same as in the conventional configuration shown in FIG. 20. Elements assigned reference numerals that are identical to those in Embodiment 1 have identical structures. Numeral 700 denotes a charge/discharge control circuit.
[0094] The configuration of this embodiment differs from that of Embodiment 1 in that the structure of the charge/discharge control circuit 700 is different and in that the capacitance Ccap of the first capacitor 200 that is arranged in the charge tank circuit 101 (see FIG. 2) is optimized in accordance with the total capacitance of the bit line pair activated during the refresh operation, and is large.
[0095] [0095]FIG. 8 shows a circuit diagram of the charge/discharge control circuit 700 according to this embodiment. Numeral 102 indicates a circuit configuration block that is identical to the charge/discharge control circuit of Embodiment 1, and 800 denotes a first AND element. The output of the charge/discharge control circuit 102 according to Embodiment 1 is input to the first AND element 800 . The refresh operation enable signal REFEN is received at the other input of the first AND element 800 . The output of the first AND element 800 is the transfer gate connection signal ACP.
[0096] [0096]FIG. 9 shows the timing of the semiconductor memory device according to this embodiment during normal operation and during the refresh operation.
[0097] Operations during normal operation are identical to those of Embodiment 1, and the refresh control signal REF is set to a high level. When the refresh control signal REF is set to a high level, the refresh operation enable signal REFEN is set to a low level. When the refresh operation enable signal REFEN is at a low level, the output of the charge/discharge control circuit 700 , that is, the transfer gate connection signal ACP, which is output from the first AND element 800 , become low level. Consequently, the transfer gate connection signal AP is held at a low level and the charge stored in the first capacitor 200 is not discharged.
[0098] When the refresh control signal REF is set to a low level at the rising edge of the outside clock signal CLK, the refresh operation enable signal REFEN become high level, and the bit line precharge signal NEQ connected to the plurality of memory array blocks 4001 corresponding to the row address that is determined by an internal refresh counter, for example, is set to a high level. After a predetermined period, the bit line precharge signal NEQ is set to a low level, at which time the transfer gate connection signal AP become high level. Accordingly, discharge of the charge that has accumulated in the first capacitor 200 is carried out, and the bit line precharge operation is performed quickly. Moreover, after the delay time τ2 determined by the second delay element 301 , the transfer gate connection signal AP become low level and charge is accumulated in the first capacitor 200 .
[0099] As detailed above, according to this embodiment, a function has been added for discharging the charge that has accumulated in the first capacitor 200 during the refresh operation, so that when a larger number of bit lines BL[n], /[BL]n than during normal operation are precharged to the high level, the precharge operation can be ended quickly and the precharge operation of the semiconductor memory device can be performed quickly.
[0100] Embodiment 3
[0101] [0101]FIG. 10 shows a circuit block diagram of a semiconductor memory device 1000 according to Embodiment 3 of the present invention. Elements that are assigned reference numerals identical to those in the conventional example or in Embodiment 1 have identical configurations. In the present embodiment, a bit line precharge power source test signal PTEST has been added. The elements that are different are a control circuit 1001 , a power source block 1002 , a bit line precharge voltage generating device 1003 , a charge/discharge control circuit 1004 , and an outside pad 1005 .
[0102] The bit line precharge voltage generating device 1003 disposed in the power source block 1002 includes the charge/discharge control circuit 1004 , the charge tank 101 , and the precharge voltage generating circuit 4200 . The bit line precharge power source test signal PTEST is input to the control circuit 1001 and the charge/discharge control circuit 1004 . The outside pad 1005 is connected to the bit line precharge voltage VBP.
[0103] [0103]FIG. 11 shows a circuit diagram of the charge/discharge control circuit 1004 . Numeral 102 is a charge/discharge control circuit like that of Embodiment 1, 1100 is a third inverter, and 1101 is a second AND element. The output of the charge/discharge control circuit 102 is input to the second AND element 1101 , and the bit line precharge power source test signal PTEST is input to the third inverter 1100 . The output of the third inverter 1100 is supplied as the differential amplifier control signal AMPEN and is also input to the second AND element 1101 . The output of the second AND element 1101 is the transfer gate connection signal ACP.
[0104] The operation of the semiconductor memory device 1000 configured as above is described below. When the bit line precharge power source test signal PTEST is at a low level, the device is in normal operation, and an operation similar to that of Embodiment 1 can be carried out. When the bit line precharge power source test signal PTEST is at a high level, the differential amplifier control signal AMPEN is at a low level, the operational amplifier 4301 is stopped, the transfer gate connection signal ACP is fixed at a low level, and the supply of current to the bit line precharge voltage VBP is not performed.
[0105] As described above, according to the present embodiment, by setting the bit line precharge power source test signal PTEST to a high level, the supply of current to the bit line precharge voltage VBP is not carried out and an arbitrary voltage can be applied in a programming test, for example, from the outside pad 1005 , so as to enable an evaluation of the operation margin, for example.
[0106] Embodiment 4
[0107] [0107]FIG. 12 shows a circuit block diagram of a semiconductor memory device according to Embodiment 4 of the present invention. Elements that are assigned reference numerals identical to those in the conventional example or in Embodiment 1 have identical configurations. A bit line precharge voltage generating device 1200 includes a precharge voltage generating circuit 1201 , the charge tank 101 , and the charge/discharge control circuit 102 . The bit line precharge voltage generating device 1200 is connected to the bit line precharge power line VBP[n].
[0108] [0108]FIG. 13 shows a circuit diagram of the precharge voltage generating circuit 1201 and the charge tank 101 according to this embodiment. The circuit configuration of the charge tank 101 is identical to that of Embodiment 1. The precharge voltage generating circuit 1201 differs from the precharge voltage generating circuit 4200 of the conventional example in that, instead of the +input of the operational amplifier 4301 being connected to the bit line precharge power line VBP[0], it is connected to the bit line precharge power line VBP[n].
[0109] With the configuration described hereinabove, the precharge operation can be performed at high speeds without being affected by the impedance between the bit line precharge power line VBP[0] and the bit line precharge power line VBP[n], even if the memory array block 4001 that is connected to the bit line precharge power line VBP[n] is activated. In addition, if the memory array block 4001 connected to the bit line precharge power line VBP[0] is activated, then time is required before detection by the operational amplifier 4301 , but from the fact that a voltage drop occurs near the power circuit, the precharge operation is not subject to delays that would cause a problem. Consequently, the precharge operation can be performed at high speeds for the entire memory array 4000 .
[0110] Embodiment 5
[0111] [0111]FIG. 14 illustrates a circuit block diagram of a semiconductor memory device 1400 according to Embodiment 5 of the present invention. Elements assigned reference numerals that are identical to those in the conventional example or in the above embodiments have identical configurations. In this embodiment, noise canceling circuits 1401 have been added. The noise canceling circuits 1401 are disposed in the memory array 4000 and joined to the bit line precharge signal NEQ that passes through the memory array blocks 4001 .
[0112] [0112]FIG. 15 shows a circuit diagram of a noise canceling circuit 1401 and a memory array block 4001 . Numeral 1500 denotes a fourth inverter and 1501 denotes a second capacitor. The circuit configuration of the memory array block 4001 is identical to that of the conventional example.
[0113] The fourth inverter 1500 receives as input the bit line precharge signal NEQ, and the output of the fourth inverter 1500 is connected to the second capacitor 1501 . The other terminal of the second capacitor 1501 is connected to the bit line precharge power line VBP[n]. The capacitance of the second capacitor 1501 is set identical to the parasitic capacitance that is present, via the transistors, between the bit line precharge signal NEQ and the bit line precharge power line VBP[n].
[0114] When the bit line precharge signal NEQ is driven at a high or low level, noise is generated in the bit line precharge power line VBP[n] via the parasitic capacitance that exists via the transistors. With this configuration, that noise can be cancelled out by the coupling capacitance of the second capacitor 1501 . Consequently, the bit lines can be precharged with greater precision.
[0115] Embodiment 6
[0116] [0116]FIG. 16 shows a circuit block diagram of a semiconductor memory device 1600 according to Embodiment 6 of the present invention. Elements assigned reference numerals that are identical to those in the conventional example or in the above embodiments have identical configurations. The elements that are different are a control circuit 1601 , a power source block 1602 , a bit line precharge voltage generating device 1603 , a second charge tank circuit 101 B, a row controller 1604 , and a column controller 1605 .
[0117] The control circuit 1601 receives as input the outside clock signal CLK, the row address strobe signal NRAS, the column address strobe signal NCAS, the write control signal NWE, the address ADDR, the refresh control signal REF, and a page length control signal PGMD. An inside page mode control signal IPG that is output from the control circuit 1601 is input to the column controller 1605 , the row controller 1604 , and the bit line precharge voltage generating device 1603 .
[0118] [0118]FIGS. 17A and 17B explain the selection of the active blocks of the semiconductor memory device according to this embodiment. As shown in FIG. 17A, when the inside page mode control signal IPG is at a low level, the bit line precharge signal NEQ, the sense amplifier activation signals SAN and SAP, and the word line drive signal WL[63:0] are output from the row controller 1604 to a single memory array block 4001 . As shown in FIG. 17B, when the inside page mode control signal IPG is at a high level, the bit line precharge signal NEQ, the sense amplifier activation signals SAN and SAP, and the word line drive signal WL[63:0] are output to two memory array blocks 4001 .
[0119] [0119]FIG. 18 shows a block diagram of the bit line precharge voltage generating device 1603 according to this embodiment. Numeral 1800 denotes a third AND element. The output of the precharge voltage generating circuit 4200 , the output of the charge tank circuit 101 , and the output of the second charge tank circuit 101 B are connected to the bit line precharge power line VBP[0]. The circuit configuration of the second charge tank circuit 101 B is identical to that of the charge tank circuit 101 shown in FIG. 2. The capacitance of the first capacitors 200 that are arranged in the charge tank circuit 101 and in the second charge tank circuit 101 B is set to the capacitance that is required for charging the bit lines BL[n], /BL[n] arranged in a single memory array block 4001 .
[0120] The buffer inverter 205 in the charge tank 101 receives the transfer gate connection signal ACP that is output from the charge/discharge control circuit 102 . The buffer inverter 205 in the second charge tank circuit 101 B receives the output of the third AND element 1800 . The third AND element 1800 receives the inside page mode control signal IPG and the transfer gate control signal ACP that is output from the charge/discharge control circuit 102 .
[0121] The above configuration operates as follows. When the inside page mode control signal IPG is at a low level, the bit line precharge signal NEQ is set to a low level, and when the precharge operation is started, the bit lines BL[n], /BL[n] disposed inside the single activated memory array block 4001 are precharged. At that time, only the charge tank circuit 101 is operated and the second charge tank circuit 101 B is stopped. When the inside page mode control signal IPG is at a high level, the bit line precharge signal NEQ is set to a low level, and when the precharge operation is started, the bit lines BL[n], /BL[n] disposed inside the two activated memory array blocks 4001 are precharged. At this time, the charge tank circuit 101 is operated, and the output of the third AND element 1800 become high level and the second charge tank circuit 101 B is operated.
[0122] According to this configuration, even if the number of memory array blocks 4001 that are simultaneously activated is different, the precharge operation can be performed at high speeds for each one, and thus the operation speed can be increased.
[0123] The invention may be embodied in other forms without departing from the spirit or essential characteristics thereof. The embodiments disclosed in this application are to be considered in all respects as illustrative and not limiting. The scope of the invention is indicated by the appended claims rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are intended to be embraced therein.
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The present invention is a semiconductor memory device provided with bit line pairs to which a plurality of memory cells are attached, a plurality of precharge circuits for precharging the bit line pairs to a first voltage that is different from a mean value between a high level and a low level, a bit line precharge power line for supplying the first voltage for precharging to the precharge circuits, a capacitor, a charging circuit for charging the capacitor, and transfer gate circuits for controlling connection and disconnection of the capacitor and the bit line precharge power line. The transfer gate circuits are controlled so that the capacitor and the precharge power line are connected during precharging of the bit line pairs. Thus, precharging of the bit lines can be performed at high speeds with high precision.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of German Application DE 19858287, filed Dec. 17, 1998, herein incorporated by reference.
FIELD OF THE INVENTION
The present invention relates to a method and apparatus for contactless yarn monitoring in a spinning or bobbin winding machine and, more particularly, to a method for contactless yarn monitoring in a spinning or bobbin winding machine, having a sensor device for detecting measured values of a yarn moving in a yarn travel direction in which the moving yarn is subject to traversing motions, perpendicular to the yarn travel direction, in the measurement region of the sensor device, and to an apparatus for performing the same.
BACKGROUND OF THE INVENTION
For monitoring the moving yarn in a spinning or bobbin winding machine, capacitive measurement systems, optical measurement systems, and measuring instruments that detect both optical measured values and capacitive values are employed. Such sensor devices are known for instance from European Patent Disclosure EP 0 423 380 A1.
In spinning and bobbin winding machines, traversing motions of the moving yarn are performed in a predetermined way, in order, for example, to create cross-wound bobbins, also known as cheeses, or to prevent the development of furrows in the surface of the typical rubber coating of the draw-off rollers that is meant to protect the yarn.
To suppress such motions of the yarn in the measurement region of a sensor device, the moving yarn, before and after the measurement location, is guided in a stationary position relative to the sensor elements by means of such stationary elements as yarn eyelets or yarn guide baffles, as shown for instance in European Patent Disclosure EP 0 423 380. A disadvantage of such yarn guide elements, however, is that by the contact of the yarn with the yarn guide elements, or the attendant friction, undesired influences or changes occur. For instance, the yarn surface becomes roughened by the eyelets or guide slits.
If the traversing motion of the moving yarn is not suppressed in the measurement region of sensor devices, then the constant change in position or spacing of the yarn from the sensor elements causes measurement errors, which can impair the reliability of the measurements and the adherence to the requisite yarn quality.
German Patent DE 26 02 465 C2 describes an apparatus in which a scattering disk for scattering diffuse light is used, the disk having a height that decreases toward the center, so that when the cross section or volume of a moving yarn is measured, more-reliable measuring results can be attained in a traversing region. If the yarn is traversing from the center toward the edges of the scattering disk, then in the process it increasingly covers the scattering disk with a greater length than in the center of the scattering disk, where the light intensity is higher. The utility of this apparatus is limited to systems that operate optically, with a non-homogeneous light intensity in the measurement region. Measurement errors that occur from changes of position of the yarn toward or away from the scattering disk are not compensated for with this known apparatus, and in a spinning or bobbin winding machine that has many winding stations, it is very complicated and expensive to equip each spinning station and to change the scattering disk manually. Also, the measurement errors that occur in capacitive measuring methods cannot be compensated for with this apparatus.
European Patent Disclosure EP 0 571 591 B1 describes an apparatus for yarn monitoring in which the yarn is monitored in the region of yarn traversing and moves back and forth between the sensor faces of the yarn monitoring apparatus in such a way that it moves toward and away again from the applicable sensor face. The traversing motion of the yarn is utilized for cleaning the sensor faces of the yarn monitoring apparatus, to counteract functional impairment of the measuring method by soiling. During the cyclical traversing motion, when the moving yarn has come quite close to the applicable sensor face, dust and fluff deposits are entrained from the sensor surface. Satisfactory measurement results are furnished by this yarn monitoring apparatus only as long as the yarn to be measured is moving in the measurement region of the sensor device within certain, quite narrow limits. The yarn monitoring device described in European Patent Disclosure EP 0 571 591 B1 is unable, or only inadequately able, to limit greater motions, such as those caused by the traversing motions of the yarn, that exceed these narrow limits. Therefore, measurement errors and considerable fluctuations in the measurement results, both of which impair the reliability and usability of measurement values for yarn monitoring, and can thus impair the yarn quality, must still be expected. The limitation of the yarn motion is accomplished by means of stops over which the yarn runs. The rounded edges and the use of wear-resistant material are indications of the considerable friction which is created by the movement of the yarn against the stops, which act as yarn guide elements, and which thus engender the above-described disadvantages of yarn guide elements.
SUMMARY OF THE INVENTION
It is accordingly an object of the invention to improve the monitoring of moving yarn upon changes of position of the moving yarn in the measurement region.
This object is attained according to the invention by a method for contactless yarn monitoring in a textile yarn winding operation. In such an operation, yarn is wound on a bobbin while being delivered lengthwise in a yarn travel direction toward the bobbin. At the same time, the yarn simultaneously executes traversing motions generally perpendicular to the yarn travel direction. According to the present invention, a sensor device is provided for detecting measured values of the yarn moving in the yarn travel direction. The sensor device has a measurement region within which the moving yarn is subject to changes of position. Position-dependent correction values are ascertained which correspond to measurement errors caused by changes of position of the yarn. The position of the yarn is monitored to determine at least one instantaneous position of the yarn, and the applicable measurement error is compensated for on the basis of the instantaneous position of the yarn.
The invention achieves a number of advantages. Compensating for the applicable instantaneous value of the measurement error as a function of the constantly monitored instantaneous position of the yarn in the measurement region assures the reliability of the measured values for yarn monitoring and thus assures the yarn quality regardless of the type of sensor device, for both optical and capacitive measurement methods. Values stored in memory can be used as standard values for other spinning stations and other spinning machines, as long as these spinning stations are structurally identical to the spinning station at which the measurements were made. The allocation and storage and memory of the values can be done in the form of a matrix.
Accurate, universally usable ascertainment of the yarn position in the measurement region is done by detecting the position of the yarn directly in the measurement region of the sensor device.
According to another aspect of the invention, the position of the yarn guide may be monitored in order to ascertain the change in position caused by the traversing motion of the yarn guide and to ascertain the applicable position of the yarn in the measurement region of the sensor device from the relationship between the position of the yarn and the position of the yarn guide, thus making a space-saving embodiment possible when only limited installation space is available at the sensor device. No additional expense for sensor parts is then necessary to detect the yarn position in this region. Both the location of the yarn guide in the cyclical course of the traversing motion and the location and geometric shape of storage brackets or guide baffles, which compensate for the difference in length between the oblique position and middle position of the yarn during the yarn guide stroke in order to prevent brief increases of yarn tension, should be taken into account in determining the positioning of the yarn in the measurement region. Each position of the yarn in the measurement region can be associated with a respective position of the yarn guide. Accurate determination of the position of the yarn guide in the measurement region is thus possible, without performing a detection in the measuring region itself. Determining the position of the yarn from the position of the yarn guide can be done by a mathematical method.
The empirical ascertainment of correction values from measurements with a comparison body at different positions, distributed within the measurement region of the sensor device, can be done quickly and simply. A reference yarn is expediently employed as the comparison body for the measurement.
According to a further feature of the invention, a sensor device is used for reference value ascertainment at a point along the yarn travel path where no traversing motion of the yarn is occurring. A measurement may be made to determine the correction value in each case at a first point along the yarn travel path where no traversing motion of the yarn is occurring and a second measurement may be made at a second point along the yarn travel path where the yarn is executing the traversing motion. The comparison of the measurement results from the two measurements, each made at the same location on the yarn, shows the position-dependent measurement error especially clearly. Thus, even measurement errors that are created by the sensor device itself, for example because of soiling or shifting, can be recognized and eliminated.
The invention can be used universally both with sensor devices that act simultaneously as yarn monitors and as yarn cleaners for correcting imperfections in the yarn, and with sensor devices in which a combination of optical and capacitive measuring methods is used for measured value detection. Such an embodiment of the sensor device is also space-saving, and by combining the functions, it lessens the expense for the required parts.
Another aspect of the invention provides that the sensor device further comprises a measurement gap which extends in the direction of the traversing motion of the yarn to prevent contact of the yarn with parts of the sensor device, and thus prevents undesired friction, even in the presence of a relatively major traversing motion of the yarn.
The invention makes it possible to obtain very accurate measured values even in the traversing regions of the yarn, without having to accept negative influences on the yarn surface from additional yarn guide elements for maintaining a certain measurement position of the yarn, and without undesirably limiting the traversing motion. Disposing a yarn monitor, which monitors the moving yarn contactlessly, in the yarn path either upstream or downstream from the pair of draw-off rollers, makes it possible, for instance, to wind bobbins with a very low winding tension.
Further details of the invention can be learned from the drawings.
DETAILED DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view of a spinning station in accordance with one embodiment of the present invention.
FIG. 2 is a graphical illustration showing an exemplary characteristic curve representing the relationship between light intensity and voltage in a photoelectric device embodiment of the sensor device of FIG. 1 .
FIG. 3 is a cross-sectional view of an embodiment of the sensor device of FIG. 1 showing sensor elements and a measuring gap.
FIG. 4 is a graphical illustration of an allocation matrix for measured values obtained using the spinning station of FIG. 1 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
A sliver 2 is introduced into the spinning box 1 , shown in FIG. 1, of an open-end spinning machine. The yarn 3 produced is drawn off from the spinning box 1 via the draw-off tubule 4 by means of the pair of draw-off rollers 5 . The yarn 3 then passes through a sensor device 6 and over a storage bracket 8 , whereupon, by means of the traversing motion of the yarn guide 9 of a yarn guide device 7 , the yarn 3 is wound up over a predetermined width to form a cross-wound bobbin, or cheese, 10 . The cheese 10 is driven by means of a friction roller 31 . The yarn guide 9 is clamped to a yarn guide rod 11 , which is moved back and forth by a yarn guide gear 12 . The movement of the yarn guide gear 12 is effected by a drive device 13 .
The sensor device 6 for monitoring the moving yarn 3 is disposed above the pair of draw-off rollers 5 , in the traversing region of the yarn 3 . The sensor device 6 communicates over a communication interface 14 with a data processing system 15 , which receives the signals transmitted by the sensor device 6 . The data processing system 15 communicates with the drive device 13 over an additional communication interface 16 . The drive device 13 may be embodied as an electric motor, in which case the position of the yarn guide 9 may be determined from the revolutions and the angular position of the motor shaft, and thus the position of the yarn 3 in the measurement region of the sensor device 6 may also be determined. In the cyclical course of the traversing motion, the effects of the location and geometric shape of the storage brackets or guide baffles on the position of the yarn 3 are also taken into account. The data processing system 15 performs an allocation of the applicable position of the yarn 3 in the measurement region of the sensor device 6 and the applicable measured value transmitted by the sensor device 6 . No other components are needed for detecting the position of the yarn 3 , and the monitoring can be done in a simple way at the drive device 13 at a readily accessible location where there is enough room.
In the illustration in FIG. 1, in the region between the draw-off tubule 4 and the pair of draw-off rollers 5 , there is an additional sensor device 18 , which communicates with the data processing system 15 over a communication interface 19 . In the exemplary embodiment of FIG. 1, no traversing motion takes place at this location. With an apparatus known per se (not shown for the sake of simplicity) for detecting and monitoring the motion of the yarn 3 in the travel direction, which for example has an initiator that serves to measure the draw-off speed of the yarn 3 and the rotary motion at a shaft of the pair of draw-off rollers 5 , the measured values detected by the sensor device 18 can be associated with the measured values that are detected at the same location of the yarn 3 by the sensor device 6 . Comparing the respective measured values detected by the sensor device 18 and by the sensor device 6 ascertains the measurement error caused by the traversing process, and this error is then associated with the respective position of the yarn 3 in the measurement gap of the sensor device 6 . The values thus ascertained are stored in memory. However, the values can also be transmitted onward over a communication interface 17 , by way of which the data processing system 15 communicates with other spinning stations, data processing devices, or spinning machines (not shown).
As shown in FIG. 2, the characteristic curve 20 of a photoelectric device, used for example as a sensor element 29 , illustrates the dependency between the light intensity I, plotted on the abscissa 21 , and the voltage U, plotted on the ordinate 22 , for forming the signal of the photo element. The characteristic curve 20 is not linear in its course. Based upon the characteristics of the yarn, such as the yarn diameter or the yarn count, a region 23 is selected for the measurement in which the course of the characteristic curve 20 is nearly linear. An intensity value 25 and a voltage value 26 correspond to the characteristic value 24 . Changes in the position of the yarn 3 in the measurement region of the sensor device 6 lead to a change in the intensity of the incident light and thus to a change in the voltage on which the signal generation is based. Since the intensity of the incident light serves as a measure of the diameter of the yarn 3 , the changes in the intensity of the incident light, which are caused by the change in position of the yarn 3 , are also interpreted as changes in the diameter of the yarn 3 and thus lead to measurement errors.
FIG. 3 shows the sensor device 6 with a measurement gap 27 and with sensor elements 28 and 29 . Depending on the embodiment, the sensor elements 28 and 29 are used for both optical and capacitive measuring methods. The measurement region is covered by an imaginary dot matrix, in which the horizontally extending rows of points are designated by lower-case letters, and the vertically extending rows of points are designated by capital letters. As shown in FIG. 3, a comparison body 30 is positioned for a measurement in such a way that its cross-sectional center point is located on the matrix point cF. This matrix point cF is thus the instantaneous position of the comparison body 30 .
Both the position of the comparison body 30 and the position of the moving yarn 3 in the measuring region of the sensor device 6 can be detected for instance with sensors positioned at the measuring gap 27 of the sensor device 6 . These sensors cooperate around the body being measured, which may be, for example, the comparison body 30 or the moving yarn 3 , in an arrangement of the kind known from French Patent FR 158 4684. Light sources emit light which causes shading or projection onto the sensors, and from the length and location of the shading or projection, the position of the body being measured can be determined unambiguously and precisely.
By sequencing through the matrix points, measured values associated with the various matrix points are ascertained empirically. The measured values are compared with the known diameter of the comparison body 30 , and for the applicable matrix point, the measurement error or a correction value for the applicable measurement is ascertained. Both the measured values and the correction values can be stored in a computer memory, associated with the points of a matrix of the kind shown in FIG. 4, by means of the data processing system 15 . The value WbC, for instance, is assigned to the matrix point bC.
During operation of the open-end spinning machine, the moving yarn 3 moves within the measuring gap 27 of the sensor device 6 , and while it is executing the traversing motion, it is instantaneously positioned, for example, at the matrix point cD. The compensation for the measurement error, caused at matrix point cD by the change of position of the yarn 3 is effected by means of the correction value assigned to matrix point cD.
The data pertaining to the position determination and the empirically ascertained correction values for a particular yarn can be collected at a first spinning station, for instance. The position determination of the yarn 3 can be done via a mathematical calculation method, with which the applicable position of the yarn 3 is calculated from the applicable position of the yarn guide 9 . The calculation takes into account the location of the yarn guide in the cyclical course of the traversing motion, and also, to the extent that they affect the position of the yarn 3 in the measurement region, the location and the geometric shape of the storage brackets or guide baffles. The values stored in memory can be called up or predetermined as standard values for other spinning stations or spinning machines by the data processing system 15 over the communication interface 17 , as long as these spinning stations are, for instance, structurally identical to the spinning station at which the measurements are made. As a result, the requisite effort for batch changes can be kept slight.
It will therefore be readily understood by those persons skilled in the art that the present invention is susceptible of broad utility and application. Many embodiments and adaptations of the present invention other than those herein described, as well as many variations, modifications and equivalent arrangements, will be apparent from or reasonably suggested by the present invention and the foregoing description thereof, without departing from the substance or scope of the present invention. Accordingly, while the present invention has been described herein in detail in relation to its preferred embodiment, it is to be understood that this disclosure is only illustrative and exemplary of the present invention and is made merely for purposes of providing a full and enabling disclosure of the invention. The foregoing disclosure is not intended or to be construed to limit the present invention or otherwise to exclude any such other embodiments, adaptations, variations, modifications and equivalent arrangements, the present invention being limited only by the claims appended hereto and the equivalents thereof.
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A method and an apparatus for contactless yarn monitoring in a textile yarn winding operation wherein a yarn is wound on a bobbin while being delivered lengthwise in a yarn travel direction toward the bobbin and simultaneously executing traversing motions generally perpendicular to the yarn travel direction. A sensor device ( 6 ) is provided which detects measured values such as diameter or mass in a moving yarn. The measurement errors caused by the traversing motions may be compensated for by ascertaining position-dependent correction values, monitoring the position of the yarn in the measurement region to determine one or more instantaneous position of the yarn, and compensating for the applicable measurement error is performed on the basis of the instantaneous position of the yarn ( 3 ). The invention is applicable to sensor devices ( 6 ) that perform measurements in the traversing region of the yarn ( 3 ).
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to International Application Serial No. PCT/CH2010/073451 filed Jun. 2, 2010, which is hereby incorporated herein for all purposes by this reference.
FIELD OF THE INVENTION
[0002] The present invention relates to an economically feasible process for manufacturing tagatose and glucose from lactose.
BACKGROUND OF THE INVENTION
[0003] D-Tagatose (tagatose, D-xylo-hexulose) is a rare naturally occurring hexoketose monosaccharide. Tagatose differs from D-glucose (glucose) and D-galactose (galactose) and D-fructose (fructose) in intramolecule atomic arrangement despite the same hexose formula C 6 H 12 O 6 (MW=180.16). Tagatose is a stereoisomer of fructose found in dairy products, some fruits and grains at concentrations between 2 to 800 ppm.
[0004] Tagatose is an odorless white crystalline solid. It is very similar in texture to sucrose, with 92% sweetness, but only 38% of the calories. Tagatose provides very fresh and sharp sweetness, and its quality of taste is similar to fructose. Tagatose has been found to be safe and efficacious for use as a low-calorie, full-bulk natural sugar in a wide variety of foods, beverages, health foods and dietary supplements. Its synergism with high-intensity sweeteners also makes it useful in sodas.
[0005] Tagatose is generally recognized as safe (GRAS) by the United States and the FAO/WHO since 2001. FDA approved tagatose as a tooth friendly ingredient in December 2002, and a food additive in October 2003. The Joint FAO/WHO Expert Committee on Food Additives (JECFA) states there is no need to limit the allowable daily intake (ADI) of tagatose, and allocates an ADI of “not specified”, the safest category in which JECFA can place a food ingredient at its 63 rd meeting in 2004. On December 2005, tagatose was formally approved as a novel food ingredient in the European Union without any restriction on usages. All regulatory hurdles have now been cleared for the beneficial food and beverage uses of this simple, naturally occurring sugar.
[0006] Various health and medical benefits are evident for tagatose for its drug and nondrug as well as nonfood uses, including the treatment of Type II diabetes, hyperglycemia, anemia, hemophilia, organ transplants, weight loss, the improvement of fetal development, and in nonchronic drugs. Tagatose has been studied as a potential antidiabetic and antiobesity as well as antihyperglycemic medication. Tagatose can be used as an intermediate for the synthesis of optically active compounds, and as an additive in toothpaste, detergent, cosmetic and pharmaceutical formulations. Tagatose is non-cariogenic and reduces insulin demand.
[0007] Tagatose is generally prepared by the isomerization of galactose at C-2 by chemical (alkaline) catalysts using alkaline-earth or rare-earth metal ions under alkaline condition, or biological (enzymatic) biocatalysts using several L-arabinose isomerases.
[0008] The economical production of tagatose requires a ready source of galactose.
[0009] Galactose is not usually found free in nature, but exists with glucose in the disaccharide lactose via a β 1 → 4 glycosidic linkage or with repeating galactose units as a polymeric galactan in hemicellulose in a variety of plant seed and timber.
[0010] Production of tagatose using commercial galactose is economically infeasible in view of the cost approximately US $90 per kilogram.
[0011] The best source of galactose is commercial lactose, a plentiful, inexpensive byproduct obtained from whey of milk, chemically known as a-lactose monohydrate. The price of lactose varies from US $0.22 to 0.66 per kilogram over recent decades. At least 4 million tons of lactose per annum is recovered from whey in the cheese processing industry worldwide.
[0012] Hydrolysis of the lactose 1-4 linkage by the action of enzyme lactase (β-galactosidase), or by the action of acid under heating condition, results in the formation of an equimolar mixture of the monosaccharide galactose and glucose.
[0013] The hydrolysis process of lactose by the action of acid is shown as follows:
[0014] The hydrolysis process of lactose by the action of β-galactosidase is shown as follows:
[0000]
[0015] E represents the β-galactosidases, E.Galactosyl represents the enzyme-galactosyl complex, K represents the reaction rate constant, and Nu (nucleophile) represents an acceptor containing a hydroxyl group. As shown in the diagram, the first step is the enzyme-galactosyl complex formation and simultaneous glucose liberation, and the second step is to transfer the enzyme-galactosyl complex to an acceptor containing a hydroxyl group. Water and sugar molecules in the solution can be the Nu to accept galactosyl moiety from the enzyme-galactosyl complex resulting in the formation of galactose and new sugar e.g. trisaccharides (β-D-galactose-(1→6)-lactose). While in a low lactose content solution, water rather than other sugars such as glucose and lactose can be more competitive as an acceptor, therefore, galactose is formed and released from the active site. On the other hand, in a high lactose content solution, lactose molecules have higher chances to act as the acceptor, binding with the enzyme-galactosyl complex to form trisaccharides. It is known that enzymatic hydrolysis of lactose in a high initial substrate concentration results in a high concentration of trisaccharides.
[0016] The economical production of tagatose from lactose requires an economically feasible manufacturing process.
[0017] U.S. Pat. Nos. 5,002,612, 5,078,796, 6,057,135 and 6,991,923 described manufacture of tagatose with lactose derived from whey by a two-stage process involving enzymatic hydrolysis of lactose by soluble or immobilized lactase to yield galactose and glucose, and isomerization of galactose to tagatose under either alkaline or enzymatic conditions.
[0018] As discussed above, enzymatic hydrolysis of lactose is a complex process involving multiple sequential reactions with saccharides as intermediate products. Concentration of oligosaccharides other than the monosaccharides glucose and galactose are increased with the initial concentration of lactose by weight (Biotechnol Bioeng 30:1019, 1987; J Agric Food Chem 54:4999, 2006). U.S. Pat. No. 6,057,135 disclosed enzymatic hydrolyzates of 9% lactose consisted of 3% lactose, 48% galactose and 50% glucose after 8 hours hydrolysis. U.S. Pat. Nos. 5,002,612 and 5,078,796 described 6 hours hydrolyzates of 20% lactose consisted of 10% lactose, 45% galactose and 45% glucose. Another hydrolyzates of 25% lactose composed of 35% monosaccharides, 11% allolactose (β-D-galactose-(1→6)-D-glucose), 5% 6-galactobiose (β-D-galactose-(1→4)-D-galactose), 31% lactose and 16% 6′-galactosyl-lactose (β-D-galactose-(1→6)-lactose) (J Agric Food Chem 56:10954, 2008).
[0019] Alkaline isomerization of galactose to tagatose is achieved with several alkaline catalysts including a combination of calcium ion and monoamine (Carbohydr Res 333:303, 2001), sodium aluminate (Carbohydr Res 337:779, 2002), and metal hydroxide such as calcium hydroxide (Process for manufacturing tagatose, U.S. Pat. No. 5,002,612, 1991; Process for manufacturing tagatose, U.S. Pat. No. 5,078,796, 1992), a process used to yield about 50% of tagatose at 10% by weight galactose over 2-4 hours.
[0020] Enzymatic isomerization of galactose to tagatose is achieved with either soluble or immobilized L-arabinose isomerase (Process for manufacturing D-tagatose, U.S. Pat. No. 6,057,135, 2000; Process for manufacturing D-tagatose, U.S. Pat. No. 6,991,923, 2006), a process used to produce 32% of tagatose at 10% galactose over 72 hours and 38% at 14% galactose by weight over 24 hours. U.S. Patent Application No. 20090306366 described a tagatose productivity of 11.6 g/L·h based on converted 232 g/L tagatose from 300 g/L galactose with boric acid under optimum reaction for 20 h.
[0021] Although these processes can be used to produce pure galactose and glucose as well as tagatose from lactose, but are technically and economically infeasible because of unacceptable industrial costs. None of the foregoing literature references or patents disclose or suggest a technically and economically feasible process for manufacturing tagatose and glucose from lactose. No processes as yet seem to have reached full-scale commercial application.
[0022] In enzyme-catalyzed hydrolysis of lactose, p-galactosidases prefers to hydrolyze lactose at low initial concentration, the rate of hydrolysis tends to be rather slow, the hydrolysis is liable to be subjected to bacteriological contamination, galactose is a product but also a competitive inhibitor of the enzyme. Unsatisfied galactose and glucose yields and the formation of oligosaccharides lead to problems of off-unwanted byproducts from hydrolyzed lactose. The process presents the drawbacks of requiring very high reaction volume for obtaining small quantities of products, too expensive and does not appear economically feasible from the industrial aspect.
[0023] In alkaline-catalyzed isomerization of galactose, function of alkaline catalysts are two-fold: catalysis of the isomerization of glactose into tagatose and catalysis of the degradation of galactose into dicarbonyl compounds and acidic species. The process presents the drawbacks of producing a high level of galactose degradation leading to the decline in the tagatose yield, complicate the extraction steps necessary to eliminate the degraded products, impoverish the syrups quality and make more difficult the preparation of crystalline tagatose.
[0024] The process of alkaline-catalyzed isomerization of galactose can be shown as follows:
[0000]
[0000] enzyme-catalyzed isomerization of galactose, the equilibrium between substrate and product is determined by L-arabinose isomerase, the rate of isomerization tends to be rather slow, separation of tagatose and unconverted galactose and recycling of unconverted galactose require complex purification and concentration steps. The process faces the same drawbacks of low productivity, making it too expensive and economically infeasible.
[0025] We assumed that the facility has a 16000 L vessel that can be utilized for the manufacture of tagatose and glucose from lactose. The hydrolysis would use 10000 L while the other 6000 L would be used for isomerization. According to the U.S. Pat. Nos. 5,002,612, 5,078,796 and 6,057,135, a facility using a 10000 L hydrolysis of 9% to 20% lactose should be able to produce 405 to 960 kg of galactose and 405 to 1000 kg of glucose per 6-8 h. According U.S. Pat. Nos. 5,002,612, 5,078,696, 6,057,135 and 6,991,923, a facility using a 6000 L alkaline isomerization of 10% galactose should be able to produce 300 kg of tagatose per 2-4 hours; and using a 6000 L enzymatic isomerization of 10 to 14% galactose should be able to produce 192 to 319 kg of tagatose per 24 to 72 h.
SUMMARY OF THE INVENTION
[0026] An objective of the present invention is to provide a process for manufacturing tagatose from galactose with essentially avoided degradation of galactose, which comprises the step: c) reaction of an aqueous suspension of galactose under the presence of metal ions and alkaline condition to convert galactose into tagatose. Step c) hereinafter is referred to as isomerization step for discussing conveniently.
[0027] This process is commercially feasible and free from the above-mentioned drawbacks in the prior arts and thus it can be used for economically manufacturing tagatose from galactose.
[0028] Another objective of the invention is to provide a process which can hydrolyze lactose into galactose and glucose without side reactions.
[0029] Still another objective of the invention is to provide a process which can prevent the decomposition of galactose and glucose during chromatographic separation.
[0030] Still another objective of the present invention is to provide a process for manufacturing tagatose and glucose from lactose, which comprises the following steps: a) hydrolysis of lactose with mineral acid in an aqueous solution to convert lactose to galactose and glucose; b) separation of the galactose and glucose from hydrolyzate; c) reaction of an aqueous suspension of galactose under the presence of metal ions and alkaline condition to convert galactose into tagatose.
[0031] One feature of the invention is the finding that lactose can be hydrolyzed selectively into galactose and glucose without byproducts by using mineral acid under heating.
[0032] The acid hydrolysis process offers the advantages in terms of increased initial lactose concentration to more than 30% by weight and shortened reaction time of hydrolysis to 2 hours, and therefore can hydrolysis lactose effectively and economically for mass production of galactose and glucose, the valuable intermediate and products of the invention.
[0033] Another feature of the invention is the finding that water is an important stabilizer for galactose and glucose at elevated temperature and pressure as well as eluent conditions typically used within chromatographic separation and detection.
[0034] Water used as eluent also offers the advantages in terms of increased effectiveness of chromatographic separation and reduced costs through preventing decomposition of galactose and glucose and removing expensive organic solvent from elution profile.
[0035] Another feature of the invention is the finding that galactose can be isomerized into tagatose by essentially voiding degradation by reacting in suspension and using metal hydroxide as catalyst.
[0036] The alkaline isomerization process offers the advantages in terms of increased initial galactose concentration to more than 30% by weight and shortened reaction time of isomerization to 2 hours, and therefore can isomerize galactose effectively and economically for mass production of tagatose, the valuable product of the invention.
[0037] In particular, the present invention provides an economically feasible process for mass production of tagatose and glucose from lactose for full-scale commercial application. A facility using a 10000 L hydrolysis should be able to produce 3000 kg of galactose and 3000 kg of glucose per 2 hours, and using a 6000 L isomerization should be able to produce 3000 kg of tagatose per 2 hours.
BRIEF DESCRIPTION OF DRAWINGS
[0038] FIG. 1 is a graph showing the conversion of lactose and the formation of galactose and glucose over the course of acid-catalyzed hydrolysis of lactose.
[0039] FIG. 2 a is a HPLC chromatogram showing the reference standard mixture containing lactose, glucose, galactose and tagatose.
[0040] FIG. 2 b is a HPLC chromatogram showing the product tagatose manufactured according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0041] In an embodiment of the present invention, manufacture of tagatose and glucose from lactose comprises a three-step process including the hydrolysis of lactose, the separation of galactose and glucose, as well as the isomerization of galactose.
[0042] In the hydrolysis step of this process, a particular hydrolysis procedure is established in ensuring to achieve the effectiveness and the general economic feasibility of the hydrolysis. Procedure that uses mineral acid as the hydrolytic catalyst according to the invention is a milder chemical hydrolysis for lactose. It is able to split lactose into to galactose and glucose without byproducts because of the complete and nondestructive characters of the hydrolysis. An additional benefit of using acidic hydrolysis is the reaction may be carried out under higher temperature where the solubility of lactose is higher. This means that more concentrated lactose can be applied in the hydrolysis of the invention. This again means a less acid consumption and a short reaction time for hydrolysis. The acid-catalyzed hydrolysis of this invention minimizes hydrolysis costs and maximizes hydrolysis yields per time unit.
[0043] The mineral acid usable in the present invention is preferable to be one or more selected from the group consisting of carbonic acid, hydrochloric acid, phosphoric acid and sulfuric acid, and more preferably sulfuric acid.
[0044] The hydrolysis step is preferable to perform with 0.2-0.6 M mineral acid and perform under temperature between 90-120° C.
[0045] By following the above procedure, it is assured to obtain a high conversion (95-100%) of lactose with a high yield (95-100%) of galactose and glucose.
[0046] With this procedure, hydrolysis of lactose yields an equimolar mixture of the galactose and glucose. The obtained hydrolysate is cooled, neutralized and demineralized according to known techniques in the art.
[0047] Subsequently, the equimolar mixture of the galactose and glucose are separated into the products of galactose and glucose respectively by any known separation technologies in the art preferably with high performance liquid chromatography (HPLC).
[0048] In the chromatographic separation step of this invention, a particular elution profile is established in ensuring to prevent the decomposition of galactose and glucose during HPLC separation.
[0049] Addition of 10.0% acetonitrile in water instead of water as eluent has significantly reduced the detection of both galactose and glucose as temperature rises when using a Ca 2+ -form carbohydrate column (Table 1).
[0000]
TABLE 1
Function of Elution Profile on Chromatogram Peak Area
Elution Profile (v:v)
Column
Acetonitrile
Chromatogram Peak Area
Temperature
Water (H 2 O)
(CH 3 CN)
Galactose
Glucose
65° C.
100
0
182016
166739
90
10
184450
164938
75° C.
100
0
182783
171939
90
10
149074
158741
85° C.
100
0
183709
172437
90
10
120506
149855
[0050] Removal of water from the start solvent gradient from the combination with acetonitrile has significantly reduced the detection of galactose and glucose when using an amino-bonded silica carbohydrate column.
[0051] The rate of decomposition of galactose and glucose is a result of elevated temperature and pressure.
[0052] It is surprisingly found that water is the most effective solvent and stabilizer in the chromatographic separation of galactose and glucose under the HPLC conditions. Following separation, the separated galactose and glucose solution are evaporated and then crystallized or dried into galactose and glucose crystals or powders, respectively.
[0053] The obtained glucose can be sold or processed further into a salable product such as high fructose corn syrup.
[0054] Developing the value of glucose can help lower overall production costs.
[0055] In the isomerization step of this process, a particular alkaline isomerization procedure is established in ensuring to reach the effectiveness and the general economic feasibility of the isomerization.
[0056] Galactose in general undergoes both reversible and irreversible reactions in alkaline aqueous solution with metal ions. The reversible reactions mainly include isomerization of galactose into tagatose. The irreversible reactions mainly include non-oxidative alkaline degradation and oxidative alkaline degradation of galactose into dicarbonyl compounds and acidic species. Therefore, a complete isomerization of one monosaccharide galactose into another monosaccharide tagatose may be impossible under these conditions.
[0057] Alkaline isomerization and alkaline degradation of galactose are two synchronous processes observed in the alkaline solution with metal ions. The process of alkaline isomerization of galactose is independent from the process of alkaline degradation of galactose. The isomerization of galactose into tagatose is faster than the degradation of galactose into dicarbonyl compounds and acidic species. Maximum production of tagatose is nearly completed within the first 0.5 hour, whereas degradation of galactose reaches the high value in the second hour of the reaction, respectively (see Table 2).
[0000]
TABLE 2
Relationship of alkaline isomerization
and alkaline degradation of galactose.
Reaction
Converted Galactose (%)
Time
Unconverted
Degradated
(Hour)
Galactose (%)
Tagatose
Products
0
100.0
0
0
0.5
15.4
54.9
29.7
1
7.9
55.2
36.9
1.5
4.0
54.6
41.4
2
1.1
55.8
43.1
3
0
53.7
47.3
4
0
54.6
45.4
5
0
53.5
46.5
30
0
21.5
78.5
[0058] The initial galactose concentration was 18% by weight in deionized water. The concentration of calcium hydroxide as alkaline reagent was 8% by weight in deionized water.
[0059] The rate of alkaline isomerization of galactose is dependent on the rate of alkaline degradation of galactose.
[0060] It is surprisingly found that galactose undergoes the isomerization while essentially avoiding degradation in alkaline aqueous suspension with metal ions. The equilibrium between the substrate of galactose and the products of tagatose and degradated products are altered toward tagatose while the reaction is performed in the alkaline suspension. As a result, the yield of tagatose formed in the isomerization becomes the highest via prevention of the concurrent degradation in alkaline suspension of galactose.
[0061] The isomerization step c) is preferable to be carried out by reaction of an aqueous suspension of galactose with sodium afuminate and metal hydroxide or the mixture thereof. The metal hydroxide preferably is one or more selected from the group consisting of aluminum hydroxide, barium hydroxide, calcium hydroxide, magnesium hydroxide, and strontium hydroxide, more preferably calcium hydroxide.
[0062] The isomerization step is preferably performed with a molar ratio for metal hydroxide:galactose of 0.5:1-2:1. The isomerization step is preferably performed at 0-30° C.
[0063] The isomerization of galactose is preferable to be carried out by adding an aqueous slurry of metal hydroxide into a suspension of galactose.
[0064] The term “slurry of metal hydroxide” in the present application refers to an aqueous suspension that contains metal hydroxide more than that could be dissolved in the water under stirring.
[0065] The slurry of metal hydroxide in the present application may be prepared by any technology known in the art, such as by adding metal hydroxide into water under stirring.
[0066] The slurry of metal hydroxide is preferably to be a slurry of calcium hydroxide in water.
[0067] The term “suspension of galactose” in the present application refers to a solution that contains galactose more than that could be dissolved in the solvent. The excessive galactose contained in the solvent stays as insoluble solutes homogenously distributed throughout the liquid under stirring.
[0068] Preferably, the solvent is water.
[0069] The suspension of galactose in the present application preferably has a galactose content of more than 30% by weight in water, more preferably 50-70% by weight.
[0070] The solubility of galactose varies depending on the adopted reacting conditions such as temperature and pressure etc., and thus the amount of galactose added in the suspension of galactose may also vary accordingly.
[0071] The suspension of galactose in the present application may be prepared according to any known technology in the art, for example by mixing the galactose with water under stirring.
[0072] The overall production costs is further lowered by preventing the alkaline degradation of galactose.
[0073] The following is a description of the preferred embodiment of the isomerization step of this process which comprises preparing an aqueous suspension of galactose with a galactose content of more than 50% and less than 70% by weight, said suspension is maintained at a temperature of 0-30° C., and preferably 5-15° C.; preparing an aqueous slurry of Ca(OH) 2 (preferably >24% by weight) by adding Ca(OH) 2 to water or by adding calcium oxide (CaO) (preferably >18% by weight) to water, said slurry is maintained at a temperature of 0-30° C., and preferably 5-15° C.; introducing the Ca(OH) 2 slurry into the suspension of galactose under stirring for 2 hours while maintaining this temperature; stopping the reaction by neutralizing the reaction mixture with most common mineral acids such as hydrochloric acid, phosphoric acid, sulfuric acid and preferably carbonic acid that frees the tagatose from intermediate calcium hydroxide-tagatose complex and forms a poorly soluble calcium salt; removing the salts by a combination of filtration and ion exchange; and recovering the pure tagatose by concentrating the solution and thus crystallizing the obtained product.
[0074] In the neutralization step, the temperature is preferably to be kept within 0-20° C. as long as the pH value is still relatively alkaline. Once the pH approaches neutral, the cooling and the introduction of mineral acid are discontinued.
[0075] The process of the invention is distinguished particularly by its extraordinary economy. It can be performed without expensive apparatus. Due to its economy, it is particularly well suited for the production of tagatose and glucose on a large commercial scale, and in this it is very much superior to the manufacturing processes known hitherto. The economical production and highest yield of tagatose and glucose obtained in this invention are unprecedented.
[0076] The following Example illustrates the present invention, which shall not be considered as limitation to the present invention.
EXAMPLES
Example 1
Hydrolysis of Lactose with Sulfuric Acid
[0077] Lactose (purity ≧99%) was produced from whey by ultrafiltration followed by crystallization. 10 L 36% lactose in 0.4 M sulfuric acid (wlv) was carried out with stirring at 100° C. The progress of the hydrolysis was monitored by HPLC each 0.5 hour, as described below. After 2 hours lactose was completely hydrolyzed into its subunits galactose and glucose. The hydrolyzate was found to contain 1764 g galactose, and 1728 g glucose based on 3600 g lactose added, showing a 99% conversion of lactose, and a yield of 49% galactose and a yield of 48% glucose.
Method of Assay
[0078] An aliquots of the reaction mixture was withdrawn from the reactor and diluted ten-fold with deionized water. The reaction mixture was neutralized and filtered through 0.2 μm filter. The detection was done by Waters HPLC using a Bio-Rad Aminex HPX-87 C column (Ca 2+ form) and a Water 2414 differential refractometer. The eluent was deionized water with 0.005% calcium acetate (w/v). The column temperature was 85° C. and the flow rate was 0.6 ml per minute. The HPLC system was calibrated before use with a mixed standard sugars at a known concentration.
Example 2
Stability of Galactose and Glucose in Chromatographic Separation
[0079] Galactose, glucose and tagatose were obtained from Sigma (Reagent grade).
[0080] Comparable analyses were performed in the ligand-exchange mode on a Ca 2+ -form Aminex HPX-87C column using a Waters HPLC system with a Waters 2414 differential refractometer. The column temperature was 65° C., 75° C. and 85° C., and the eluent was water and 10% acetonitrile in water (v/v), respectively. The flow rate was 0.6 ml per min. All analytical samples were diluted with deionized water and filtered through a 0.2 μm filter prior to HPLC-analysis.
[0081] The results revealed a drop in the detection of both galactose and glucose as column temperature was elevated but no similar effect was detected on tagatose when using 10% acetonitrile in water as eluent. The column temperature effect was found to be more pronounced for galactose (34% reduction) than for glucose (13% reduction). The systematic decrease of both galactose and glucose was not observed when using water as eluent.
Example 3
Isomerization of Galactose in the Solution with Calcium Hydroxide
[0082] Calcium hydroxide slurry (37% by weight, 5M) was prepared by carefully mixing calcium oxide (CaO, called lime or quicklime) with deionized water and cooled to about 5 to 15° C. Galactose solution (18% by weight, 1M) was prepared by dissolving galactose in deionized water and cooled to about 5 to 15° C. At that temperature, 1 L of the calcium hydroxide slurry were gradually added into the 5 L of galactose solution under stirring and cooling, the temperature not being allowed to rise above 20° C. The progress of the reaction was monitored by HPLC analysis each 0.5 hour, as described in Example 1.
[0083] This resulted in the formation of a mass which gradually became jelly-like, becoming increasingly viscous upon one hour of standing in the cold state. After approximately 2 hours, galactose conversion reached greater than 95% and the reaction was terminated by slowly adding carbonic acid until the pH was below 7. As the gel dissolved, tagatose released and calcium carbonate precipitated in the reaction mixture. The calcium carbonate solids were separated from the reaction mixture by filter press.
[0084] The analysis of the solution showed that 900 g of galactose had been consumed and 486 g of tagatose had been produced with a conversion of 100% and a yield of 54.8%.
[0085] The filtrate containing tagatose was deionized through ion-exchange resins according to known procedures. The collected deionized filtrate was concentrated via evaporation to form a thick syrup. Tagatose was crystallized from the syrup by addition of ethanol and cooling in a freezer. Tagatose crystals were refined with 95% ethanol to obtain a composition of 99.1% tagatose and 0.9% unknown.
Example 4
Isomerization of Galactose in the Suspension with Calcium Hydroxide
[0086] Calcium hydroxide slurry (49% by weight, 6.67M) was prepared by carefully mixing calcium oxide with deionized water and cooled to about 5 to 15° C. Galactose suspension (55% by weight, 3.08M) was prepared by mixing galactose in deionized water and cooled to about 5 to 15° C. At that temperature, 2.2 L of the calcium hydroxide slurry were gradually added to the 5 L of galactose suspension under strong agitation and good cooling, the temperature was not allowed to rise above 20° C. The progress of the reaction was monitored by HPLC analysis each 0.5 hour, as described in Example 1.
[0087] This resulted in the formation of a mass which gradually became jelly-like, becoming increasingly viscous upon one hour of standing in cold state. After approximately 2 hours, galactose conversion reached greater than 95% and the reaction was terminated by slowly adding carbonic acid until the pH was below 7. In this process, the precipitate dissolved to release tagatose and calcium carbonate precipitated. The calcium carbonate solids were separated from the reaction mixture by filter press.
[0088] The analysis of the solution showed that 2772 g of galactose had been consumed and 2550 g of tagatose had been produced with a conversion of 100% and a yield of 92%. The calcium hydroxide slurry converted 554 g/L galactose to 510 g/L tagatose within 2 hours, the tagatose productivity with alkaline isomerization in suspension was 255 g/L·h.
Example 5
Product Identity
[0089] The identity of the tagatose manufactured according to the present invention was achieved via reference standard sugars by a Waters HPLC system together with a Waters 2414 differential refractometer on a Ca 2+ -form Aminex HPX-87C column (Bio-Rad) using the conditions described in the Method of Assay.
[0090] Sugars used as reference standards were lactose, glucose, galactose and tagatose and were of the best commercial grade from Sigma.
[0091] HPLC elution profiles of a reference standard mixture containing lactose, glucose, galactose and tagatose and of three representative batches of tagatose products are shown in FIG. 2 . The retention time for the chromatogram of the tagatose product corresponds to that for tagatose in the chromatogram of reference standard mixture. Results of HPLC data confirming the identity of the tagatose manufactured according to the present invention are identical to the commercial tagatose in the reference standard mixture.
[0092] Although the invention has been described with preferred embodiments, it is to be understood that variations and modifications may be resorted to as will be apparent to those skilled in the art. Such variations and modifications are to be considered within the purview and the scope of the claims appended hereto.
REFERENCES CITED
[0093] 1. Prenosil J E., Stuker E., and Bourne J R. 1987. Formation of oligosaccharides during enzymatic lactose: Part I: State of Art. Biotechnol Bioeng. 30:1019-25.
[0094] 2. Tanase T., Takei T., Hidai M., and Yano S. 2001. Substrate-dependent chemoselective aldose-aldose and aldose-ketose isomerization of carbohydrates promoted by a combination of calcium ion and monoamines. Carbohydr Res. 333:303-12.
[0095] 3. Ekeberg, D., Morgenlie, S., and Stenstrom, Y. 2002. Base catalyzed isomerisation of aldoses of the arabino and lyxo series in the presence of aluminate. Carbohydr Res. 337:779-86.
[0096] 4. Splechtna B., Nguyen T H., Steinböck M., Kulbe K D., Lorenz W., and Haltrich D. 2006. Production of prebiotic galacto-oligosacchrides from lactose using β-galactosidases from Lactobacillus reuteri. J Agric Food Chem. 54: 4999-5006.
[0097] 5. Alejandra C., Nieves C., Mar V., and Agustin O. 2008. Isomerization of lactose-derived oligosaccnarides: A case study using sodium aluminate. J Agric Food Chem. 56:10954-9.
[0098] 6. Beadle J R., Saunders, J P., and Wajda T J. 1991. Process for manufacturing tagatose. U.S. Pat. No. 5,002,612.
[0099] 7. Beadle J R., Saunders J P., and Wajda T J. 1992.Process for manufacturing tagatose. U.S. Pat. No. 5,078,796.
[0100] 8. Ibrahim O O., and Spradlin J E. 2000. Process for manufacturing D-tagatose. U.S. Pat. No. 6,057,135.
[0101] 9. Bertelsen H., Eriknauer K., Bottcher K., Christensen H J S., Stougaard P., Hansen O C., and Jorgensen F. 2006. Manufacturing of tagatose. U.S. Pat. No. 6,991,923.
[0102] 10. Kim S B., Park S W., Song S H., Lee K P., Oh D K., Lim B C., and Kim H J. 2009. Manufacturing method of tagatose using galactose isomerization of high yield. U.S. Patent Application 20090306366.
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An economically feasible process for manufacturing tagatose is provided. The process includes hydrolyzing lactose to galactose and glucose, separating galatose from hydrolysates, and isomerizing galactose to tagatose with metal hydroxide in an aqueous suspension.
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FIELD OF THE INVENTION
This invention relates in general to the field of lighting fixtures and devices, with particular application to movable lighting devices of the type designed to provide illumination required for surgical procedures and medical examinations.
BACKGROUND OF THE INVENTION
Providing illumination for operations of any kind which involve small objects has always been a problem, particularly where the object is a part of the human anatomy and proper observation and/or modification of the same by surgery or other procedure is involved. Among the desired features for any lighting device directed for application for surgical and medical procedures are: providing illumination of the required intensity, minimizing shadows, minimizing heat and infrared radiation to the work zone and task site and, minimizing ultra-violet radiation. A concern for heat build-up within the lamphead itself with its effect upon the performance and safety of the device upon medical/surgical staff, needs always to be addressed. It is also desirable that any lighting device be extremely safe from the standpoint of possible contact with any high voltage electrical power sources, offer long lamp light, assure that no light bulb breakage would result in glass being dropped onto the subject being operated upon, and prevent any small items from being dropped into the lighting device itself where short circuiting might occur or the items passed through the lighting device and dropped onto the area being operated upon or examined by the surgeon or physician.
DESCRIPTION OF THE PRIOR ART
Numerous minor surgical lighting devices have been devised over the years, but their principal objective appears to have been only to provide illumination of desired intensity in the area to be observed. Such devices have usually disregarded such considerations such as the creation of shadows by the surgeon's hands or instruments, the minimizing of heat and other radiation directed toward the area of operation, and other desired features toward which the present invention is directed.
A previous effort was made by the present inventor to meet certain objections to prior minor surgical and exam lighting devices by providing in a single fixture three lamps having reflective backings and holders which could allow some degree of air circulation. The present invention constitutes a substantial improvement over the prior lighting device in the areas of increased illumination and in decreasing the amount of heat and infra-red radiation being directed at the subject of light focus. As a result, more effective cooling of the lamps, provides an incidental benefit in the form of greatly extended lamp life.
SUMMARY OF THE INVENTION
The present invention minimizes the heat and undesirable radiation which are emitted (by prior art lighting devices of the surgical and medical type), toward the area which receives the lighting concentration by providing in each of the three circular openings in the face of the housing a special receptacle into which is inserted a novel lamp/reflector assembly comprising a low voltage lamp with a unitary dichroic reflector about the lamp, which assembly, when thus inserted, is carried by its receptacle. The receptacle itself is especially designed to hold the lamp/reflector and mount it in the housing with two other similarly mounted lamp/reflector assemblies. Each lamp/reflector assembly contains a front heat filter through which the light passes. In addition, the receptacle provides unique annular spaces forward of the lamp and leading into the housing. The opposite side of the housing is constructed with circular louvered openings disposed coaxially with the openings of the face of the housing. Thus, when the device is directed toward a task site to be illuminated, not only is the heat and radiation which might otherwise reach such area with the light, minimized, but any heat which develops at the outer face of the heat filter will tend to be drawn through the housing by passing first through the uniquely designed and positioned annular spacings into the housing and up and out of the louvered openings on the other side of the housing, i.e. to attain a much improved chimney effect.
The present lighting device thus represents a substantial improvement over lighting devices which have heretofore been available.
BRIEF DESCRIPTION OF THE DRAWINGS
In the accompanying drawings, FIG. 1 is a perspective view of the lighting device taken from its underside in its intended downwardly directed orientation.
FIG. 2 is an underside plan view of one of the three lighting assemblies and receptacle shown in FIG. 1.
FIG. 3 is a section taken on the line 3--3 of FIG. 2.
FIG. 3A is an enlarged corner section of FIG. 3.
FIG. 4 is a plan view of the backside of the lighting assembly of FIG. 3 looking in the direction of the arrows shown in FIG. 3 along the line 4--4.
FIG. 5 is a sectional view corresponding to FIG. 3 of a prior art lighting assembly.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, the lighting device of the present invention is comprised of a housing 10 which supports on its underside 12 three lighting assemblies 14a, 14b and 14c disposed equidistantly and equiangularly about a centerpoint 16. The housing 10 may be supported by a flexible goose-neck type element 18, either extending upwardly from a floor stand (not shown) or from some apparatus which itself may be supported on a wall, table, cabinet, bench or ceiling of an operating or examining room.
The housing 10 desirably may be formed of a pair of upper and lower relatively thin walled polycarbonate sections 10a, 10b, which are clamped together centrally on opposite sides of a rigid plastic frame 28 by threaded elements 30. The frame 28 desirably is provided with a reinforced portion 32 including a tubular section 34 into which an end of the flexible goose-neck type element 18 may be inserted and secured.
The frame 28 may be configured to provide an opening 20 through which a person's hand or fingers may be inserted to grip a rim portion 22 to manipulate the housing 16 so that the lights of the three light may be directed to a desired area.
The underside 12 of the housing 10 is circularly appertured at 24a, 24b and 25c, to receive respectively the three lighting assemblies 14a, 14b and 14c. Each of these appertures 24a, 24b and 24c desirably is radially recessed for a short segment as shown at 26 in FIG. 1, preferably at three locations, each being spaced from the other two locations by 120 degrees.
Referring to FIG. 3, each lighting assembly 14a, 14b and 14c desirably may comprise a receptacle 36 molded of a high impact, high temperature polycarbonite material specially designed to receive an MR-16 lamp/reflector 38 and a lamp retainer spring 40 removably to secure the lamp/reflector 38 in the receptacle. The MR-16 which is sold by, among others, the General Electric Company of Schnectady, N.Y., is itself a unitary element which includes a bulb 42 centrally disposed within a dichroic reflector 44 which is generally hemispherical in shape and terminates in an annular segment 46 capped by a flanged rim 48. A bulb base 50 is permanently secured centrally to the outside of the reflector 44 and includes a pair of plugs 52 adapted to be inserted into a connecting element 54 itself connected by wires 56 to a source (not shown) of a 12 volt electrical current.
The receptacle 36 includes a cylindrical segment 58 having an inside diameter greater than the outside diameter of the flanged rim 48 capping the annular segment 46 of the lamp/reflector 38. The lower end 57a of the cylindrical segment 58 terminates in a radially extending flange 60 and the upper end 57b of the cylindrical segment 58 has a radially inwardly extending flange 59 with an inner diameter at least slightly greater than the outside diameter of the flanged rim 48 of the annular segment 46 of the lamp/reflector 38.
The upper end 57b of the cylindrical segment 58 may also be provided with a small radially outwardly extending flange 64 to which are molded a plurality of support elements 66 extending axially of the cylindrical segment 58 and disposed about the flange 64 and preferably spaced equidistantly from adjacent support elements 66. These members 66 support a first frustoconical, preferably stepped annular member 68 which is flared outwardly from the flange 64 and is held in spaced relationship to the latter flange by the elements 66. A second annular member 70 having an inside diameter sufficiently greater than the base 72 of the first frustoconical stepped member 67 so that when, disposed thereabout, an annular spacing 74 will appear. The second annular member 70 is secured in such spaced relationship to the ring 68 by a plurality of support elements 76 extending between the first annular member 68 and the second annular member 70 with the support members 76 being spaced equidistantly from the adjacent members about the circumference of the base 72 of the annular member 68.
The outside diameter of the second annular member 70 desirably is slightly less than the diameter of the opening 20 in the housing 10. However, extending radially outwardly from the member 68 is an annular flange 78 which, however, may be segmented for the purpose of reducing the amount of material required. In addition, three projections 80a, 80b and 80c are provided to extend radially outwardly as far as the outside diameter of the annular flange segments 78. These projections 80a, b and c are spaced axially below the annular flange segments by at least the thickness of the wall of the housing 10 which defines the opening 20, and are spaced from each other by 120 degrees, or by the same distances about the periphery of the member 68 as the recesses 26 are spaced about their appertures 24a, 24b and 24c.
Inside, and spaced slightly from the end 58a of the cylindrical segment 58 is an annular recess 82, the function of which is to receive the retainer spring 40.
As previously indicated, the various components of the receptable 36, namely the cylindrical segment 58, the support members 66, the first frustoconical stepped annular member 68 and the second annular member 70 with the support member 76 desirably are molded as a unitary structure. Each assembly 14a, 14b and 14c also includes a heat resistent glass filter 84. It is also a feature of the present invention to provide in the lower section 10b of the housing 10 coaxially with each apperture 24a, 24b and 24c in the underside 12 of the housing 10, a corresponding opening 86 which is covered by a circular louvre assembly 88 formed of a plurality of annular members 90 unitarily molded with a plurality of radiating ribs (not shown). This louvre assembly 88 desirably should also be molded of the same high impact, high temperature of polysulfanate material of which the receptacle 36 is molded and may be permanently seated in an opening 86 by means of its flanged outer ring 92.
To assemble and set up the directable lighting device of the present invention, the wires 56 are connected to a source of current through the flexible goose-neck type element 18 in a parallel connection for each of the lighting assemblies 14a, 14b and 14c. The circular louvres 88 are mounted in the openings 86 in the section 10b of the housing 10 and the section 10b is then secured to the rigid plastic frame 28 by a threaded element 30. A lighting assembly 14a, 14b and 14c is then made ready for insertion in each of the appertures 24a, 24b and 24c in the section 10a of the housing 10. Each assembly 14a, 14b and 14c is put together by inverting a unitarily molded plastic receptacle 36 and first dropping into the cylindrical segment 58 a glass filter 84 to where it seats on the inwardly extending flange 62. An MR-16 lamp/reflector assembly 38 is then similarly inserted within the cylindrical segment 58 to where it rests upon the glass filter 84. Retention within the cylindrical segment is accomplished by inserting the U-shaped retainer spring 40 into the annular recess 82 inside the cylindrical segment 58. The plugs 52 are then pushed into the connecting element 54, following which the entire assembly 14a, 14b or 14c is then dropped into the opening 32, with the projections 80a, 80b and 80c being aligned with the recesses 26 to pass therethrough so that the segmented annular flange 78 comes to rest upon the edge of the housing which defines an apperture 24a, 24b and 24c. By rotating the entire assembly 14a, 14b and 14c for a short distance, it then is held within the opening by the projections 80a, 80b and 80c which have been moved away from the recesses 26 and under the wall of the housing. Thereby, each of the assemblies 14a, 14b and 14c is secured within the section 10a of the housing 10, and if not done earlier, section 10a of the housing 10 may be secured to the frame 28 by a threaded element 30.
When current is applied to the three lighting assemblies and the housing 10 is turned to direct the lighting assemblies 14a, 14b and 14c downwardly towards a desired area, because of the slight angular orientation provided by the upper half of the housing 10a, the lighting from all three of the assemblies 14a, 14b and 14c will be found to come together to form a harmonious pattern which is in focus from 15" to 5 feet below the face of the housing 10a. It will also be found that the heat produced by the assemblies thus concentrated is minimized, not only because of the glass filter 84 and low voltage lamp/reflector 38 in each assembly 14a, 14b and 14c, but because of the greatly improved chimney effect provided by the receptacle 36. It will be readily appreciated that any heat which may appear on the outside face of the glass filter 84 of the downwardly directed lighting assemblies 14a, 14b and 14c will tend to rise and pass through the spacing 67 between the flange 64 and the first annular member 68, and further between the spacing 74 between a first annular member 68 and the second annular member 70. As the heat rises and passes through that spacing and into the housing 10, it immediately passes further through the circular louvre assemblies 88 and up and away from the entire lighting device housing 10. Thereby, any heat generated by the several lighting assemblies 14a, 14b and 14c, which is initially minimized by their use of 12 volt bulbs, is further minimized in the area to which the lighting is directed and where the surgeon may be working, or the doctor is examining a patient. The lighting device of the present invention, therefore, constitutes a substantial improvement over prior art lighting devices, such as that shown in FIG. 5 where the only escape for heat generated by the bulb is around the base of the hot bulb itself and the mounting does not produce the air escape effect of the present invention.
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A directable light device particularly suited for surgical or other medical use wherein preferably three 12 volt halogen lamps with built in dichroic reflectors are mounted in high impact polycarbonate molded receptacles each providing at least two annular vents to remove heat generated by the bulb through a coaxial louvered opening in the back of the housing. Light from the bulbs is also passed through filter means.
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BACKGROUND OF THE INVENTION
This application is a continuation-in-part application of our application Ser. No. 289,404 for Process for Preparing Aldehydes filed Aug. 3, 1981, now U.S. Pat. No. 4,361,706.
1. Field of the Invention
This invention is directed to a catalyst particularly suitable for selectively producing aldehydes, particularly acetaldehyde, which comprises (1) cobalt, (2) iodine and (3) a ligand containing atoms from Group VB of the Periodic Table separated by sterically constrained carbon-carbon bonding.
2. Description of the Invention
In European Patent Application No. 79302053.8, filed in the names of B. R. Gane and D. G. Stewart and published on Apr. 30, 1980, it is disclosed that when methanol is reacted with synthesis gas in the presence of a catalyst comprising (a) cobalt, (b) an iodide or a bromide and (c) a polydentate ligand, wherein the donor atoms are exclusively phosphorus, the product obtained will contain a substantial proportion of ethanol. When the polydentate ligand used is one wherein at least one of the donor atoms is phosphorus and another is aresenic, it is alleged by Gane et al. that the product will contain a mixture of ethanol and acetaldehyde.
SUMMARY OF THE INVENTION
We have found that if we introduce into a reaction zone containing (1) methanol, (2) carbon monoxide, and (3) hydrogen, a novel catalyst system containing (1) cobalt, (2), iodine and (3) a ligand containing atoms from Group VB (that is, phosphorus, arsenic and antimony) of the Periodic Table separated by sterically constrained carbon-carbon bonding, while controlling the proportion of the reaction components and the reaction parameters, we can obtain a reaction product predominating in aldehydes, including compounds convertible thereto, particularly acetaldehyde. By "compounds convertible thereto" we mean to include acetals, such a dimethyl acetal. In general the reaction product will contain at least about 30 weight percent, especially from about 35 to about 85 weight percent, of aldehydes and compounds convertible thereto. The acetaldehyde content of the reaction product will be at least about 25 weight percent, especially about 27 to about 75 weight percent. At the same time, the alcohol content of the reaction product, including compounds convertible thereto, will be very small. By "compounds convertible thereto", in the latter instance, we mean to include acetates, such as ethyl acetate. In general the reaction product will contain less than about 23 weight percent of alcohols and compounds convertible thereto, but more often from about two to about ten weight percent of alcohols and compounds convertible thereto. As to the ethanol content of the reaction product, it will be less than about 18 weight percent, but more often in the range of about 0 to about seven weight percent. The compounds referred to above that can be converted to aldehydes or alcohols can be converted thereto by any known or suitable process, for example, by hydrolysis, that is, contacting a precursor thereof with water, with or without an acid (sulfuric) or a basic (sodium hydroxide) catalyst.
As noted, the ligand component of the novel catalyst system defined and claimed herein contains atoms from Group VB of the Periodic Table. As pointed out above, by "Group VB atoms" we mean to include phosphorus, arsenic, and antimony. by "sterically constrained carbon-carbon bonding" we mean to include carbon-carbon bonding which is part of an organic divalent, trivalent or tetravalent radical, whereas a component of the bonding between these radical centers possesses a constrained geometry and a fixed spatial arrangement; this constrained geometry between these carbon atoms can be introduced by either bond unsaturation or by their incorporation into an alicyclic ring system. By "bond unsaturation" we mean to include an alkylene bond, such as ##STR1## and an arylene bond, such as: ##STR2## or an acetylenic bond such as --C.tbd.C-- wherein any of the above-defined R substituents can be hydrogen, a hydrocarbyl, such as defined hereinafter, a halogen, such as chlorine or bromine, a sulfur-containing substituent, such as a sulfonato group, a nitrogen-containing substituent, such as a nitro group or an amino group, an oxygen-containing substituent, such as a hydroxyl group, etc. By "cyclic ring system" we mean to include alicyclic compounds, such as cycloparaffins, cycloolefins, and cycloacetylenes; condensed aromatics; and heterocycles which can be monocyclic, bicyclic, or tricyclic ring systems in which each component ring of the system comprises a three- to eight-membered ring and can be the same or different from the other component rings in the system. The ring skeleton atoms of these systems can be substituted with hydrogen; a hydrocarbyl, such as defined hereinafter; a halogen, such as chlorine or bromine; a sulfur containing substituent, such as a sulfonato group; a nitrogen-containing substituent, such as a nitro group; and oxygen-containing substituent such as a hydroxyl group, etc.
Especially preferred ligands for use herein can be defined by the following formula: ##STR3## wherein R 1 and R 2 , either alike or different members selected from the group consisting of alkyl radicals having from one to 24 carbon atoms, preferably from two to 10 carbon atoms; aryl radicals having from six to 20 carbon atoms, preferably from six to 10 carbon atoms; alkenyl radicals having from two to 30 carbon atoms, preferably from two to 20 carbon atoms; cycloalkyl radicals having from three to 40 carbon atoms, preferably from three to 30 carbon atoms; and aralkyl and alkaryl radicals having from six to 40 carbon atoms, preferably from six to 30 carbon atoms, preferably aryl or alkyl; R 3 and R 4 are either alike or different members selected from R 1 and R 2 , defined above, and hydrogen, preferably hydrogen or alkyl; E can be phosphorus, arsenic, or antimony, preferably with each E being phosphorus or arsenic, most preferably with each E being phosphorus; and n being an integer ranging from 0 to 2, preferably from 0 to 1, provided that the sum of all n's=0-4, preferably 0-2; x is an integer equal to 2, 3 or 4; and A can be an organic divalent, trivalent or tetravalent radical when x is respectively 2, 3 or 4, whereas the bonding between these radical centers possesses a constrained geometry and a fixed spatial arrangement; moreover every E, as defined above, and which are bonded to these radical centers and as part of this constrained arrangement, can bond to the same metal atom. This constrained geometry between these centers can be introduced by bond unsaturation, e.g. aromatic, heterocyclic, olefinic, or acetylenic, or by their incorporation into cyclic ring systems comprising monocyclic, bicyclic or tricyclic systems, with each system possessing three- to eight-membered rings. When A is an alicyclic group or includes an alkylene linkage, the bidentate ligand includes cis-type and trans-type steric isomers. In the present invention, both isomers can be used. Included among the ligands that can be employed herein, are those defined below in Table I, referring to the structural formula hereinabove defined.
TABLE I__________________________________________________________________________R.sub.1 R.sub.2 R'.sub.1 R'.sub.2 R.sub.3 R.sub.4 R'.sub.3 R'.sub.4 E E' A x n__________________________________________________________________________ Phenyl Phenyl Phenyl Phenyl -- -- -- -- P P ##STR4## 2 0 Phenyl Phenyl Phenyl Phenyl H H H H P P " 2 1 Ethyl Ethyl Ethyl Ethyl -- -- -- -- P P " 2 0 Phenyl Phenyl Phenyl Phenyl -- -- -- -- P P ##STR5## 2 0 Phenyl Phenyl Phenyl Phenyl H H H H P P " 2 1 Phenyl Phenyl Phenyl Phenyl CH.sub.3 H H H P P " 2 1 Phenyl Phenyl Phenyl Phenyl CH.sub.3 H CH.sub.3 H P P " 2 1 Phenyl Phenyl Ethyl Ethyl -- -- -- -- P P " 2 0 Phenyl Phenyl Ethyl Ethyl CH.sub.3 H H H P As " 2 110. Phenyl Phenyl Phenyl Phenyl -- -- -- -- As As " 2 0 Phenyl Phenyl Phenyl Phenyl -- -- -- -- P P ##STR6## 2 0 Phenyl Phenyl Phenyl Phenyl -- -- -- -- P As " 2 0 Phenyl Phenyl Phenyl Phenyl -- -- -- -- P P ##STR7## Phenyl Phenyl Phenyl Phenyl -- -- -- -- P P ##STR8## 2 0 Phenyl Phenyl Phenyl Phenyl -- -- -- -- P P ##STR9## 2 0 Phenyl Phenyl Ethyl Ethyl H H H H P P " 2 1 Phenyl Phenyl Ethyl Ethyl H H H H P P ##STR10## 2 1 Phenyl Phenyl Phenyl Phenyl H H H H P P ##STR11## 2 2 Phenyl Phenyl Phenyl Phenyl -- -- -- -- P P ##STR12## 2 020 Phenyl Phenyl Phenyl Phenyl -- -- -- -- P P CC 2 0 Phenyl Phenyl Phenyl Phenyl H H H H P P " 2 2 Phenyl Phenyl Phenyl Phenyl -- -- -- -- P P ##STR13## 2 0 Phenyl Phenyl Phenyl Phenyl H H H H P P " 2 10 -24. Phenyl Phenyl Phenyl Phenyl -- -- -- -- P P ##STR14## 2 0 Phenyl Phenyl Phenyl Phenyl H H H H P P " 2 1 Phenyl Phenyl Phenyl Phenyl -- -- -- -- P P ##STR15## 2 0 Phenyl Phenyl Phenyl Phenyl -- -- -- -- P P ##STR16## 2 0 Phenyl Phenyl Phenyl Phenyl H H H H P P " 2 1 Phenyl Phenyl Phenyl Phenyl -- -- -- -- P P ##STR17## 2 030. Phenyl Phenyl Phenyl Phenyl H H H H P P " 2 1__________________________________________________________________________
Any source of iodine which is capable of dissociating, that is, ionizing to form free iodide ions in the reaction medium, can be used in the present invention. Illustrative examples of iodine compounds especially suitable for use herein include iodine, potassium iodide, calcium iodide, sodium iodide, lithium iodide, aluminum iodide, bismuth iodide, hydrogen iodide, methyl iodide, ethyl iodide, tetraalkyl ammonium iodide, tetraalkyl phosphonium iodide, tetraarylphosphonium iodide, etc., and mixtures thereof.
The cobalt entity suitable for use herein can be defined as being a cobalt carbonyl, a hydrido cobalt carbonyl or a cobalt-containing compound convertible to a cobalt carbonyl or a hydrido cobalt carbonyl. By "cobalt carbonyl" we intend to define a compound containing only cobalt and carbon monoxide, such as Co 2 (CO) 8 or Co 4 (CO) 12 . By "hydrido cobalt carbonyl" we intend to define a compound containing only cobalt, carbon monoxide and hydrogen, such as HCo(CO) 4 . By "cobalt-containing material convertible to a cobalt carbonyl or a hydrido cobalt carbonyl" we intend to define any material which when mixed with hexane and sujected to 4000 pounds per square inch gauge (27.6 MPa) in an atmosphere containing hydrogen and carbon monoxide in a molar ratio of 1:1 at 150° to 200° C. for a period of three hours will result in the formation of a cobalt carbonyl, a hydrido cobalt carbonyl or mixtures thereof. Specific examples of a cobalt-containing material so convertible to a cobalt carbonyl or a hydrido cobalt carbonyl include cobalt (II) sulfate, cobalt oxide (Co 3 O 4 ), cobalt(II)tetrafluoroborate, cobalt(II)acetate, cobalt(II)oxalate, cobalt(II)propionate, cobalt(II)octoate, cobalt(II)butyrate, cobalt(II)benzoate, cobalt(II)valerate, cobalt(II)formate, cobalt(II)cyclohexanebutyrate, cobalt(II)2-ethyl-hexaoate, cobalt(II)gluconate, cobalt(II)lactate, cobalt(II)naphthenate, cobalt(II)oleate, cobalt(II)citrate, cobalt(II)acetylacetonate, cobalt(II)iodide, etc.
The relative amounts of carbon monoxide and hydrogen employed in the homologation process using the novel catalyst herein can be varied over a wide range. However, in general, the molar ratio of carbon monoxide to hydrogen is from about 2:1 to about 1:2, preferably about 1.5:1 to about 1:1.5, but most preferably about 1.25:1 to about 1:1.25. Compounds or reaction mixtures which give rise to the formation of carbon monoxide and hydrogen under the reaction conditions defined herein can be used instead of mixtures comprising carbon monoxide and hydrogen which are used in the preferred embodiments of this invention.
In order to obtain a product herein that predominates in aldehydes, particularly acetaldehyde, the amount of cobalt employed relative to the ligand and to iodine is critical. Thus, the molar ratio of cobalt based on the element cobalt, to the ligand must be in the range of about 1:2 to about 7:1, preferably about 1:1.5 to about 4:1. The molar ratio of cobalt, based on the element cobalt, to iodine, based on the element iodine, must be in the range of about 1:1.15 to 1:15, preferably about 1:1.25 to about 1:5. Based on the methanol introduced into the system, the weight percent of combined cobalt and iodine, in their elemental form, can range from about 0.01 to about 10 percent, preferably from about 0.1 to about five percent.
The catalyst herein can be used either in a batch operation or by passing the reactants continuously through a reaction zone. In each case the reactor is provided with agitation means, and the pressure is maintained therein by the addition of hydrogen and carbon monoxide, or compounds producing hydrogen and carbon monoxide, as required. In order to facilitate the introduction of the phosphorus-containing ligand and the cobalt and iodine entities into the reaction zone and/or to facilitate recovery of the components of the reaction herein, they can be dissolved in an inert solvent, such as ethylene glycol, diethylene glycol monomethyl ether, acetone, sulfolanes, such as tetramethylene sulfone, lactones, such as γ-butyrolactone and ε-caprolactone, hydrocarbons, such as 1,2,3,4-tetrahydronaphthalene, mesitylenes, etc.
In the reaction zone the contents thereof are maintained at an elevated temperature and at an elevated critical pressure for a time sufficient to convert methanol to the desired aldehydes. The total pressure (based on hydrogen, carbon monoxide and any produced gases) must be at least about 2200 pounds per square inch gauge (15.02 MPa) but need not be in excess of about 10,000 pounds per square inch gauge (68.30 MPa). Especially desirable are pressures in the range of about 2500 pounds per square inch gauge (17.07 MPa) to about 7500 pounds per square inch gauge (51.19 MPa). Temperatures which are suitable for use using the novel catalyst herein are those temperatures which initiate a reaction between the reactants herein to selectively produce alcohols generally from about 150° to about 250° C., preferably from about 170° to about 220° C. The reaction is conducted for a time period sufficient to convert methanol to aldehydes, normally from about five minutes to about five hours, preferably from about ten minutes to about 2.5 hours.
Recovery of the desired aldehydes, for example acetaldehyde, from the reaction product can be effected in any convenient or conventional manner, for example, by distillation, at ambident pressure and about 21° C. The components will distill off in the following sequence for the desired recovery: acetaldehyde, propionaldehyde, methyl acetate, methanol, butyraldehyde, ethyl acetate, ethanol, etc.
DESCRIPTION OF PREFERRED EMBODIMENTS
A series of runs was carried out as follows.
In each of Runs Nos. 1, 3, 4 and 7, there was charged into a 300 cc. stainless steel autoclave equipped with agitation means, 100 milliliters of methanol, 10 millimols of cobaltous acetylacetonate, 10 millimols of iodine (I 2 ) and five millimols of a specific ligand containing atoms from Group VB of the Periodic Table separated by an unsaturated linkage. These ligands were as follows:
(Run No. 1) cis-bis(1,2-diphenylphosphino)ethylene;
(Run No. 3) bis(1,2-diphenylphosphino)benzene;
(Run No. 4) bis-alpha-alpha'-diphenylphosphino)-o-xylene; and
(Run No. 7) bis(diphenylphosphino)acetylene.
The reactor was next purged twice with nitrogen gas and then pressurized with carbon monoxide and hydrogen to a pressure of about half the desired reaction pressure. The system was then heated to a temperature of 200° C. and the pressure was adjusted to the reaction pressure, while maintaining selected molar ratios of carbon monoxide to hydrogen in the reaction zone, and such pressure was maintained throughout the reaction period. At the end of the reaction period the reactor contents were cooled by an internal cooling coil to about -75° C. The reactor was vented through a dry gas meter, and a gas sample was taken for mass spectral analysis; and the liquid product was then analyzed by gas choromatography. The data obtained are set forth below in Table II.
TABLE II__________________________________________________________________________ Co:Ligand.sup.(a) Co:I Pressure Reaction, Percent.sup.(b) Molar Molar PSIG Time MeOHRun No.R.sub.1, R.sub.2 x n R.sub.3, R.sub.4 A Ratio Ratio CO:H.sub.2 (MPa) Hours Conversion__________________________________________________________________________I Phenyl 2 0 Hydrogen ##STR18## 2:1 0.5:1 1:1 4000(27.3) 1.0 92.0II Phenyl 2 0 Hydrogen ##STR19## 4:1.sup.(p) 0.5:1 1:1 4000(27.3) 1.0 93.0III Phenyl 2 0 Hydrogen ##STR20## 2:1 0.5:1 1:1 4000(27.3) 1.0 93.0IV Phenyl 2 1 Hydrogen ##STR21## 2:1 0.5:1 1:1 4000(27.3) 1.0 79.7V Phenyl 2 0 Hydrogen ##STR22## 2:1.sup.(p) 0.5:1 1.5:1 4000(27.3) 1.0 90.0VI Phenyl 2 0 Hydrogen ##STR23## 2:1.sup.(p) 0.8:1 1:1 4000(27.3) 1.0 86.0VII Phenyl 2 0 Hydrogen CC 2:1 0.5:1 1:1 4000(27.3) 1.0 61.7__________________________________________________________________________ Total Total Weight Weight Per- Per- cent centRun Oth- Alde- Alco-No. Me.sub.2 O.sup.(c) HAc.sup.(d) MeF.sup.(e) EtOH.sup.(f) Et(OMe).sub.2.sup.(g) EtCHO.sup.(h) MeOAc.sup.(i) PrCHO.sup.(j) EtOAc.sup.(k) HOAc.sup.(l) ers.sup.(m) hydes.sup.(n) hols.sup.(o)__________________________________________________________________________I 3.7 53.8 0.6 5.5 0 0.4 11.5 17.4 3.8 0 3.2 72.6 5.6II 4.8 41.0 0.2 0.8 0.8 0.2 19.7 19.7 6.3 3.3 3.2 64.1 7.9III 1.9 51.2 0.7 0.5 3.4 0.4 15.4 17.3 6.1 0 2.7 69.7 6.6IV 6.5 28.0 0.1 1.0 2.5 2.8 24.6 7.0 2.5 0 24.9 60.3 8.5V 7.1 43.7 0.6 17.0 3.7 0.6 8.4 7.8 5.9 2.2 3.0 56.4 22.9VI 2.0 43.7 0.5 9.0 1.3 1.0 19.8 12.7 8.2 1.0 0.9 58.2 17.2VII 1.5 28.9 0 0 1.2 0.6 27.4 5.7 1.7 2.2 20.7 53.1 5.8__________________________________________________________________________ ##STR24## .sup.(b) Methanol- .sup.(p) Cobalt carbonyl (5.0 mmol) was used. .sup.(c) Dimethyl ether CH.sub.3 .sup.(d) Acetaldehyde CH.sub.3 CO .sup.(e) Methyl formate HCOOCH.sub.3 .sup.(f) Ethanol C.sub.2 H.sub.5 OH .sup.(g) Dimethyl acetal CH.sub.3 CH(OCH.sub.3 .sup.(h) Propanol C.sub.2 H.sub.5 CHO .sup.(i) Methyl acetate CH.sub.3 .sup.(j) Butanal C.sub.3 H.sub.7 CHO .sup.(k) Ethyl acetate CH.sub.3 COOC.sub.2 .sup.(l) Actic acid CH.sub. 3 COOH .sup.(m) Mixtures of 1,1dimethoxy ethane, 1,1dimethoxy butane, 1,1diethox ethane, diethylether, crotonaldehyde and other aldehyde condensation products .sup.(n) Aldehydes + material convertible to aldehydes, for example, by hydrolysis .sup.(o) Alcohols + meterials convertible to alcohols, for example, by hydrolysis-
The data in the above tables clearly show that when ligands defined herein are used in the claimed novel catalyst composition, a product is obtained containing the desired amounts of aldehydes, including the desired amounts of acetaldehyde.
Obviously, many modifications and variations of the invention, as hereinabove set forth, can be made without departing from the spirit and scope thereof, and therefore only such limitations should be imposed as are indicated in the appended claims.
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A catalyst particularly suitable for selectively producing aldehydes, particularly acetaldehyde, which comprises (1) cobalt, (2) iodine and (3) a ligand containing atoms from Group VB of the Periodic Table separated by a sterically constrained carbon-carbon bonding.
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[0001] This application is a divisional of U.S. patent application Ser. No. 12/331,477, filed Dec. 10, 2008, which claims priority from U.S. Provisional Application Ser. No. 61/007,144 filed Dec. 11, 2007.
BACKGROUND
[0002] It is often important to be able to load particles, such as catalyst particles, to the correct elevation in the tubes of a vertical tube chemical reactor. This can become even more critical when the tubes require special loading, with catalyst particles at certain elevations and inert spacer particles in other specific elevations or with different types of catalyst particles at different elevations.
SUMMARY
[0003] The present invention provides an arrangement for precision loading of particles at the correct elevations within the tubes of a vertical tube chemical reactor that is accurate and treats the particles gently, avoiding damage to the particles during dispensing and measurement.
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] FIG. 1 is a schematic, partially broken away, section view of a chemical reactor vessel including a loading arrangement made in accordance with the present invention;
[0005] FIG. 2A is a partially broken away, side view of the loading arrangement of FIG. 1 ;
[0006] FIG. 2B is the same view as FIG. 2A , but with the framework removed for clarity;
[0007] FIG. 3 is an enlarged schematic section view of a sensor from FIG. 2B ;
[0008] FIG. 4A is a side view of the sensor of FIG. 3 as it is being inserted into a reactor tube;
[0009] FIG. 4B is the same view as FIG. 4A but showing the sensor having made contact with the particles in the reactor tube;
[0010] FIG. 4C is a view along line 4 C- 4 C of FIG. 4A ;
[0011] FIG. 4D is a view along line 4 D- 4 D of FIG. 4B ;
[0012] FIG. 5 is the same view as FIG. 2B but with the sensor extending into one of the reactor tubes and with the plate closing off the feed from the dispensing bin to the conveyor belt;
[0013] FIG. 6 is the same view as FIG. 5 but with the sensor retracted and the reactor tube fully loaded with particles;
[0014] FIG. 7 is a schematic front view of the arrangement of FIG. 2B with one reactor tube full and the next adjacent tube still filling;
[0015] FIG. 8 is a schematic top view of the mounting support for the bin of FIG. 2A ;
[0016] FIG. 9 is a schematic front view of the mounting support of FIG. 8 ;
[0017] FIG. 10 is a schematic top view of the plate from FIG. 8 ;
[0018] FIG. 11 is a schematic top view of the end of the belt and the funnels of the arrangement of FIG. 2B ;
[0019] FIG. 12 is a view similar to FIG. 2B , but for a different embodiment of a loading arrangement, with the tubes being loaded with particles;
[0020] FIG. 13 is the same view as FIG. 12 , but with the diverter plate sending the particles to the collection bin and the sensor in position to be deployed;
[0021] FIG. 14 is the same view as FIG. 13 but with the sensor deployed to determine the elevation of particles in the tube;
[0022] FIG. 15 is a view similar to FIG. 2B , but for a different embodiment of a loading arrangement, with the tubes being loaded with particles;
[0023] FIG. 16 is the same view as FIG. 15 , but with the diverter mechanism sending the particles to the collection bin and the sensor deployed to measure the elevation of particles in the tube;
[0024] FIG. 17 is an enlarged schematic section view of an alternate embodiment of a sensor as it is inserted into a reactor tube, which may be used with any of the loading arrangements disclosed;
[0025] FIG. 18 is the same view as FIG. 17 but showing the sensor having made contact with the particles in the reactor tube;
[0026] FIG. 19 is a view similar to that of FIG. 16 but for a different embodiment of a loading arrangement;
[0027] FIG. 20 is a side view of a catalyst container;
[0028] FIG. 21 is a front view of the catalyst container of FIG. 20 , secured to a magazine by means of a strap; and
[0029] FIG. 22 is a side view of the catalyst container and magazine of FIG. 21 .
DETAILED DESCRIPTION
[0030] FIG. 1 depicts a typical chemical reactor vessel 10 , which is a vertical shell and tube heat exchanger, having an upper tubesheet 12 and a lower tubesheet 14 with a plurality of vertical tubes 16 welded or expanded to the tubesheets 12 , 14 to form a tightly packed tube bundle. There may be from one to many hundreds or even thousands of tubes 16 extending between the tubesheets 12 , 14 . Each tube 16 has a top end adjacent the upper tube sheet 12 and a bottom end adjacent the lower tubesheet 14 . The vessel 10 includes a top dome (or top head) 13 and a bottom dome (or bottom head) 15 , as well as manways 17 , 18 , 20 for access to the tubesheets 12 , 14 inside the vessel 10 . The manways are closed during operation of the reactor but are opened for access, such as during catalyst handling. In this instance, the tubes 16 are filled with catalyst particles (not shown in this view), which facilitate the chemical reaction. However, similarly-shaped shell and tube vessels may be used for other purposes, such as for a boiler or other heat exchanger, and the particles may be inert spacers or other particles besides catalyst particles.
[0031] Reactors have either fixed or removable heads. In this embodiment, the heads are fixed, and they include manways 17 and 18 at the top and 20 at the bottom.
[0032] This particular reactor vessel 10 is fairly typical. Its tubes can range in length from 5 feet to 65 feet, and it is surrounded by a structural steel skid or framework 22 , which includes stairways or elevators (not shown) for access to the tubesheet elevations of the reactor vessel 10 as well as access to intermediate elevations and to a topmost elevation which may be located at or near the elevation of the top opening 18 of the reactor vessel 10 . On a regular basis, which can be every 2 to 48 months or longer, as the catalyst becomes less efficient, less productive, or poisoned, it is changed out, with some or all of the old catalyst being removed and a new charge of catalyst being installed in the tubes 16 of the reactor vessel 10 . Catalyst handling also can occur on an unplanned and undesirable schedule.
[0033] A catalyst change operation requires a complete shutdown of the reactor, resulting in considerable lost profits due to lost production. (The disclosed invention can be used not only for catalyst change operations but also on new reactors and tubes for their initial catalyst loading.) It is desirable to minimize the amount of time required for the catalyst change operation and yet the catalyst loading operation must be done carefully to ensure proper loading of the catalyst or other particles in the tubes 16 as these particles have a tendency to bridge and create voids inside the reactor tube if they are loaded improperly. FIG. 1 also schematically depicts an example of a particle loading arrangement 24 made in accordance with the present invention.
[0034] Referring now to FIG. 2A , this particular particle loading arrangement 24 is skid mounted on a framework 26 which can be broken down readily into subassemblies 28 , 30 which can be handled easily, especially for introduction into the top head 13 via one of the manways 17 , 18 . In this embodiment, the framework 26 includes a top subassembly 28 , which rests atop the bottom subassembly 30 . These two subassemblies 28 , 30 may be temporarily held together via fasteners (not shown) such that they may be moved as a unit when assembled inside the top head 13 of the reactor vessel 10 . Of course, the framework 26 may include any number of subassemblies as may be desired for ease of handling and in order to fit through the manways to introduce the loading arrangement 24 into the reactor head 13 .
[0035] Vertical tube chemical reactors typically have rows of reactor tubes extending between upper and lower tube sheets with the alternate rows being offset from each other so that the tubes lie on an equilateral triangular pitch. FIG. 2B is a side view, partially in section, of a particle loading arrangement 24 and shows the upper tube sheet 12 and several different tubes 16 a , 16 b , 16 c , 16 d , 16 e , 16 f , 16 g which lie on several different respective rows 116 a , 116 b , 116 c , 116 d , 116 e , 161 f , 116 g . This loading arrangement is intended to advance from row to row, loading several tubes within a row at a time. In this particular case, ten adjacent tubes 16 c along the row 116 c have just been loaded, and the device is now in the process of loading ten adjacent tubes 16 b in row 116 b . After these tubes 16 b have been loaded, the device will advance further left to load ten of the tubes 16 a in row 116 a , and so forth. Thus, while FIG. 2B shows only one of the tubes 16 in each row 116 , it is understood that the device actually is loading ten tubes 16 in each row as it advances from one row to the next.
[0036] This loading arrangement includes several components, as is best appreciated in FIG. 2B . There is a dispensing bin 32 , which holds a supply of particles and dispenses them for loading into the tubes. There is a wide conveyor belt 34 , which spans the distance of the ten adjacent tubes 16 and conveys the particles from the dispensing bin 32 to the ten reactor tubes 16 along a row 116 . In this view, the loading arrangement 24 currently is loading ten adjacent tubes 16 b in row 116 b . There is a measuring system 36 , which includes a plurality of sensors 66 on reels 60 to independently measure the elevation (or level) of particles 21 in each of the ten tubes 16 b , and there are ten individual diverter plates 58 , which divert falling particles 21 away from their respective tubes 16 b and into a collection bin 40 (as depicted in FIG. 6 ) once the respective tube 16 b has been loaded to the desired elevation.
[0037] It should also be pointed out that the particle loading arrangement 24 may be designed and installed with some of its elements being outside the dome 13 of the reactor vessel 10 . For instance, the dispensing bin 32 may be mounted outside the reactor vessel 10 , and the conveyor belt 34 may extend through the manway 17 and into the reactor dome 13 with the motor 52 and belt drive 48 for the belt 34 being located either inside or outside of the reactor vessel 10 .
[0038] The magazine closure at the bottom of the dispensing bin 32 is shown in more detail in FIGS. 8 , 9 , 21 , and 22 . The bin 32 is open at the bottom and is secured by a strap 88 to a rail 42 , which is received in a support panel 43 that is secured to the top subassembly 28 , as by welding. A sliding shut-off plate 44 (See also FIG. 10 ) is also supported on the rail 42 and can be slid in and out, acting as a guillotine-type gate, to regulate the size of the opening through which particles fall onto the belt 34 . This sliding shut-off plate 44 is shown in the closed-off position in FIGS. 2A and 5 , and is shown in a partially open position in FIGS. 2B , 6 , and 12 - 14 . The position of this plate 44 is controlled by a central processor which controls a linear actuator (not shown) connected to the plate 44 . A sensor 45 senses the position of the plate 44 and communicates that information to the central controller. FIG. 2B depicts the shut-off plate 44 in a partially open position to allow the flow of particles out of the dispensing bin 32 and onto the belt 34 .
[0039] Stationary V-shaped divider plates 38 (Seen in FIGS. 2A and 11 ) are located between the dispensing bin 32 and the belt 34 , either resting directly on the belt 34 or preferably being mounted at an elevation just slightly above the belt 34 . These divider plates 38 are oriented substantially in the direction of travel of the belt and serve to divide the flow of particles along the belt into ten lanes, each aligned with its respective tube 16 .
[0040] The divider plates 38 or other device in contact with the belt 34 , such as a roller (not shown) in contact with the bottom surface of the belt 34 also may be attached to a vibratory motor 46 (Shown in FIG. 11 ) such as the type found in cell phones, using a rotating eccentric mass of sufficient size and vibratory force capacity to fluidize the particles on the belt to help them adequately segregate into a proper volume on the belt 34 , to help ensure that the volume along the belt 34 remains substantially constant and with a consistent packing density. The vibratory motor 46 may also be attached to the top of the divider plates 38 by means of a horizontal bar, as shown in FIG. 11 , and located perpendicular to them in such a manner to form a weir 47 , or gate, to regulate the height and therefore the volume of particles on the belt 34 . Alternatively, a separate, non-vibratory weir 47 may be used.
[0041] The conveyor belt 34 is driven by a drive roller, which is driven by a drive belt 48 , which extends around pulleys 50 and is driven by a motor 52 , the speed of which is controlled by the central controller.
[0042] There are ten funnels 54 , one funnel 54 in each of the tubes 16 b that are being loaded, and the end of the conveyor belt 34 is aligned with the openings in the funnels 54 so that the particles 21 falling off the end of the conveyor belt 34 fall into the funnels 54 and into the tubes 16 b.
[0043] The funnels 54 are mounted on a movable frame 31 that is connected to the frame 30 of the loading device 24 so they can be raised and lowered together, raising them to remove them from one row of tubes 16 b , for example, and then advancing the loading device 24 and then lowering the funnels 54 into the next set of tubes 16 a . The movable frame 31 may be moved manually by an operator shifting a lever, or it may be moved automatically by a central processor that controls an actuator connected to both the movable frame 31 and the frame 30 .
[0044] When it has been determined that a particular tube 16 b has been filled to the desired height, or when it is otherwise desired to stop loading a particular tube, its respective actuator 56 actuates its respective diverter plate 58 , pivoting the diverter plate 58 toward the conveyor belt 34 to the diverting position shown in FIG. 6 , diverting the particles 21 , that would otherwise fall into that tube 16 b , into the collection bin 40 . FIG. 7 shows two of the diverter plates 58 , with the diverter plate 58 on the right side in the diverting position and the diverter plate 58 on the left in the non-diverting position. The other eight diverter plates 58 and their respective actuators 56 are not shown here, but it is understood that there is one for each tube 16 b that is being filled and that each actuator 56 is independently controlled by the central controller. Once the ten tubes 16 b have all been filled, the plate 44 is slid to the closed position, as shown in FIG. 5 , and the conveyor belt 34 is stopped. Then the device is advanced to the next row 116 a of tubes 16 a to load those tubes 16 a in the same manner.
[0045] The measuring arrangement 36 for each tube being loaded includes a reel 60 , a wire cable 62 , an encoder 64 , and a sensor 66 . The sensor 66 is shown in more detail in FIGS. 3 and 4 A- 4 D and is explained in more detail below.
[0046] As shown in FIG. 3 , the wire cable 62 includes a ground wire 68 and a power cable 70 , which support a weight 72 . The ground wire 68 is electrically connected to a spring 74 . The upper end of the spring 74 is suspended from the weight 72 , and the lower end of the spring 74 defines a downwardly-projecting extension 76 which projects below a rubber boot 78 which partially encases the spring 74 .
[0047] A pin 80 is electrically connected to the power cable 70 , is suspended from the weight 72 , and is centered inside the spiral spring 74 , as shown in FIGS. 3 and 4C .
[0048] Each wire cable 62 is wound onto its respective reel 60 , which is controlled by a motor including an encoder 64 . This powered reel 60 is controlled by the central controller as well as being calibrated and indexed to quantify the length of wire 62 that has played out as the sensor 66 is lowered into the tube in order to know the elevation of the sensor 66 at all times.
[0049] As the sensor 66 is being lowered into the reactor tube 16 b , as shown in FIGS. 4A and 5 , the pin 80 extends axially through the spring 74 , and the pin 80 does not make contact with the spring 74 .
[0050] As the sensor 66 is lowered further, the extension 76 of the spring 74 makes contact with the particles 21 , as seen in FIG. 4B . With a slight additional downward movement of the weight 72 , the extension pushes the lower portion of the spring 74 sideways, which moves the spring 74 into contact with the pin 80 , as shown in FIG. 4D . This completes an electrical circuit, acting as a switch or trigger which signals that the sensor 66 has reached the level of the particles 21 . The closing of this switch is registered by the encoder 64 , which sends a signal to the central controller to indicate the elevation (or level) of particles 21 in that tube 16 b.
[0051] The switch may be connected to an operational amplifier triggering circuit, not shown but well understood in the field of electronics, which serves as the input to a flip-flop circuit that can be read as a digital input/output and then reset as desired. The flip-flop circuit can be tuned to ensure that the sensor 66 has actually touched the particles 21 so as not to give false particle level indications.
Operation:
[0052] In order to operate this loading arrangement 24 , the dispensing bin 32 is loaded with particles 21 , the funnels 54 are aligned with and inserted into the tubes 16 b to be loaded within the row 116 b , and a button is pushed to turn the device on to begin loading. This causes the central processor to turn on the motor 52 and slide the shut-off plate 44 outwardly, as shown in FIG. 2B , to create the desired size of opening for dispensing the particles from the bin 32 . The particles 21 fall onto the conveyor belt 34 , being divided into separate, substantially equal volume streams by the dividers 38 and the vibrating weir 47 . The height of the weir 47 above the belt 34 preferably is adjusted to allow only a single layer of particles to continue on the belt 34 in order to help ensure a uniform density of particles 21 to permit each funnel 54 to feed its corresponding tube 16 b without causing bridging in the tube 16 b . Any excess particles 21 rejected by the weir 47 will fall into the collection bin 40 for later reuse.
[0053] As the particles 21 reach the end of the belt 34 , they fall off the end of the belt 34 and into the funnels 54 . The particles 21 then flow through the funnels 54 and into the respective tubes 16 b.
[0054] The central controller is programmed to close the plate 44 and stop the belt 34 at a preset time before loading is completed. Preferably, the time is set to correspond with the tubes 16 being loaded approximately to 80%-90% completion. Then, the central controller causes an elevation measurement of the particles 21 to be taken in each tube 16 b that is being loaded. In this embodiment, this measurement is accomplished by lowering a sensor 66 into each tube 16 b being loaded. As the cable 62 plays out, the encoder 64 keeps track of how much cable 62 has played out so as to determine the exact position of the sensor 66 at all times. Once the sensor 66 makes contact with the particles 21 in the tube 16 b (See FIG. 4B ), the spring 74 is deflected until it makes contact with the pin 80 (See FIG. 4D ), signaling the central processor that the sensor has reached the elevation of the particles 21 in the tube 16 b . The central processor captures the length of cable 62 which has been played out as indicated by the encoder 64 , which corresponds to an elevation of particles 21 in the tube 16 b.
[0055] Based on the feed rate (indicated by the sensed position of the plate 44 ) and the time it took to reach that elevation, the processor calculates what is needed to complete the loading of the tube 16 b to the desired target elevation. This calculation can be as simple as a calculation of how much longer the belt 34 has to run in order to complete loading that tube, or it can calculate both a new feed rate as well as an additional time based on this new feed rate. Therefore, the calculation may assume either a constant feed rate of the particles or an adjustable feed rate. In both instances, the feed rate is a controlled feed rate. It generally is preferable to maintain a constant feed rate.
[0056] Then, the central controller causes the elevation sensor 66 to be pulled out of the tube 16 b by reversing the direction of rotation of the reel 60 , and, once the elevation sensor 66 is out of the way (as shown in FIG. 2B ), the central controller causes the belt 34 to begin moving again and the plate 44 to be slid open again, to resume loading particles 21 . As the remaining time for each tube 16 b elapses, the controller causes its respective actuator 56 to actuate its respective diverter plate 58 (as shown in FIG. 6 ), altering the particle flow path from the original path, which sent particles from the bin 32 to the tube 16 b , to a second path, diverting those particles to the collection bin 40 , which stops the loading for that tube 16 b , while the conveyor belt 34 continues to run and one or more other tubes continue to be loaded. Once the calculated time has elapsed for all the tubes 16 b being loaded, the central controller causes the plate 44 to be closed and the belt 34 to be stopped.
[0057] The central controller may then cause the elevation sensors 66 to be lowered again to measure the elevation of particles 21 in each tube 16 b to ensure that the tubes are loaded to the correct elevation. If more loading is needed, the central controller may cause loading to continue for one or more tubes, as desired, with the other lanes having their diverter plates 58 actuated. Since it is easy to correct by adding particles and more difficult to correct by removing particles, this system may be deployed conservatively to avoid overloading.
[0058] The particles in the collection bin 40 may periodically be poured into the dispensing bin 32 by manually opening the lid 84 , pouring in the particles, and then closing the lid 84 .
[0059] Once the correct elevation of particles has been reached in all the tubes 16 b , the central controller causes the funnels 54 to be raised. The operator then positions the loading device over the next group of tubes 16 a to be loaded, the funnels 54 are lowered, and the process is repeated until all the tubes are loaded to the desired elevation.
[0060] Laser tracking of the position of the loading device 24 may be done automatically as part of the automated sequence by means of a laser measuring device mounted on the loading device 24 . The laser measuring device reflects a light beam off of a reflector at a known position within the reactor vessel and the distance to the reflector is used to automatically determine the position of the loading device 24 and which tubes are being loaded. The elevation measurement data, loading times, plate position, belt speed, and other related data may be associated with and recorded for each tube in a similar manner to that in which the position and data were recorded for the tubes in U.S. Pat. No. 6,725,706, which is hereby incorporated herein by reference. This device also may transmit its data to a remote location in real time, as described in that referenced patent, and the data for each tube may be reported graphically at the remote location as described in that patent. The process described above may be repeated for each layer of particles in the tubes 16 .
[0061] The device described above may be mounted on wheels, on a skid plate, or in some other manner that permits it to be supported on the upper tube sheet 12 and moved from place to place along the upper tube sheet 12 . It also may have locator pins (not shown) that may be inserted into holes in the tube sheet 12 in order to help align it with the tubes to be loaded. Alternatively, the funnels 54 may be used to align the device 24 with the reactor tubes. It should be noted that, once the particle loading arrangement 24 (or any of the alternate embodiments described herein) has been aligned with a row of tubes, the operator just pushes a button (or otherwise signals the processor) to begin the sequence which will automatically run, with no further input required from the operator, until the particle loading arrangement 24 has properly filled that batch of tubes.
[0062] It should also be noted that, if for any reason a tube 16 b in a row 116 b is not to be loaded with particles (for instance, the tube 16 b may have been permanently plugged, it may need to be hand loaded because it is a thermocouple location, or it may correspond to a tubesheet support), then the diverter plate 58 associated with that particular tube 16 b may be left in the diverting position shown in FIG. 6 to divert the particles away from the tube 16 b and into the collection bin 40 while the other tubes in the group are being loaded.
Alternate Embodiments
[0063] FIGS. 12 , 13 , and 14 depict an alternate embodiment of a particle loading arrangement 24 ′ made in accordance with the present invention. A comparison of FIG. 12 with FIG. 2B shows that the difference is that in this embodiment the measuring system 36 has been repositioned from a position that is substantially vertically above the actuator 56 in FIG. 2B to a position that is at a lower elevation than the actuator 56 and is offset forward of the actuator 56 .
[0064] This reconfiguration allows the sensor 66 to be deployed to take a reading of the particle elevation in the tube 16 b being loaded without interrupting the flow of particles from the dispensing bin 32 or along the conveyor belt 34 . As shown in FIG. 13 , when it is desirable to check the elevation of particles 21 in the tube 16 b , the controller causes the actuator 56 to move the diverter plate 58 such that the diverter plate 58 deflects the particles falling from the conveyor belt 34 away from the funnel 54 and into the collection bin 40 . In this embodiment, the cable 62 that is connected to the elevation sensor 66 extends through a pulley mounted on the diverter plate 58 , so that movement of the diverter plate 58 to the deflection position depicted in FIG. 13 also places the sensor 66 in a position directly above the funnel 54 .
[0065] Therefore, in this embodiment of a loading arrangement 24 ′, the flow of particles 21 from the dispensing bin 32 and the flow of particles on the conveyor belt 34 are never disrupted or changed. Instead, when it is time to take a reading of the elevation of the particles 21 in the tube 16 b , the path of the particles is altered from a first path, which led from the bin 32 to the tube 16 b , to a second path, which sends the particles 21 away from the tube 16 b and to a collection bin 40 . In this embodiment 24 ′, this is accomplished by a diverter plate 58 which simultaneously diverts the particles 21 to the collection bin 40 and places the sensor 66 is position to be deployed into its respective tube 16 b . (As will be appreciated in embodiments described later, other means may be used to alter the path of the particles 21 away from the inlet of the tube 16 b .)
[0066] In FIG. 14 , the elevation sensor 66 has been deployed to measure the elevation of particles 21 in the tube 16 b . The shut-off plate 44 in the dispensing bin 32 is still in its open position, allowing particles 21 to continue to flow onto the conveyor belt 34 . Furthermore, the particles 21 continue to flow along the conveyor belt 34 , but the particles for this particular lane are now being diverted into the collection bin 40 by their respective diverter plate 58 . This allows the elevation of particles 21 in the tube 16 b to be measured without changing any of the settings. This helps maintain a constant feed rate of the particles 21 in the loading arrangement 24 ′ so that, once the diverter plate 58 is returned to its non-diverting position, the particles 21 will resume being fed at the same rate as before, with no change at start-up that might occur if the belt had been stopped and started instead of just diverting the flow of particles. This also allows the elevations of different tubes to be measured at different times, as desired, while particles continue to flow along with the moving belt 34 .
Operation of this Alternate Embodiment
[0067] In order to operate this loading arrangement 24 ′, the dispensing bin 32 is loaded with particles, the funnels 54 are inserted into the tubes 16 b to be loaded within the row 116 b , and the motor 52 is turned on. The shut-off plate 44 is slid outwardly, as shown in FIG. 12 , to create the desired size of opening for dispensing the particles from the bin 32 , and the particles fall onto the conveyor belt 34 , being divided into separate, substantially equal volume streams by the dividers 38 and vibrating weirs 47 .
[0068] If desired, a constant flow rate of the particles 21 may first be established by diverting the particles 21 into the collection bin 40 for a period of time before beginning to load the tubes. (This could be done in other embodiments, as well, if desired.) Once a constant flow rate has been established, the diverter plates 58 are moved to their vertical, non-diverting position (as shown in FIG. 12 ), and the particles begin to flow into the tubes 16 b.
[0069] The central controller starts a timer the instant the diverter plates 58 are shifted to the non-diverting position to allow the particles 21 to flow into the tubes 16 b . After a user-determined amount of time has elapsed (estimated to be the amount of time required for the tubes 16 b to be 80% to 90% loaded), the actuators 56 move the diverter plates 58 so as to divert the particles 21 into the collection bin 40 , and a sensor 66 is reeled down into its respective tube at each tube location to take a measurement reading of the elevation of particles 21 in each respective tube 16 b . These readings are compared with the desired setpoint elevation, and an algorithm converts the ratio (of actual reading to desired reading) into a very accurate estimate of the additional loading time required, at the constant flow rate, to reach the desired setpoint for each tube 16 b . That is, based on the time it took to reach that elevation, the computer calculates how much longer the particles must continue to flow in order to complete loading each individual tube. Each diverter plate 58 corresponding to each tube 16 b which is being loaded is then returned to its vertical, non-diverting position (as shown in FIG. 12 ) to allow particles 21 to continue to be loaded in the tube 16 b for the calculated additional loading time required to reach the fully loaded condition.
[0070] Since, in this operating condition, the position of the shut-off plate 44 and the speed of the conveyor belt 34 remain unchanged, the particle flow rate remains constant, so the calculation as to the remaining time required to reach the setpoint (the desired elevation) for each tube 16 b can be made very precisely, very accurately, and with a very high degree of repeatability.
[0071] As the remaining time for each tube 16 b elapses, its respective actuator 56 actuates its respective diverter plate 58 back to the diverting position shown in FIG. 13 , stopping the loading for that tube 16 b and diverting the particles 21 for that particular tube 16 b into the collection bin 40 . At that point, the sensor 66 for that tube 16 b may be lowered again to measure the elevation of particles in that tube to ensure that the tube is properly loaded. If additional loading is needed, the diverter plate 58 may be returned to the non-diverting position, and loading may continue for a desired period of time. Once it is confirmed that the correct elevation of particles 21 has been achieved for each tube 16 b being loaded, the plate 44 is closed and the belt 34 is stopped.
[0072] An algorithm may be used by the central controller to compare the particle elevation of each tube 16 b (either in the intermediate measurement or at the final measurement elevation, or both) against one or more parameters (such as the overall mean, the highest elevation, the lowest elevation, the elevation of the adjacent tubes, etc.) and, if a deviation of more than a target amount (for instance, a deviation from the overall mean of more that 5%) is detected, a warning may be raised to flag the particular tube with an out-of-range reading. For instance, an excessively low reading could indicate an “open tube” condition wherein the retaining spring at the bottom of the tube was inadvertently omitted, causing the particles to fall right through the problem tube. Likewise, an excessively high reading may indicate a partially plugged tube or a tube which has experienced a bridging of the particles as it is being loaded into the problem tube.
[0073] If the position of the shut-off plate 44 is consistently open to the same extent, and the speed of the conveyor belt 34 is also consistently set at the same speed, then the steady state flow rate should also be very consistent and repeatable as the loading arrangement 24 ′ is moved from one row of tubes 116 b to the next row of tubes 116 a . In this instance, the calculations to compare the particle elevation in the tubes 16 b may be made not only against the other tubes being loaded at the same time, but also against the tubes that were loaded previously or even against the entire population of tubes being loaded, even if other tubes are being loaded by a different loading arrangement 24 ′ (as long as its settings of conveyor belt 34 speed and shut-off plate 44 opening are the same).
[0074] FIGS. 15 and 16 depict an alternate embodiment of a loading arrangement 24 ″ made in accordance with the present invention. This new embodiment 24 ″ is very similar to the embodiment 24 described earlier and depicted in FIGS. 2B and 5 . The most significant difference is that the funnel 54 ′ is much taller, reaching almost to the point where the particles 21 fall off of the conveyor belt 34 . Furthermore, the funnel 54 ′ is skewed to the right, and it incorporates the actuator 56 ′ and the diverter plate 58 ′ right into the funnel 54 ′.
[0075] The operation of this loading arrangement 24 ″ is quite similar to that of the loading arrangement 24 ′ described earlier, in that the shut-off plate 44 in the dispensing bin 32 and the conveyor belt 34 may continue to operate during the process of taking an elevation measurement of the particles 21 in the tube 16 b being loaded, as depicted in FIG. 16 . The path of the particles 21 is altered by opening the side of the funnel 54 ′, in a manner similar to that of a trap door by having the actuator 56 ′ move the diverter plate 58 ′ to the lowered position which allows the particles 21 to fall through the opening on the side of the funnel 54 ′ and into the collection bin 40 . This clears the way for the sensor 66 to be deployed into the tube 16 b being loaded without the particles 21 interfering with the deployment, even though the steady state flow of the particles 21 remains uninterrupted.
[0076] FIG. 19 depicts yet another embodiment of a loading arrangement 24 * made in accordance with the present invention. This embodiment 24 * is quite similar to the loading arrangement 24 ″ disclosed above, with the most significant difference being the elimination of the actuator 56 ′ and of the diverter plate 58 ′. In this embodiment 24 * the funnel 54 * is simply shifted such that the skewed portion of the funnel 54 * faces away from the conveyor belt 34 during the process of taking a measurement of the elevation of particles 21 in the tube 16 b being loaded. The particles 21 simply fall directly into the collection bin 40 so as not to interfere with the deployment of the sensor 66 , even though the steady state flow of the particles 21 remains uninterrupted, as was the case with the loading arrangement 24 ″.
[0077] The shifting of the skewed portion of the funnel 54 * may be accomplished by any number of means. For instance, the funnel 54 * may be rotated 180 degrees about its longitudinal axis to obtain the desired configuration. This could be achieved by a rotary actuator or manually. It is preferable for the movement to be automated so it can be controlled by the central controller in order for the central controller to accurately know the time period during which the tube is being filled. In another example, the conical mouth of the funnel 54 * may be hinged (like an accordion-like hinge of a drinking straw) at its stem to allow the funnel 54 * to shift (from the position shown in FIG. 15 to that shown in FIG. 19 ) without having to move its stem. The funnel 54 * could then be shifted automatically, as desired, by a mechanical linkage (not shown) or even by a non-mechanical linkage (such as by a puff of air, or by magnetic attraction and repulsion).
[0078] The operation of this loading arrangement 24 * is substantially the same as that for the loading arrangement 24 ″ described earlier. The main difference is in the mechanism for altering the path of the particles 21 . In this embodiment 24 *, the mechanism for altering the path is simply the removal of a part of the original path to allow the particles 21 to fall directly into the collection bin 40 .
[0079] FIGS. 17 and 18 depict an alternate of a sensor 66 ′ which may be used instead of the sensor 66 described above. The wire cable 62 includes a ground 68 ′ and a power cable 70 ′ which support a housing 78 ′. A guide 72 ′ is mounted to the housing 78 ′ and guides a rod 76 ′ for vertical movement relative to the housing 78 ′. A shorting plate 74 ′ is mounted on the rod 76 ′ for movement with the rod 76 ′, and a shorting pad 80 ′ is fixed within the housing 78 ′. The lowermost tip 82 ′ of the rod 76 ′ may be enlarged as shown to provide a larger surface for contacting the particles 21 and to provide protection for the rod 76 ′.
[0080] As the sensor 66 ′ is being lowered into the reactor tube 16 b , the rod 76 ′ is in its lowermost position relative to the housing 78 ′, with the shorting plate 74 ′ resting on the shorting pad 80 ′ to complete the circuit. When the lowermost tip 82 ′ of the rod 76 ′ contacts the particles 21 within the tube 16 b (as shown in FIG. 18 ), the rod 76 ′ moves upwardly relative to the housing 78 ′, thereby breaking the contact between the shorting plate 74 ′ and the shorting pad 80 ′. The opening of this switch is registered by the central controller. The central controller then reverses the direction of rotation of the reel 60 , raising the sensor 66 ′ until the shorting plate 74 ′ again contacts the shorting pad 80 ′, closing the switch and serving as a trigger responsive to the sensor contacting the particles in the tube. The position that is indicated by the encoder 64 when the switch closes is recorded and indicates the elevation of particles 21 in that tube 16 b . It may therefore be seen that the operation of the measuring system 36 is substantially the same regardless of whether the sensor 66 or 66 ′ used.
[0081] FIGS. 20-22 show how the dispensing bin 32 may actually be a catalyst container, which may be provided by the catalyst manufacturer and shipped to the customer packed with catalyst. This helps minimize handling of the catalyst particles, which is desirable since the catalyst can be friable and abrasive, and unnecessary handling can result in excessive dust and fines which can undesirably restrict gas flow in a given tube as well as creating other process problems such as localized and destructive exothermic heating. In this embodiment, the container 32 is a rectangular box with a lid 84 . (The container could be cylindrical or have other shapes, in which case the shapes of the mating parts would be changed accordingly.) In order to use the container 32 as a dispensing bin, it is flipped upside down and the bottom is removed, with a can opener for instance, and the magazine 86 is secured to the open end of the container 32 by means of a strap 88 . The magazine 86 includes the rail 42 and the guillotine plate 44 , which were described earlier.
[0082] The dispensing bin/container 32 is then flipped right side up and, with the strap 88 keeping the magazine 86 secured over the open bottom of the bin, it is lowered into magazine support panel 43 , which is shown in FIG. 2A .
[0083] It will be obvious to those skilled in the art that modifications may be made to the embodiments described above without departing from the scope of the present invention. For instance, even though the description refers to taking particle elevation readings at approximately 80% to 90% of the desired final elevation, any number of intermediate particle elevation readings may be taken, and these readings may be at any desired estimated “percentage complete” elevation. Also, as was indicated earlier, some of the components of the particle loading arrangement may be installed outside the reactor vessel 10 , and the collection bin 40 may be replaced by a second conveyor belt to take any diverted particles to another location, such as back into the dispensing bin or out of the reactor vessel 10 .
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A measurement device for measuring the elevation of particles in a vertical tube, including a reel, means for driving said the in forward and backward directions, a cable wound onto the reel and having a free end, a sensor mounted on the free end of the cable, the sensor including a particle contact portion, and trigger means responsive to the particle contact portion's contacting the particles in the tube.
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BACKGROUND OF THE INVENTION
Some trace elements are important for normal bodily functions. In the event of deficiency symptoms, the targeted supply of trace elements beyond the amounts taken in with the customary diet is required or at least desirable. Deficiency symptoms of this type can occur in the case of malnutrition, but also in the case of disturbed absorption due to physical malfunctions. Sufficient supply with trace elements is important not only in the case of humans, but also in animal growth. Trace elements and their importance are described, for example, in Römpp Chemie Lexikon [Römpp's Chemistry Lexicon], 9th edition, under this headword. These trace elements include, in particular, iron, zinc, copper, manganese and cobalt.
However, it is a problem for sufficient supply of trace elements, in particular in the form of their salts, that many salts of these trace elements taste unpleasant, even in small amounts, and in particular have an astringent taste. Incorporation of compounds of these trace elements into suitable foods, medicaments or feeds and supply via specific preparations can therefore be difficult owing to lack of acceptance by humans and animals. Provision in a pleasant-tasting form would markedly improve the targeted application in foods, medicaments and feeds.
It has now been found that the known sweetener acesulfame (6-methyl-3,4-dihydro-1,2,3-oxathiazin-4-one 2,2-dioxide), which has hitherto only been offered as potassium salt (acesulfame-K) and of which salts with alkali metals and alkaline earth metals, for example sodium salts, potassium salts, magnesium salts and calcium salts, the acid-reacting acesulfame itself, which represents acesulfamic acid, and some amine salts are known, forms with these elements stable complexes, preferably with in each case two acesulfame anions per metal atom. These complexes are surprisingly distinguished by a pleasantly sweet taste from which the astringent note of many salts of these trace elements is absent.
BRIEF DESCRIPTION OF THE INVENTION
The present invention thus comprises complex compounds of the trace elements, preferably of the metallic trace elements, for example iron, copper, zinc, chromium, selenium, cobalt, molybdenum, silicon, manganese, nickel, vanadium and boron, in particular preferably zinc, copper, iron, manganese and cobalt, with acesulfame. These are preferably metal complexes of acesulfame which are composed of one trace element metal and 2 acesulfame molecules and which, in addition, if appropriate can contain water of crystallization. These are defined compounds of which the metal is present in the cationic form and the acesulfame molecules are present in the anionic form.
DETAILED DESCRIPTION OF THE INVENTION
By means of the fact that the trace elements or metal cations in these complexes are preferably bound as salts, they are bioavailable after solvolysis by water and can be absorbed as such by metabolism.
These complexes can be used without problems in the customary processing steps of foods and production of preparations for supplementing the diet, or used in medicaments and cosmetic compositions, for example toothcare and oralcare compositions or in feeds or as feed additives, for example in the form of a premix. Processing is simple and is performed by known methods. In the case of solid preparations, the inventive complexes are mixed in solid form, if appropriate in suitable particle size, with the other ingredients. For use in tablets, compressed compositions and comparable products and pulverulent preparations, they can be granulated together with other ingredients suitable for this and further processed as granules. Owing to their good solubility, however, they can also readily be used in liquid products from the said fields or processed in the form of their aqueous solutions.
The present invention thus also comprises the use of the inventive acesulfame-trace element complexes as food supplements or food additives and their use in medicaments, feeds or cosmetic compositions, for example toothcare or oralcare compositions, in any form suitable therefor, for example as solid preparations in the form of, for example tablets, capsules, compressed compositions, granules, solid premix, pulverulent preparations or as liquid preparations, for example solutions, preferably aqueous solutions or liquid premix.
Finally, the present invention also relates to a process for preparing the inventive complex compounds. The acesulfame or its potassium salt, acesulfame-K, serving as starting substance, are commercially available or can, as can other desired acesulfame salts, be prepared by the process described in EP-A 0 155 634.
To prepare these complexes a process is used by which other ionic constituents of the starting materials suitable for the preparation may be eliminated. This can be achieved either by separating off sparingly soluble compounds of the other ionic constituents or by using starting materials in which from the start only trace elements and acesulfame remain in a solution from which the complexes are isolated in a suitable manner. This process comprises
reacting salts of acesulfame, whose cations form suitable sparingly soluble compounds which may be precipitated, in particular the calcium salt but also the barium salt of acesulfame, with soluble salts of the trace elements whose anions form sparingly soluble compounds with the cations of the acesulfame salt, for example sulfates or
reacting basic carbonates of the trace elements with acesulfamic acid (acesulfame) with release of CO 2
in which precipitates formed in each case are if appropriate separated off before the desired acesulfame complexes are isolated. This isolation is preferably achieved by crystallization, for example by evaporation of the solvent, preferably water or water-miscible solvents, or by adding water-miscible solvents to the reaction mixture. Preferred water-miscible solvents are, for example alcohols.
The acesulfame salts serving as starting materials of the reaction can be introduced, for example, as aqueous solution or else formed in what is termed a one-pot reaction from acesulfame and a suitable alkaline earth metal carbonate (Ba, Ca salt) before addition of the trace element salt.
The invention is described in more detail by the examples below without thereby restricting its extent:
The invention is described by the following examples:
EXAMPLE 1
Acesulfame-zinc Complex
Method 1
20 mmol (3.947 g) of sparingly soluble barium carbonate (or 20 mmol of calcium carbonate) are introduced into 20 ml of water and 40 mmol (6.525 g) of acesulfame-H are added. After CO 2 formation has ended, a homogeneous solution is obtained from which sparingly soluble barium sulfate (or calcium sulfate) is precipitated out by 20 mmol (0.575 g) of zinc(II) sulfate heptahydrate. After filtering off the precipitate and concentrating the solution, the acesulfame-zinc complex crystallizes out in the form of colorless crystals with 97% yield.
Method 2
10 mmol (3.42 g) of sparingly soluble basic zinc carbonate hydrate (ZnCO 3 .2Zn(OH) 2 .H 2 O) are introduced into 20 ml of water and 60 mmol (9.789 g) of acesulfame-H are added. After CO 2 formation has ended, a homogeneous solution is obtained. The acesulfame-zinc complex crystallizes out, after concentrating the solution, in the form of colorless crystals with 99% yield.
The acesulfame-zinc complex decomposes at 255° C.
The crystal structure of the acesulfame-zinc complex was established by X-ray structural analysis.
(Ace) 2 Zn, 2C 4 H 4 NO 4 S.Zn.2H 2 O, M r =425.69, monoclinic, C2/c, a=12.907(4), b=5.584(2), c=21.222(8) Å, β=91.31(3)°, V=1529.2(8) Å, Z=4, D x =1.849 Mg m −3 , λ (Mo−Kα)=0.71073 Å, μ=1.932 mm −1 , F(000)=864, T=293(2) K, R=0.0235 and R W =0.0649 for I>2δ(I) (1356 reflections), R=0.0255 and R W =0.0669 for all 1436 unique CCD data. Σ(F o 2 −F c 2 ) 2 was minimized.
EXAMPLE 2
Acesulfame-copper complex
Method 1
20 mmol (3.947 g) of sparingly soluble barium carbonate (or 20 mmol of calcium carbonate) are introduced into 20 ml of water and 40 mmol (6.525 g) of acesulfame-H are added. After CO 2 formation has ended, a homogeneous solution is obtained from which sparingly soluble barium sulfate (or calcium sulfate) is precipitated out by 20 mmol (0.499 g) of copper(II) sulfate pentahydrate. After filtering off the precipitate and concentrating the solution, the acesulfame-copper complex crystallizes out in the form of blue crystals with 96% yield.
Method 2
10 mmol (2.21 g) of sparingly soluble basic copper carbonate (CuCO 3 .Cu(OH) 2 ) are introduced into 20 ml of water and 40 mmol (6.526 g) of acesulfame-H are added. After CO 2 formation has ended, a homogeneous blue solution is obtained. The acesulfame-copper complex crystallizes out in the form of blue crystals with 98% yield after concentrating the solution.
The blue acesulfame-copper complex decolorizes at 117° C. and decomposes at 179° C.
The crystal structure of the acesulfame-copper complex was established by X-ray structural analysis.
(Ace) 2 Cu, 2C 4 H 4 NO 4 S.Cu.3H 2 O, M r =441.87, monoclinic, C2/c, a=19.30(2), b=9.677(9), c=9.007(8) Å, β=102.92(2)°, V=1640(3) Å 3 , Z=4, D x =1.790 Mg m −3 , λ (Mo−Kα)=0.71073 Å, μ=1.645 mm −1 , F(000)=900, T=293(2) K, R=0.0371 and R W =0.0753 for I>2δ(I) (1251 reflections), R=0.0440 and R W =0.0791 for all 1448 unique CCD data. Σ(F o 2 −F c 2 ) 2 was minimized.
The other acesulfame-trace element metal complexes, for example manganese-acesulfame, cobalt-acesulfame and iron-acesulfame complexes, may be prepared in a similar manner.
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Acesulfame-metal complexes, formed from a trace element, preferably Fe, Zn, Cu, Mn, Co and 2 molecules of acesulfamic acid by precipitation reaction with the use of suitable salts, are distinguished by a pleasantly sweet taste and are therefore suitable as sweeteners, food supplements and for enrichment of food, medicaments and feeds with trace elements.
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CLAIM OF PRIORITY
The present application claims priority from Japanese application serial no. 2005-371282, filed on Dec. 26, 2005, the content of which is hereby incorporated by references into this application.
BACKGROUND OF THE INVENTION
1. Field of Technology
The present invention relates to a decentralized solution of microscopic particles including nano-particle clusters and to a circuit formation device by using the decentralized solution of microscopic particles.
2. Background of Art
A conventional general method of forming arbitrary conductive patterns on a circuit board or the like is a method in which lithography technology, etching technology, and plating technology are combined. This method requires a mask for exposure that needs much time in designing and preparation as well as advanced machining technique. In addition, since a series of processes are complex, a long preparation time is needed, resulting in a high cost. If it becomes necessary to modify the mask in, for example, limited production of a wide variety of products, a high cost, delayed delivery, and other problems occur. The use of large quantities of materials hazardous to the environment, such as resists and etching solutions, is indispensable, so extra costs have been needed in management and processing of waste materials.
In other proposed conductive pattern forming methods in which processes are simple, printing processes that use a conductive microscopic particle decentralized solution, in which conductive microscopic particles, binder resin, and other materials are decentralized in a solvent, are used; the printing processes include a screen printing process, a dispenser printing process, an ink jet printing process, and an electrophotography process. These methods achieve simple processes because of less steps, use less materials, and produces less waste materials, so they are expected as processes that greatly reduces costs.
In the printing processes in which conductive patterns are formed by using a conductive microscopic particle decentralized solution in which conductive microscopic particles are decentralized, however, distances among microscopic particles in the conductive microscopic particle decentralized solution become large. As a result, when conductive wires are formed by, for example, heating, many voids are generated and thereby the wires become more resistive and are weakened in strength. To reduce the heating temperature when wires are formed, nano-scale microscopic particles having a property for reducing a melting point may be used in the conductive microscopic particle decentralized solution used in the printing process. In this case, however, the primary particle diameters of the above nano-scale microscopic particles are small, so the thickness of a film formed in one printing is small. To achieve the desired wire film thickness, films have to be laminated by repeating patterning, which may reduce the productivity.
To address these problems, a method was studied in which clustered conductive microscopic particles, for example, are used to reduce the resistance by shortening the distances among the conductive microscopic particles in advance (Patent Document 1).
Patent Document 1: Japanese Application Patent Laid-open Publication No. 2003-288812
SUMMARY OF THE INVENTION
Problems to be Solved by the Invention
Even if the clustered conductive microscopic particles shown in Patent Document 1 are used, there are still problems; the resolution of a wire pattern obtained from microscopic particles having larger diameters is lowered, and the ratio of voids in the pattern is increased due to the larger microscopic diameters so that a thickness of a film is reduced after heating and fusing.
The present invention addresses these problems with the object of providing a conductive microscopic particle decentralized solution that enables the forming of low-resistance patterns with thick films at high speed and at low heating temperature, without reducing the resolution.
To achieve the above object, instead of using a conductive microscopic particle decentralized solution in which only microscopic particle clusters decentralize, as in conventional methods, the present invention uses a conductive microscopic particle decentralized solution which has two granularity distribution peaks satisfying the following relationships; R>r and n>3.84×(R/r) 3 ×N, where R is a large particle diameter (of a microscopic particle cluster), r is a small particle diameter (of a microscopic particle), N is the number of large particles, and n is the number of small particle.
When a conductive microscopic particle decentralized solution according to the present invention is used in a printing process, a fine, low-resistance conductive pattern with a high thickness is obtained at high speed and at low heating temperature, without lowering the resolution.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 schematically shows a conductive microscopic particle decentralized solution, including clusters, according to the present invention.
FIG. 2 schematically shows a conductive particle having low-molecular weight organic molecules shown in FIG. 1 .
FIG. 3 schematically shows a large-diameter particle which is a cluster of small-diameter particles shown in FIG. 1 .
FIG. 4 schematically shows a large-diameter particle having a layer of small-diameter particles on the surface shown in FIG. 1 .
FIG. 5 schematically shows an embodiment of a circuit formation device according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
An embodiment of the present invention will be described below in detail.
FIG. 1 shows a form of a conductive microscopic particle decentralized solution 4 proposed in the present invention. As shown in FIG. 1 , in the conductive microscopic particle decentralized solution 4 proposed by the present invention, large-diameter particles 1 and small-diameter particles 2 decentralize concurrently in a decentralized solution 3 . That is, the conductive microscopic particle decentralized solution 4 has two peaks in its granularity distribution, at a large diameter and a small diameter. The large-diameter particles 1 contribute to obtaining a higher thickness and increasing a pattern forming speed in conductive pattern formation, and the small-diameter particles 2 contribute to lowing the resistance of the conductive pattern and increasing the strength thereof in conductive pattern formation because the resolution is increased and the density of the conductive pattern is increased by filling voids generated by deposited large-diameter particles 1 .
When the diameter of a large-diameter particle 1 in the inventive conductive microscopic particle decentralized solution 4 is R, and the diameter of a small-diameter particle 2 is r, the following relational expression (1) holds.
R>r (1)
When the number of large-diameter particles 1 is N, and the number of small-diameter particles 2 is n, if the following relational expression (2) is satisfied, the number of voids in a formed pattern is minimized.
n> 3.84×( R/r ) 3 ×N (2)
Assuming that all particles are spherical, the relational expression (2) represents a condition for the number n of small-diameter particles 2 required to fill, with small-diameter particles 2 , 24% of the voids generated when large-diameter particles 1 are supplied with a maximum filling factor so as to further lower the density.
The diameter r of the small-diameter particle 2 is preferably smaller than the diameter R of the large-diameter particle 1 by at least one order of magnitude.
FIG. 2 shows details of the small-diameter particle 2 in the inventive conductive microscopic particle decentralized solution 4 shown in FIG. 1 . The diameter of the inventive small-diameter particle 2 is 100 nm or less so as to provide a melting point lowering property and achieve a high resolution. To enable fusion by heating at a temperature of 200° C. or below, the diameter is preferably 10 nm or less. To form a conductive pattern with a line width of 100 nm or less, the diameter is further preferably 5 nm or less.
On the surface of a small-diameter particle nucleus 8 , a decentralizer layer 7 is formed to prevent excessive clustering. When the decentralizer 7 comprises a high polymer, the high polymer is a homopolymer or copolymer of styrene or its replacement body, such as polystyrene, poly-p-chlorstyrene, polyvinyl toluene, a styrene-p-chlorstyrene copolymer, or a styrene-vinyl toluene copolymer; a copolymer obtained from styrene and acrylic ester, such as a styrene-methyl acrylate copolymer, styrene-ethyl acrylate copolymer, or styrene-n-butyl acrylate copolymer; a copolymer obtained from styrene and methacrylic ester, such as styrene-methyl methacrylate copolymer, styrene-ethyl methacrylate copolymer, or styrene-n-butyl methacrylate copolymer; a multi-dimensional copolymer obtained from styrene, acrylic ester, and methacrylic ester; another styrene-based copolymer obtained from styrene and another vinyl-based monomer, such as styrene-acrylic nitrile copolymer, styrene-vinyl methyl ether copolymer, styrene-butadiene copolymer, styrene-vinyl methyl ketone copolymer, or styrene-ester maleate; or single or mixed high-polymer resin with a carboxylic acid group, an amino acid group, or another functional group to which ionicity can be added, the resin being, for example, methacrylic ester resin such as polymethyl methacrylate or polybutyl methacrylate, acrylic ester resin such as methyl polyacrylate, ethyl polyacrylate, or butyl polyacrylate, polyester resin, epoxy resin, or a cycloolefin copolymer.
A low-molecular weight organic molecule 5 is, for example, an aliphatic carboxylate inorganic salt that consists of the low-molecular weight organic molecule 5 and an inorganic ion 6 such as Ag, Cu, Au, Pd, Pt, Ni, W, Mo, or Cr, the aliphatic carboxylic acid being dicarboxylic acid such as oxalic acid, malonic acid, succinic acid, adipic acid, glutaric acid, 2,4-diethyl glutaric acid, pimelic acid, azelaic acid, sebacic acid, cyclohexane dicarboxylic acid, maleic acid, fumaric acid, or diglycolic acid, fatty acid such as caprylic acid, lauric acid, myristic acid, palmitic acid, stearin acid, arachidic acid, behenic acid, linolic acid, oleic acid, or linolenic, acid, or hydroxycarboxylic acid such as lactic acid, hydroxy pivalic acid, dimethylol proprionic acid, citric acid, malic acid, or glyceric acid. If the amount of organic molecules in the conductive pattern is reduced to obtain a low resistance and heating is performed at a low temperature to form a conductive pattern on a resin board such as a polyimide board, the latter low-molecular weight organic molecule 5 is preferably used, as shown in FIG. 2 .
FIG. 3 shows details of the large-diameter particle 1 in the inventive conductive microscopic particle decentralized solution 4 shown in FIG. 1 . The inventive large-diameter particle 1 is a cluster in which two or more small-diameter particles 2 are aggregated so as to maintain the low-melting point property, as shown in the figure to the right. A decentralizer 7 is applied to the surface of each small-diameter particle 2 . Since the decentralizer 7 may be applied uniformly or nonuniformly, small-diameter particles 2 having a nonuniformly applied decentralizer 7 aggregate, resulting in a cluster of small-diameter particles 2 . Accordingly, an extremely large number of clusters are not formed. In addition to a cluster of small-diameter particles, a structure in which small-diameter particles 2 are attached to the surface of a bulky large-diameter particle nucleus 9 to form a layer, as shown in FIG. 4 , is also allowed. In this case, the diameter of the large-diameter particle 1 is preferably 10 μm or less to achieve wiring in the order of micrometers.
In the present invention, the large-diameter particle nucleus 9 of each large-diameter particle 1 and the small-diameter particle nucleus 8 of each small-diameter particle 2 may be a single metal such as Ag, Cu, Au, Pd, Pt, Ni, W, Mo, or Cr, its oxide, or its alloy. When a conductive body is formed, however, Ag or Cu, which has a low volume resistivity, is preferably used. A mixture of conductive particles described above may be used.
Any type of decentralized solution may be used as the decentralized solution 3 in the present invention if microscopic particles can be stably decentralized in the decentralized solution. To achieve quick evaporation, however, the boiling point of the decentralized solution is preferably 250° C. or less. When the decentralized solution 3 is used for electrophotography, the solvent of the decentralized solution 3 must be a nonpolar solvent so that an electrostatic latent image 14 is not deleted. The nonpolar solvent is preferably an aliphatic hydrocarbon solvent such as, for example, isoparaffin, petroleum naphtha, Isopar from Exxon, IP Solvent from Idemitsu Kosan, Soltol from ConocoPhillips, or another hydrocarbon.
Next, a circuit formation device using static electricity will be described as an example of the inventive circuit formation device using the conductive microscopic particle decentralized solution 4 .
FIG. 5 schematically shows a circuit formation device provided according to the present invention. The device mainly comprises a photosensitive body having a dielectric thin film 13 on the outer periphery of a metal drum, a charging device 10 for uniformly charging the dielectric thin film 13 on the outer periphery side of the photosensitive body, an exposure device 12 for forming an electrostatic latent image on the uniformly charged dielectric thin film, a developing device 15 including the conductive microscopic particle decentralized solution 4 used to develop the electrostatic latent image, a transferring device 17 for transferring the developed image to a board 16 , and a heating device 19 for fixing the image, which has been transferred onto the board 16 , onto the board. To remove the conductive particles left on the photosensitive drum after the transfer, there are also provided an eraser (remaining charge eliminating device) 21 for eliminating the charges on the conductive particles as well as a cleaning device 22 equipped with a blade, blush, or the like for scraping the conductive particles from which the charges have been removed.
A device for forming an electrostatic latent image 11 according to the present invention uses a dielectric thin film 13 having a photosensitive property; the charging device 10 based on corotron charging, roller contact charging, brush contact charging, or the like is used to uniformly charge the surface of the dielectric thin film, as indicated by 11 in the figure. Then, the exposure device 12 , which scans laser beams according to image signals from an image information processing device such as a personal computer, emits light to an arbitrary part so as to form a desired electrostatic latent image 14 . As another method, stamp charging is performed to form a desired electrostatic latent image 14 ; in this method, static charges are applied to a convex part of a transferred electrostatic latent image, on the surface of which a desired pattern is formed in advance, and the convex part is brought into contact with the surface of the dielectric thin film 13 . To allow a conductive pattern (electrostatic latent image) to be modified easily, however, the former method, in which uniform charging is performed as indicated by 11 in the figure and the surface is exposed to form an electrostatic latent image 14 , is preferable. In both methods, either positive charges or negative charges may be applied.
The inventive developing device 15 develops a conductive pattern by supplying the conductive microscopic particle decentralized solution 4 to the electrostatic latent image 14 so that the conductive microscopic particle decentralized solution is brought into contact with the electrostatic latent image. The developing device 15 comprises a tank for storing the conductive microscopic particle decentralized solution 4 and a supplying device (two pairs of developing rolls are provided in the figure) for supplying the conductive microscopic particle decentralized solution to the electrostatic latent image 14 on the dielectric thin film 13 . A device for adjusting the concentration of the conductive microscopic particle decentralized solution 4 is preferably provided in the storage tank, which adjusts the concentration by adding the decentralized solution 3 or conductive particles according to concentration information obtained from a concentration detecting device for detecting the concentration of the conductive microscopic particle decentralized solution 4 .
The conductive microscopic particle decentralized solution 4 includes the large-diameter particles 1 , so the large-diameter particles 1 may settle down. Since the settling causes a concentration gradient in the storage tank, the relational expression (2), which the microscopic particles must satisfy in the conductive microscopic particle decentralized solution 4 , may not be satisfied. To prevent this, the tank storing the conductive microscopic particle decentralized solution 4 preferably has a mixing device for preventing settling and uniforming the concentration over the entire area. The mixing device may be, for example, a device for performing mixing by generating convection in liquid by use of an ultrasonic wave emitting mean, a device for mechanically mixing the liquid, or a device for vibrating the storage tank itself for mixing purposes. If the above device is provided, the conductive microscopic particle decentralized solution 4 supplied to the developing section can maintain the relational expression (2) that has been set at the initial stage. Accordingly, a similar ratio can also be maintained when a pattern is formed at the time of adhesion to the electrostatic latent image 14 .
The supplying device for supplying the conductive microscopic particle decentralized solution 4 may use, for example, a method by which a layer of the conductive microscopic particle decentralized solution 4 is formed on a roll and the layer is brought into contact with the electrostatic latent image 14 , a method in which a nozzle is used to spray the conductive microscopic particle decentralized solution 4 , or a method by which the dielectric thin film 13 , on which the electrostatic latent image 14 is formed, is dipped in a tank including the conductive microscopic particle decentralized solution 4 .
The inventive circuit formation device has a transfer device 17 for transferring a conductive particle pattern 18 developed on the dielectric thin film 13 to the board 16 . The transfer to the board 16 may be performed after the conductive particle pattern 18 has been transferred to an intermediate transfer body. In this case, the board 16 on which to transfer the conductive particle pattern 18 needs to be insulative.
The inventive circuit formation device has a heating device 19 for fixing a conductive particle pattern 18 , which has been transferred onto the board 16 , on the board 16 so as to form a conductive pattern. Preferably, the heating device 19 can not only bond the conductive particles by fusion but can also bake the decentralizer layer 7 on the conductive layer surface. A function may also be provided which can pressurize the conductive particle pattern 18 on the board 16 while it is being heated. The temperature during pressurizing is preferably 300° C. or less so as to sufficiently bond the conductive particles by fusion and bake ionic organic molecules and to prevent the board 16 from being deformed or denatured. An exhausting device for exhausting baked organic components may be provided.
The inventive circuit formation device may have a drying device for evaporating the solvent component remaining in the conductive particle pattern 18 by drying the solvent component. Furthermore, the evaporated solvent may be liquefied and returned to the developing device 15 so that the solvent can be recycled as a decentralized solution 3 used to reduce the concentration of the conductive microscopic particle decentralized solution 4 .
In the inventive circuit formation device, the dielectric thin film 13 may be such that after the conductive particle pattern 18 is transferred, a latent image is formed again to develop the conductive particle pattern 18 . The shape is preferably a belt shape or a drum shape. In this case, the circuit formation device preferably has a remaining charge eliminating device 21 for deleting electrostatic latent images remaining on the dielectric thin film 13 and deleting remaining charges from remaining charged particles as well as a remaining conductive particle cleaning device 22 for removing and collecting remaining conductive particles. The remaining conductive particle cleaning device 22 may use, for example, a method in which a blade is brought into contact with the dielectric thin film 13 to scrap the remaining conductive particles or a method in which the remaining conductive particles are washed out. The conductive particles removed and collected may be recycled by being returned to the developing device 15 and decentralized again in the conductive microscopic particle decentralized solution 4 .
In addition to the above device using electrophotography, the circuit formation device using the inventive conductive microscopic particle decentralized solution 4 can be applied to printing processes such as a letterpress printing, a surface printing, a copperplate printing, a screen printing, a nanoimprinting, an inkjet printing, and a dispenser printing. The inventive conductive microscopic particle decentralized solution 4 not only can be used to form a pattern as described above, but also can be used in a process for forming a conductive film that is solid over the entire surface by being applied by a roll coater, a spin coater, or a spray.
A conductive pattern formed by the inventive conductive microscopic particle decentralized solution 4 may be used as wiring on a board in, for example, a personal computer, a large-scale electric computer, a notebook personal computer, a pen-based personal computer, a notebook word processor, a mobile phone, a mobile card, a wrist watch, a camera, an electric shaver, a cordless telephone, a facsimile machine, video equipment, a video camera, an electronic organizer, a calculator, an electronic organizer equipped with a communication function, a mobile copying machine, a liquid crystal television, an electric tool, a vacuum cleaner, a game machine equipped with a virtual reality function or the like, a toy, an electric bicycle, a walker for medical care, a wheelchair for medical care, a movable bed for medical care, an escalator, an elevators, a forklift, a golf cart, a backup power supply, a load conditioner, or a power storage system. In addition to consumer products, the conductive pattern can be used in military supplies and cosmic products.
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Microscopic particle decentralized solution having microscopic particles with different diameters are decentralized, wherein: the microscopic particle decentralized solution has two peaks in a granularity distribution, at a large diameter and a small diameter; and microscopic particle mixtures satisfying the following relationships are decentralized in the solution;
R>r and n >3.84×( R/r ) 3 ×N,
where R is a large particle diameter, r is a small particle diameter, N is the number of large particles, and n is the number of small particle.
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REFERENCE TO PRIOR APPLICATIONS
[0001] This application is a continuation of: (i) U.S. Design patent application Ser. No. 07/745,995 filed Aug. 9, 1991, which is a continuation of Design patent application 07/292,742 filed Jan. 3, 1989; and (ii) U.S. patent application Ser. No. 07/763,870 filed Sep. 19, 1991, which is a continuation of application Ser. No. 07/507,002 filed Apr. 10, 1990, which is a continuation of application Ser. No. 07/319,852 filed Mar. 3, 1989, which is a continuation of application Ser. No. 07/101,832 filed Sep. 28, 1987, which is a continuation-in-part of application Ser. No. 07/926,291, filed Nov. 3, 1986, and now issued as U.S. Pat. No. 4,724,642. The disclosure of U.S. Pat. No. 4,724,624 is hereby incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] This invention relates to outdoor residential constructions, and is particularly concerned with support devices for use in deck construction.
[0003] Various types of devices have heretofore been used for supporting and/or connecting building elements, such as horizontal beams joists, stringers, posts and pillars, to a base slab, footing, foundation of block member. For example, such devices include anchor studs, metal brackets, or other supports or devices which are permanently embedded in the concrete in the manufacturing process of the blocks and which are required to make them functional. Such devices or additional components are used to provide vertical and lateral mechanical connection of building elements to a base or as components to other elements but do not have an individual identity or non-mechanical application which facilitates the inexpensive and convenient construction of a simple deck, such as a deck that may be built by the average home owner on unprepared and unleveled ground typical to a residential backyard.
SUMMARY OF THE INVENTION
[0004] According to the present invention and forming a primary objective thereof, a deck construction is provided including a novel construction support device, which amounts to an improvement over prior structures.
[0005] A more particular object of the invention is to provide a construction support device of the type described having a novel arrangement of recesses, walls, and sockets for receiving horizontal beams and the like, and also capable of receiving vertical pillars or posts, all in a variety of selected support connections not heretofore available.
[0006] Another object of the invention is to provide an embodiment of the invention comprising a plurality of integrated wall portions disposed in a zig zag pattern and forming one or more full width slots for receiving horizontal beams and the like and also forming a rectangular central socket for receiving a vertical pillar or post.
[0007] Another object of the invention is to provide a pier block of the type described having a novel arrangement of recesses and central socket for receiving horizontal two-inch thick (12-inch nominal) surface supports, and also capable or receiving vertical wood posts without mechanical connections or additional components, all in a variety of selected support configurations not heretofore available.
[0008] In carrying out these objectives, a construction support device is provided for anchoring a beam or other element to the ground or other building site. The device includes a body having upper and lower portions. The lower portion rests on the building site, and the upper portion includes an open slot for holding a beam edgewise. The slot is formed by spaced-apart side walls. The side walls themselves include connected wall portions, which are integrally jointed at right angles.
[0009] The slot includes a center socket portion that is adapted for securely holding the bottom end of a vertically oriented post. The center socket portion is formed by the side walls extending at right angles away from each other to form corner sections. The corner sections are spaces apart substantially further than the width of the open slot to provide substantial corner support to the post.
[0010] In some cases, the side walls which define the slot are part of spaced-apart projections which extend from the upper portion of the body. These projections can be integrally molded with the body to form a single-cast, one-piece block or pier. Alternatively, they may be formed of plastic or metal and suitably attached to a base.
[0011] The invention may be practiced with a pair of recesses emanating from the central socket portion to form a single slot which extends unobstructed across the entire breadth of the body. Alternatively, a second pair of recesses may be employed to form a total of two mutually perpendicular slots.
[0012] Support devices in accordance with the invention are particularly suited to the construction of residential decks. Horizontal, coplanar deck support members may be carried by a plurality of the foregoing support devices arranged in rows and columns. The horizontal deck support members are securely seated in the slots defined by the spaced apart side walls.
[0013] Where the deck is to be built on uneven ground, the horizontal members can be supported in a level attitude by a plurality of vertical support pillars. The bottom ends of the vertical support pillars are securely seated in one of the center socket portion, while their respective top ends bear the horizontal members in supporting engagement. The height of the vertical support pillars can vary to span the vertical distance between the uneven ground that the desired plane in which the horizontal support members reside.
[0014] In one embodiment, the construction support device of the invention comprises a body member having a lower surface which serves as a support on a base such as a slab, footing, or pier block. The body member has one or more recess means arranged to receive horizontal beams and the like. The body member also has a central socket for receiving a vertical pillar or post. The recess means are disposed on each of four sides of the body member at 90 degrees apart and communicate with the central socket and the exterior, the pairs of recesses opposite from each other being aligned whereby construction beams or the like can be laid therein in edge and/or end relations. Also, in such embodiment, the construction device has fastener-receiving means therein for attaching a beam; or beams and a pillar together, and also for attaching the assembly to the base. In another embodiment, side edges of the body member at the recess openings have downturned projections shaped on a rear portion thereof to frictionally fit on top of pier blocks for anchoring the body member against lateral shifting.
[0015] In another embodiment, the construction support device of the invention is a single cast, one-piece pier block which comprises a body member servicing as a capable support on unprepared and unleveled building sites, having localized dips, slopes and random level areas therein. The body member has a single recess means molded into the top surface capable receiving horizontal deck surface support members and also capable of receiving the bottom end of a vertical wood post or pillar. The recess means can have particular dimensions for using conventional, existing lumber sizes and also such dimensions are such that the required integral strength of the block is maintained due to the manufacturing process and application without the necessity of using reinforcing bar steel or additional integral components. All of these features combine in a structural arrangement which automates and standardizes the manufacture and facilitates marketing, at a lower unit and resale cost, a deck that can be preplanned and pre-cut. Such a deck is simplified and inexpensive, and capable of construction by the average do-it-yourself homeowner who desires a deck on the unprepared and unleveled ground of a typical backyard.
[0016] The invention will be better understood and additional objects and advantages will become apparent from the following description taken in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] [0017]FIG. 1 is a top perspective view of a support device in accordance with a first embodiment of the invention;
[0018] [0018]FIG. 2 is a bottom perspective view of the device shown in FIG. 1
[0019] [0019]FIG. 3 is a bottom perspective view of a construction support device in accordance with another embodiment of the invention.
[0020] [0020]FIG. 4 is a bottom perspective view of a construction support device in accordance with yet another embodiment of the invention.
[0021] [0021]FIGS. 5, 6, 7 and 8 perspective views showing various applications of the device of FIG. 1 in association with structural building elements;
[0022] [0022]FIG. 9 is a perspective view of a construction support device which includes lateral stabilizing elements in accordance with another embodiment of the invention.
[0023] [0023]FIG. 10 is a bottom perspective view of the construction support device of FIG. 9;
[0024] [0024]FIGS. 11 and 12 are perspective views showing various applications of the device of FIG. 9 in association with structural building elements;
[0025] [0025]FIG. 13 is a perspective view of a construction support device in accordance with another embodiment of the invention;
[0026] [0026]FIG. 14 is bottom perspective view of the construction support device shown in FIG. 13;
[0027] [0027]FIG. 15 is a top perspective view of the construction support device shown in FIG. 13;
[0028] [0028]FIG. 16 is a top plan view of a construction support device shown in FIG. 13;
[0029] [0029]FIG. 17 is a perspective view a construction support device in accordance with another embodiment of the invention;
[0030] [0030]FIG. 18 is a top perspective view of the construction support device shown in FIG. 17;
[0031] [0031]FIG. 19 is a top plan view of the construction support device show in FIG. 17;
[0032] [0032]FIGS. 20 and 21 are perspective views showing various applications of the device of FIG. 17 in association with structural building elements;
[0033] FIGS. 22 is a perspective view of a deck construction in accordance with the invention employing the construction support device shown in FIG. 17.
[0034] FIGS. 23 is a perspective view of another deck construction in accordance with the invention employing the construction support device shown in FIG. 17.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0035] According to the present invention, a construction support device is provided which conveniently provides anchoring of a building element to a building site. As illustrated herein, the invention may be practiced in accordance with a first embodiment of FIG. 1, wherein the construction support device is securely attached to a concrete base or pier. The device of FIG. 1 can be inexpensively molded from plastic or stamped from metal and is simplified in its use and constructions.
[0036] Alternatively, the invention may be practiced in accordance with other embodiments, such as shown in FIGS. 13 and 17. There, the device is inexpensively poured from concrete together with a pier block to form a single cast, one-piece body. In either type of embodiment, the invention provides a new and advantageous support for securely seating construction members in either a horizontal or vertical orientation.
[0037] With reference first to FIGS. 5 through 8, the numeral 10 represents a base or pier block of conventional structure which is commonly used to support decks, carports, etc. This block is generally constructed of concrete and assumes different shapes. In most cases, the block is tapered to a lesser dimension toward the top. The top and bottom surfaces 22 and 13 , respectively, are flat.
[0038] FIGS. 1 - 8 illustrate a construction support device 14 in accordance with a first embodiment of the invention. Construction support device 14 which may be molded, stamped, or otherwise formed from a tough plastic or metal. The body member of the device 14 includes a flat bottom wall 16 and four identically shaped or symmetrical upright quarter sections 18 . Each of the sections 18 comprises four zig zag panels 18 a joined ;integrally at right angles. These symmetrical quarter sections are shaped to form a recess or opening 20 on each side, with oppositely located recesses being laterally aligned. Also, with this quarter section construction, a square central socket 22 is formed. Laterally aligned recesses 20 provide a pair of full width slots open at the sides.
[0039] Each of the panel sections 18 a has one or more apertures 24 therein provided to receive fasteners, to be seen hereinafter, for securement of building elements to the device 14 . As seen in FIG. 2, cutouts 26 are provided in the bottom wall 16 for reducing the weight of the member as well as for conserving material. Also, apertures 28 are provided in the wall 16 for secured attachment of the member 14 to a base, such as to a block 10 , a concrete slab, or other support means.
[0040] [0040]FIGS. 5, 6, 7 and 8 show various applications of the construction device 14 with building elements such as support members and pillars. FIG. 5 for example shows a horizontal decking surface support member 30 seated edgewise on the bottom wall 16 and extending fully through the device and out both side recesses 20 . FIG. 6 shows a support member 30 similarly supported as in FIG. 5 but also showing a right angle support member 32 extending through a 90 degree side recess 20 and abutted against the support member 30 . FIG. 7 shows a vertical pillar 34 supported ion the device 14 and fitted in the central socket 22 . FIG. 8 shows a pillar 34 similarly fitted in the socket 22 as in FIG. 7 but also showing side beams 32 extending in from all four of the side recesses. These members may simply be fitted in the respective recesses 20 or socket 22 . Preferably, however, secured attachment to the member 14 is accomplished by fasteners 36 extending through the apertures 24 . Also, device 14 can first be secured to the base member 10 by fasteners extending through the apertures 28 .
[0041] [0041]FIG. 3 is a bottom perspective view of a construction device 14 ′ having a bottom wall 16 and side walls 18 in an arrangement similar to that shown in FIGS. 1 and 2. This structure, however, is formed (such as by integral molding) with a plurality of depending foot member 38 . Four of such foot members are shown, as well as a central foot member, but any number of such foot members maybe provided. In the FIG. 3 embodiment, the foot members 38 are hollow whereby long fasteners can be inserted down from the top through the wall 16 and into a base for secured attachment of the construction device 14 ′ to the base. FIG. 4 shows a structure similar to FIG. 3 except that the outer foot members 38 ′ are solid and not hollow. This embodiment may be employed in circumstances where it is not necessary to use vertical fasteners around an outer portion of the member.
[0042] FIGS. 9 - 12 illustrate an embodiment of the invention employing means for anchoring the body member against lateral shifting. In this embodiment, the body member 14 ″ is the same as that shown in FIG. 1 with respect to quarter panel sections 18 a and their formation of aligned recesses 20 and central socket 22 . To accomplish the lateral anchoring feature, the outermost panel section 18 a of each quarter section has a depending projection or lip 40 defined by a bottom wall portion 42 integral with side extensions 44 and a rear wall portion 46 . Rear wall portion 46 preferable angles outwardly toward the bottom to coincide with the angle of the side surfaces of pier block 10 . Reel wall portion 46 can extend at a desired angle, so as to have flush engagement with pier block sides or varying shape.
[0043] [0043]FIGS. 11 and 12 show application of the device 14 ″ of FIG. 9 to a pier block. In such arrangement, the device 14 ″ and the building elements therein are anchored or locked against lateral shifting. Fasteners extending through the bottom wall of the device are not necessary, although such fasteners can be used if desired. The cross dimension of the device between rear wall portions 46 can be preselected according to the size of the pier block so that a snug or frictional fit is provided.
[0044] Referring to FIGS. 13 - 21 , it will be seen that the device 14 may be ;made of concrete and integrally molded into the upper surface 12 ′ of a pier block such as pier block 50 . As shown in FIGS. 13 - 16 , the four upright quarter sections 18 ′ include zig-zag walls 18 a ′ which project from flat bottom wall 16 ′. Recesses 20 ′ define two perpendicular slot portions extending across the full width of upper surface 12 ′. Zig-zag walls 18 a ′ also define the four corners of a square central socket 22 ′.
[0045] With reference to FIGS. 17 - 21 , the concept of the invention can also utilize a pier block 50 ′ having a central socket portion 22 ′ and only two equal narrower recesses 20 ′ which extend inward from outer edges of two opposite side of the top surface of the block 50 ′ and lead into the central socket portion, as best shown in FIG. 18. The two narrower recesses 20 ′ form but a single slot for receiving a horizontal decking surface support member 30 which also passes through the central socket portion 22 ′, as shown in FIG. 20. The central socket portion 22 ′ is for receiving vertical pillar supports 34 , independent of the two equal narrower recesses 20 ′, as shown by FIG. 21. The horizontal decking surface support members 30 and vertical pillar support members 34 being mutually exclusive to each other in the recess of block 50 ′ and also mutually interchangeable with each other in the same recess of the same block 50 ′.
[0046] The combination of slots and sockets allows a support in accordance with the invention to accommodate both vertical and horizontal beams, and is particularly well-suited for constructing decks on unprepared and unleveled building sites, two examples of those being shown in FIGS. 22 and 23. Such decks, by using the present block, are extremely simplified in their construction and can be supplied in pre-planned, pre-cut units. Other advantages also exist in the structure, as will be apparent hereinafter.
[0047] The deck shown in FIG. 22, designed by the numeral 52 , comprises the pier blocks 50 ′ as the base or ground support for the deck and can have such lumber as two-inch thick (1-2 inch thick nominal) horizontal decking surface support member 30 received by the two equal narrower portions 20 ′, also passing through the central socket portion 22 ′ when the vertical pillar support 34 is not in the block 50 ′, those members 30 then supporting the deck surface structure 54 which is nailed in place and those blocks 50 ′ directly receiving member 30 being on localized high or level ground within an unprepared and unleveled building site.
[0048] The deck shown in FIG. 23, designated by the numeral 56 , similarly uses some pier blocks 50 ′ as the base or ground support for vertical pillar supports 34 set in the central socket 22 ′ when the member 30 is not in block 50 , member 34 then providing support to member 30 when member 30 is not directly received by block 30 due to localized variations of the ground within unprepared and unleveled building site. A deck support member 30 can also be fastened to a building 60 , as shown in FIG. 23.
[0049] The particular structure of the manufactured pier blocks 50 and 50 ′ makes it possible to construct an extremely simplified deck and one which can be pre-planned and pre-cut if desired. That is, such lumber as 2-inch thick deck support members 30 and vertical wood pillars 34 which can be used therewith comprise conventional existing material, namely, the two-inch thick deck support number 30 can comprise 2×6's or 2×4's and pillars 34 can comprise 4×4's.
[0050] The two equal narrower recesses 30 ′ can be inches deep and have a width of 2-: inches. This latter dimension would receive conventional finished 2×6's (1-2 inches thick) and 2×4's (also, 1-2 inches thick). 2×6's and 2×4's have finished height dimensions of 5-2 and 32 inches, respectively, whereby the deck support members, whether 2×6's or 2>4's, project to a minimum necessary height above the top surface o the blocks 50 when seated in the recess for supporting the decking thereon.
[0051] The central socket portion 22 ′ can be 2 inches deep, similar to the recess portion 20 ′. Such socket is square, and can have dimensions of 3-: inches for receiving a conventional ;finished 4×4 (3-2 inches square) lumber support pillar. The vertical pillar becomes sufficiently fixed in socket portion 22 ′ in the block for deck construction purposes, as does the deck horizontal support member in the two narrower portions 20 ′, also being within the central socket portion 22 ′ when the member 34 is not in the block 50 , for lateral stability.
[0052] Pier blocks 50 and 50 ′ are designed to provide support to a deck on unleveled or unprepared building sites with no additional components required. For this purpose, the blocks 50 and 50 ′ are tapered to a larger dimension toward the bottom. The top and bottom surfaces are flat and square. The enlarged bottom surface allows the block to serve as its own footing. When two of such recesses 20 ′ are provided, they are standardly aligned across the block. Furthermore, the width of these recesses is less than one-third the width of the block at the top, thus maintaining lateral integral strength of the block. This arrangement maintains a strong concrete block without the necessity of re-bar reinforcement and thus contributes to manufacture of a pier block and deck structure in a pre-planned and pre-cut unit which is also sufficiently simplified in its use, standardized in its manufacture, and sufficiently inexpensive for deck construction by the average do-it-yourself homeowner.
[0053] Since the recess can be two inches deep, the recesses of the pier blocks 50 and 50 ′ of FIGS. 13 ;and 17 automatically and non-mechanically center the horizontal decking surface support member 30 and vertical pillars 34 in the pier block (FIGS. 20 and 21) and automates connection and securement of these support members to the pier block for deck constructions 52 and 54 shown in FIGS. 22 and 23. Mounted engagement of the horizontal surface support members and vertical pillars with the block is accomplished without metal-brackets or embedded connectors thus allowing individual blocks of a deck construction on unleveled and unprepared building sites to be adjusted without the need of any disassembly of the deck (i.e. removing bolts, nails or screws). Also, the recess of the pier blocks 50 and 50 ′ maintains horizontal and vertical members in parallel which is critical in construction of the deck.
[0054] It is to be understood that the forms of our invention herein shown and described are to be taken as preferred examples of the same and that other changes in the shape, size and arrangement of parts may be resorted to without departing from the spirit of our invention or the scope of the following claims.
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A deck construction including a plurality of supports for anchoring deck construction elements to a building site. The supports include a body (which may be an integrally molded concrete pier) having upper and lower portions. The upper portion includes at least one slot for seating a horizontally oriented construction member. The slot includes a center socket portion having four extended corners for seating the bottom end of a vertically oriented construction member. The slot and center socket are defined by connecting wall portions which may be integral to the body or may be of plastic or metal and suitable secured to the body. In some cases, two mutually perpendicular slots are provided.
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[0001] This application claims Paris Convention priority of DE 10 2005 062 522.3 filed Dec. 19, 2005 the complete disclosure of which is hereby incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] The invention concerns a method for frictionally connecting the front surfaces of two machine components for transmitting high torques or transverse forces, and a structural component which is formed from these machine components and produced in accordance with this method.
[0003] Frictional connections of two machine component surfaces are used in many fields of mechanical engineering for transmitting transverse forces or torques. The force that can be transmitted is thereby substantially produced by the surface pressure and the resulting friction between the connected surfaces. Such connections are important mainly in drive technology, e.g. for driving auxiliary units. The power that can be transmitted is often limited by the force that can be transmitted through contact between the two abutting surfaces.
[0004] Such connections are mostly realized through force/friction fit in the form of shaft/hub connections. Depending on the geometry of the active surfaces, these are front, conical or cylindrical compression joints and associated friction fit combinations (flanges, clamping elements, screw heads). All of these connections are based on surface contact. The generated frictional force depends on different factors, e.g. on the type of joint, the surface roughness and the surface compression which preferably acts perpendicularly to the surfaces.
[0005] Hard particles are conventionally introduced between the two surfaces to be connected in order to increase friction. A micro-positive locking is produced in the area where the hard particles penetrate into the material of the softer surfaces to be connected. The increase in friction results from the resistance of the material of the surfaces relative to grooves due to the hard particles. Such connections are disclosed e.g. in DE 31 49 596 A1, DE 101 48 831, DE 18 16 854 A1 and DE 23 46 275 C2. Resilient-elastic foils (diamond foils) are also conventionally used into which particles of hard material (diamond) are embedded (EP 0 961 038 B1, EP 1 564 418 A1). They are disposed between the surfaces to be connected.
[0006] The production of these foils, in particular, of the diamond particles embedded in the foil, is expensive. The method for producing such connections and the constructive considerations are complex.
[0007] It is therefore the underlying purpose of the invention to create a method for producing frictional connections between the front surfaces of two machine elements for transmitting high torques, which is considerably simpler than conventional methods and also produces structural components of two machine elements for transmitting high torques, which can be produced in a considerably easier and less expensive fashion than up to now.
SUMMARY OF THE INVENTION
[0008] In accordance with the invention, this is achieved by the features of the independent claims. The invention moreover concerns advantageous further developments thereof.
[0009] The inventive method is extremely simple, since there are conventional methods for producing depressions (micro-shaped pockets) and thereby also elevations, surrounding them, in metallic surfaces through suitable laser radiation systems, although the elevations are subsequently removed again through honing. The micropockets that remain in the surfaces improve the tribological properties, i.e. reduce friction (compare DE 20 2005 011 772 U, DE 20 2005 005 905 U, EP 0 565 742 B1; DE 43 16 012 C2, DE 295 06 005 U; EP 1 275 864 B1, and compare also U. Klink and G. Flores, Laser-Strukturieren von Zylinderlaufbahnen, 9. Internationales Feinbearbeitungskolloquium, 12. to 14. 10.1999, Braunschweig; Vulkan-Verlag, Essen (1999), ISBN 3-8027-8644-0; T. Abeln and U. Klink, Laserstrukturieren zur Verbesserung der tribologischen Eigenschaften von Oberflächen, in: Dausinger, F. et al., Stuttgarter Lasertage, 2001, pages 61 to 64). This technology for laser structuring supplements the present description in view of the applied devices and is hereby incorporated by reference.
[0010] It has turned out that the simple method in accordance with the invention transmits much higher torques than conventional devices for a given pressure surface and contact pressure. It is thereby also possible to transmit transverse forces between flat, non-rotating and non-rotationally symmetric surfaces. The inventive content and quality of the method therefore greatly exceed the conventional improvement of the adhesive force of bearing shells in connecting rod eyes, as is disclosed in EP 1 420 177.
[0011] One embodiment of the invention and its advantageous further developments are described below with reference to the enclosed drawings.
BRIEF DESCRIPTION OF THE DRAWING
[0012] FIG. 1 shows a connection between a crankshaft and a pulley produced in accordance with the inventive method;
[0013] FIG. 2 shows the detail designated with II in FIG. 1 in an enlarged scale;
[0014] FIG. 3 shows the front surface 1 ′ of the crankshaft 1 in accordance with FIG. 2 , also in an enlarged scale;
[0015] FIG. 4 shows a top view of the front surfaces 1 ′ in the direction of arrows IV-IV in FIG. 3 ;
[0016] FIG. 5 shows the connection between the front surface 1 ′ of the crankshaft 1 and the front surface 2 ″ of the front surface 2 on an enlarged scale in correspondence with FIG. 3 ;
[0017] FIG. 6 shows further geometries for arranging the elevations on a front surface.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0018] FIGS. 1 and 2 show the connection of the end of a crankshaft 1 (first machine component), two pinions 2 and 3 and a pulley 4 (further machine components) to a structural component. The front surface 1 ′ of the crankshaft 1 , the front surface 2 ′ of the pinion 2 and the front surface 3 ′ of the pinion 3 have elevations 20 ( FIGS. 2 and 3 ). When the crankshaft 1 , the pinions 2 , 3 and the pulley 4 are tightened perpendicularly to the above-mentioned surfaces using a hexagon socket screw 15 which extends through a bore 16 in the axial projection of the pulley 4 and engages in a thread 17 in the crankshaft 1 ( FIG. 1 ), the hardened elevations 20 dig into the smooth, non-hardened front surface 2 ″ of the pinion 2 , the smooth, non-hardened front surface 3 ″ of the pinion 3 , and the smooth, non-hardened front surface 4 ″ of the pulley 4 and thereby form a micro-positive locking in each case, which accepts transmission of torques which are considerably larger than those realized by pressing smooth surfaces against each other with the same force.
[0019] The hardened elevations 20 are mounted e.g. to the front surface 1 ′ through laser structuring in FIG. 3 , i.e. through high-energy, focused laser beams which are directed onto the surface to be processed, using e.g. a YAG laser (yttrium aluminium garnet laser) (compare e.g. the schematic representation of such a laser in Popraw, R., Lasertechnik für die Fertigung, Spinger-Verlag Berlin/Heidelberg 2005, page 232′ and the above-mentioned references to patent literature). A surface 1 ′ may be exposed to a laser of his type to produce e.g. elongated pockets 21 (see FIGS. 3 and 4 ). Such structures may be introduced in different patterns, e.g. also with dots. In this case, the pockets 22 are round. These round or elongated pockets may, in turn, be mounted linearly (e.g. as grooves 23 ) or in circles in different geometries ( FIG. 6 ).
[0020] When the elevations 20 are introduced by laser radiation, the elevations are produced by point-focus melting of the material of the surfaces that warps at the edges, subsequently solidifies and hardens through cooling. The high concentration of energy at the focus of the laser beam melts and hardens the elevations of the material in the otherwise softer and smooth surface.
[0021] In consequence thereof, when pressing these molten and hardened elevations 20 of the surfaces 1 ′, 2 ′, 3 ′ against each other ( FIG. 1 ), they dig into the smooth, non-hardened, softer surfaces 2 ″, 3 ″, 4 ″ that serve as a partner for forming structural components, thereby forming a connection that is resistant to torques and transverse forces, respectively. This connection may be released again.
[0022] The invention extends beyond the above-described preferred embodiment. It comprises not only elevations which are produced through laser structuring, i.e. in principle through point-focus melting and hardening for digging into a softer surface. The elevations may also be introduced through an electron beam or mechanically. It is important that they are harder than the “soft” surface of the respectively other machine component.
LIST OF REFERENCE NUMERALS
[0000]
1 crankshaft
1 ′ front surface of 1 provided with elevations 20
2 pinion
2 ′ front surface of 2 provided with elevations 20
2 ″ smooth front surface of 2
3 pinion
3 ′ front surface of 3 provided with elevations
3 ″ smooth front surface of 3
4 pulley
4 ″ front surface of 4 provided with elevations 20
15 hexagon socket screw
16 bores
17 thread
20 elevations in 1 ′, 2 ′, 3 ′
21 elongated pockets
22 round pockets
23 grooves
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Method for frictionally connecting the front surfaces of two machine components ( 1′, 2″; 2′, 3″; 3′, 4″ ) for transmitting high torques or transverse forces, wherein elevations ( 20 ) are provided on one ( 1′, 2′, 3′ ) of the surfaces ( 1′, 2″; 2′, 3″; 3′, 4″ ) to be connected, which are harder than the material of the other surface.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Patent Application Ser. No. 60/872,057, filed on Nov. 29, 2006 and entitled DISCRETE ELEMENT MODELING OF ROCK CUTTING UNDER HIGH PRESSURE CONDITIONS, the disclosure of which application is hereby incorporated herein in its entirety by this reference.
TECHNICAL FIELD
[0002] The present invention, in various embodiments, relates to discrete element modeling (DEM) of cutting or otherwise destroying subterranean rock under high pressure conditions, and employing such modeling to improve cutting efficiency of cutters, drill bits and other tools for removing subterranean rock in the context of, by way of nonlimiting example only, drilling or reaming a subterranean borehole.
BACKGROUND
[0003] During the early part of the twentieth century, the drilling community did not account for the strengthening effect of downhole pressure on rock. I. G. Kühne, 1952, Die Wirkungsweise von Rotarymeiseln and anderen drehenden Gesteinsbohrem, Sonderdruck aus der Zeitschrji, Bohrtecknik-Brunnenbau, Helf 1-5, pointed out the effect of pressure and suggested that rock may be treated as a Mohr-Coulomb material. Research conducted at Rice University explored the ramifications of Kühne's proposal. R. O. Bredthauer, Strength Characteristics of Rock Samples Under Hydrostatic Pressure , Rice University Master's Thesis; R.A. Cunningham, The Effect of Hydrostatic Stress on the Drilling Rates of Rock Formations, 1955, Rice University Master's Thesis; E. M. Galle, 1959, Photoelastic Analysis of the Stress Near the Bottom of a Cylindrical Cavity Due to Non-Symmetrical loading , Rice University Master's Thesis. Similar research spread rapidly through the industry.
[0004] This early research showed that the most important factor governing drillability downhole is the differential pressure, defined as the difference between the pressure of the mud in the borehole (borehole pressure) and the pressure in the pores of the rock (pore pressure). Differential pressure defines an effective stress confining the rock matrix and is much more important as an indicator of rock drillability than the tectonic stresses. These early researchers adopted a Mohr-Coulomb model in which differential pressure defines the hydrostatic component of stress. The drilling community still uses the parameters of a Mohr-Coulomb model, namely Unconfined Compressive Strength (UCS) and Friction Angle (N) to characterize rock. However, rates of penetration based on these models under-predict the effect of pressure on drilling, which suggests that there must be other rock properties that govern drilling under pressure.
[0005] Drilling data, reported as early as Cunningham's thesis referenced above, showed that differential pressure had a more profound effect on the rate of penetration than would he expected by the increase in strength of a Mohr-Coulomb material. It has also been proposed that there are other mechanisms at work which they described as various forms of a phenomenon called “chip hold down.” A. J. Garnier and N. H. Van Lingen, 1959, Phenomena Affecting Drilling Rates at Depth, Trans AIME 217; N. H. Van Lingen, 1961, Bottom Scavenging-A Major Factor Governing Penetration Rates at Depth, Journal of Petroleum Tech., Feb ., pp. 187-196. Chip hold down refers to force that the drilling mud may exert on a cutting, or a bed of crushed material, due to differential pressure. The industry also recognized that permeability has a strong effect on differential pressure. R. A. Bobo and R. S. Hoch, 1957, Keys to Successful Competitive Drilling, Part 5b, World Oil , October, pp. 185-188. As a drill bit shears rock, the rock dilates, causing the pore volume to increase. If the rock is impermeable, this will cause a reduction of pore pressure, increasing differential pressure, strengthening the rock. More recent studies quantify these relationships. E. Detournay and C. P. Tan, 2002, Dependence of Drilling Specific Energy on Bottom-Hole Pressure in Shales, SPE/ISRM 78221, presented at the SPE/ISRM Rock Mechanics, Irving, Tex.; J. J. Kolle, 1995, Dynamic Confinement Effects on Fixed Cutter Drilling, Final Report, Gas Research Institute.
[0006] Complexities of the drilling process led some researchers to abandon confined strength measured in triaxial tests and define a “drilling strength” that can be determined empirically with a drill bit itself R. A. Cunningham, 1978, An Empirical Approach For Relating Drilling Parameters, Journal of Petroleum Technology , July, pp. 987-991. While useful in predicting rates of penetration, such models give little insight into the physical process of rock destruction.
[0007] Another approach based on specific energy has also been used. R. Simon, 1963, Energy Balance in Rock Drilling, SPE Journal , December, pp. 298-306; R. Teale, 1964, The Concept of Specific Energy in Rock Drilling, Int. J. Rock Mech. Mining Sci . vol. 2, pp. 57-73. Specific energy is the energy required to remove a unit volume of rock and has the units n/m 2 (psi). When drilling rock efficiently at atmospheric pressure, the specific energy approaches a number numerically close to the UCS of the rock. This is useful as a measure of the drilling efficiency. A driller can measure the specific energy of a drilling process, compare that to the UCS, and quantity how efficient the drilling process is.
[0008] It has been suggested that the foregoing concept could be applied to drilling under pressure. R. C. Pessier and M. J. Fear, 1992, Quantifying Common Drilling Problems with Mechanical Specific Energy and a Bit-Specific Coefficient of Sliding Friction, SPE 24584, presented at the 67 th annual Technical Conference and Exhibition of the SPE, Washington. However, there remains the question of what strength should be used to define efficient drilling in the pressure environment. An obvious first guess might be that Confined Compressive Strength (CCS) defines the limit. However, the inventor herein has learned that plugging CCS determined by Mohr-Coulomb type relations into specific energy-based models of drilling under-predicts the increased difficulty of drilling at a given differential pressure. Recently, several papers have appeared exploiting specific energy methods in oil and gas drilling. F. E. Dupriest, 2005, Maximizing Drill Rates with Real-Time Surveillance of Mechanical Specific Energy, SPE 92194, presented at the SPE/IADC Conference. Amsterdam; H. Caicedo and B. Calhoun, 2005, SPE 92576, Unique ROP Predictor Using Bit-specific Coefficient of Sliding Friction and Mechanical Efficiency as a Function of Confined Compressive Strength, presented at the SPE/IADC Drilling Conference, Amsterdam; D. A. Curry and M. J. Fear, 2005, Technical Limit Specific Energy—An Index to Facilitate Drilling Performance Evaluation, presented at the SPE/IADC Drilling Conference, Amsterdam. Typically, these papers have laboratory-derived empirical relations defining a drilling strength, a number that is higher than the CCS.
[0009] In summary, the industry has realized for a long time that UCS and N are not sufficient to account for the increased difficulty of drilling with increasing hydrostatic pressure. However, these properties continue to be measured and quoted when describing rock.
[0010] Rates of penetration based on these models under-predict the effect of downhole pressure on drilling, which suggests that there must be other rock properties that govern drilling under pressure.
BRIEF SUMMARY OF THE INVENTION
[0011] Discrete Element Modeling (DEM) of rock cutting under high pressure conditions such as are experienced during subterranean drilling, indicates that mechanical properties of crushed rock detritus are more significant indicators of rock drillability than the mechanical properties of the original elastic rock. Specifically, the deformation and extrusion of crushed rock detritus consumes the bulk of the energy expended in rock destruction down hole. As used herein, the term “rock drillability” includes encompasses rock destruction under pressure by any mechanical means such as, by way of nonlimiting example, a fixed cutter employed on a so-called “drag” bit, an insert or other tooth of a roller cone, and a percussion, or “hammer,” bit. The term “bit” as used herein includes and encompasses any tool configured for removing rock of a subterranean formation.
[0012] These results suggest that some measure of the inelastic behavior of rock under pressure, such as the area under the stress/strain curve, which is a measure of specific energy, may be a more appropriate measure of rock drillability in high pressure environments. Characterizing rock in terms of the area under the stress/strain curve may enable more accurate ways to parameterize specific energy models of drilling and optimize design of cutting elements and drill bits for subterranean drilling.
[0013] In an embodiment of the invention. DEM modeling of rock is employed to predict behavior of “virtual” rock under high pressure conditions as subjected to cutting by a fixed cutter configured as a polycrystalline diamond compact (PDC) cutting element, as a thermally stable polycrystalline diamond cutting element, as a natural diamond cutting element, or as a superabrasive grit-impregnated cutting segment for various cutter configurations and orientations, including without limitation and where applicable, cutting face topography, cutting edge geometry, and cutting element back rake.
[0014] In further embodiments of the invention, DEM modeling of rock is employed to predict behavior of “virtual” rock under high pressure conditions as subjected to rock destruction by an insert or other tooth of a roller cone as employed in rolling cutter bits, as well by cutting structures of percussion bits. As used herein, the terms “cutting,” and “cutter” or “cutting structure” refer, respectively, to destruction of subterranean rock and to cutting elements and other structures for effecting such destruction.
[0015] In another embodiment of the invention, DEM modeling may be employed to simulate selected rock characteristics to provide a virtual rock to assess cutting structure performance, with or without reference to any specific, actual rock formation. Aspects of this embodiment specifically encompass using a virtual rock created by DEM modeling to model rock destruction in a high pressure environment by any mechanical means.
[0016] In yet another embodiment of the invention, a virtual rock material is created by establishing an equivalence of stress/strain behavior of real rock material over a variety of above-ambient pressures when subjected to measured applied stresses and through measured, resulting rock strains in laboratory tests with the virtual stress/strain behavior of a virtual rock material as simulated by DEM over the same variety of pressures. Aspects of this embodiment encompass establishing such equivalence in both the elastic and the inelastic regions of the stress/strain curve, and over a wide enough range or set of confining pressures that both strain softening and strain hardening of the rock are captured.
[0017] In yet another embodiment of the invention, DEM modeling may be employed to predict performance of various drill bit designs, including without limitation drilling efficiency of such designs.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1 is a graph of stress/strain curves generated using PFC (Particle Flow Code) for a rock simulated using PFC and FIGS. 1 a and 1 b are images of PFF triaxial specimens;
[0019] FIG. 2 a is a PFC model of rock cutting at atmospheric pressure using a fixed cutter at a 15° back rake while FIG. 2 b is a PFF model of rock cutting at a high pressure of 20.7 MPa (3,000 psi) using a fixed cutter at a 15° back rake;
[0020] FIG. 3 is a PFC model of rock cutting at a high pressure of 20.7 MPa (3,000 psi) using a fixed cutter at a 30° back rake;
[0021] FIG. 4 a includes line drawings taken from photographs of a test bit showing metal rods bent by formation material chips flowing on a blade of the bit from a frontal and side perspectives, and FIG. 4 b is a line drawing taken from a photograph of a formation material chip bent by contact with one of the metal rods;
[0022] FIG. 5 is graph of stress difference versus axial strain for Bonneterre Dolomite at 34.4 MPa (5,000 psi) confining pressure in an actual triaxial test;
[0023] FIG. 6 is a PFC model of cutting unbonded formation material;
[0024] FIG. 7 is a Yield Surface and High Strain Flow Enveloped for Carthage Limestone; and
[0025] FIG. 8 is a PFC model of rock destruction at high pressure using a tooth configuration of a roller cone as is employed on a rolling cutter bit.
DETAILED DESCRIPTION OF THE INVENTION
Discrete Element Modeling of Rock Cutting
[0026] Discrete Element Modeling (DEM) materials are created by establishing an equivalence between the mechanical response of selected lab tests and DEM models of the same lab tests. D. O. Potyondy and P. A. Cundall, 2004, A bonded-particle model for rock, Int. J. Rock Mech. Min. Sci. 41(8). pp. 1329-1364. Success in the DEM method requires that appropriate lab tests and mechanical parameters be chosen to calibrate the DEM material. This, of course, presupposes that appropriate lab tests and mechanical parameters may be selected to characterize drilling under pressure. A common practice in the mining industry is to establish an equivalence in: density, elastic modulus, Poisson ratio, Brazilian strength, UCS and N. However, none of these equivalencies describe the inelastic response of the rock.
[0027] Rock cutting under pressure is very different from rock cutting at atmospheric conditions. At atmospheric conditions, a cutter drives long cracks into the rock, creating large chips of elastic rock. These chips usually fly away from the cutting face due to the release of elastic energy. Rock cutting under pressure in a drilling fluid, or “mud,” environment does not create such chips. Instead, the cuttings generated are long “ribbons” of rock material that extrude up the face of the cutter and exhibit a saw-toothed shape. T. M. Warren and W. K. Armagost, Laboratory Drilling Performance of PDC Bits, SPE Drilling Engineering , June 1988, pp. 125-135. However it has been discovered that such cuttings, contrary to previous speculations, are not composed of chips of elastic material bonded. More recent examination of cuttings shows that the cuttings typically consist of completely crushed and recompacted material. A. Judzis, R. G. Bland, D. A. Curry, A. D. Black, H. A. Robertson, M. J. Meiners, and T. Grant, 2007, Optimization of Deep Drilling Performance; Benchmark Testing Drives ROP Improvements for Bits and Drilling Fluids, SPE/IADC 105885, presented at the SPE/IADC Drilling Conference, Amsterdam. The crushed material is held together and, indeed, strengthened by the borehole pressure because drilling mud inhibits penetration of fluid into the crushed material.
[0028] One major challenge in modeling rock cutting with DEM is that of simulating the confining effect of drilling fluid under pressure on a cutting, as the surface of the cutting is not known a priori. Instead, a topological routine is employed that is run every n th time step which examines the current state of the DEM specimen and identifies all “balls” simulating particles of formation material on the surface of the cutting and the cut surface of the formation. The routine then applies a force representing a hydrostatic pressure to the balls on these surfaces. This pressure boundary condition simulates an impermeable, real life filter cake of drilling fluid. As a result, the extreme condition of a very impermeable rock and cutting are modeled. Such an approach provides an upper bound as far as cutting forces are concerned. The other extreme, the atmospheric case, can be modeled easily, since the foregoing pressure boundary condition is not needed, and represents a lower bound as far as cutting forces are concerned.
[0029] Because a large amount of plastic deformation occurs in the above-described rock extrusion process the inventor has determined that the inelastic properties of rock are significant to drillability. It is also expected that strain softening or strain hardening will play a role. The conventional practice of looking at UCS and N to characterize rock does not capture any of this inelastic behavior.
[0030] The practice adopted in an embodiment of the present invention for calibrating DEM rock material is to match the stress/strain response of actual rock and the virtual DEM-simulated “rock” material, to high strain, and over a wide range of hydrostatic pressures. One DEM code which has been found to be particularly suitable for modeling according to an embodiment of the present invention is Particle Flow Code (PFC) produced by Itasca Consulting Company of Minneapolis, Minn. While the “FISH” functions that are commonly used to simulate triaxial tests in PFC do not allow deformation to large strain because the confining pressure is applied by “walls” which cannot deform as the lateral sides of the specimen deform, one embodiment of the present invention includes a new means of modeling triaxial tests in PFC by applying confining pressure with the same topological routines that apply pressure to the surface of a chip. While this disclosure describes DEM in the context of PFC, other discrete element modeling codes may be adapted to implement embodiments of the present invention. For example, another commercially available code, termed “EDEM” and produced by DEM Solutions of Edinburgh. Scotland, may be modified for use in simulating rock destruction under pressure. Accordingly, the terms “discrete element modeling” and “DEM” are nonlimiting in scope, and the use of Particle Flow Code as described herein is to be taken as only one representative example of how discrete element modeling may be used to implement embodiments of the present invention.
[0031] In triaxial tests, most rocks exhibit transition from shear localization at low confining pressures to shear-enhanced compaction at high confining pressures. V. Vajdova, P. Baud, and T. F. Wong, 2004, Compaction, dilatancy, and failure in porous carbonate rocks, Journal of Geophysical Research , Vol. 109; T. F. Wong and P. Baud, 1999, Mechanical Compaction of Porous Sandstone, Oil and Gas Science and Technology , Vol. 54, no. 6, pp. 715-727. In the shear localization mode, cracks coalesce along diagonal shear planes and, after this, large elastic wedges of material slide past each other, shearing the rubble on these shear planes. In the shear-enhanced compaction mode, most of the rock volume is failed.
[0032] It was unknown whether PFC materials would exhibit this same transition from shear localization to shear-enhanced compaction. However, triaxial tests using DEM with several different PFC “virtual” rocks, over a wide range of porosity, have shown that a similar mechanism occurs. FIG. 1 shows PFC-generated stress/strain curves for a PFC rock. The curves to the right of the origin (0.00) are for axial strain and those to the left represent volumetric strain, with dilation being negative. Images of PFC triaxial specimens showing both strain localization and shear enhanced compaction under an applied load are designated as FIGS. 1 a and 1 b , respectively. The shaded, slightly darker particles (balls) on these figures represents cracks and balls that have broken all bonds with other balls (e.g., crushed material). The confining pressure was varied in the tests from atmospheric pressure to 275 MPa (40,000 psi), As used herein, the term “triaxial” as used with reference to tests in the DEM environment and to actual tests employed to establish equivalency of the two test formats (actual and DEM) using a cylindrical specimen placed between two load platens tor application of an axial load arc, in fact, bi-axial tests. However, the colloquial term “triaxial” to describe such a test in a physical environment is used by the industry and, thus, herein.
[0033] It is not common to conduct triaxial tests to such high strain in the oil and gas industry. Tests are usually terminated after the elastic limit or proportional limit is reached. It is also common to conduct only a few triaxial tests at confining pressures in the neighborhood of the in-situ pressure of interest. But FEA (finite element analysis) and DEM models both show that the hydrostatic component of stress in the rock ahead of an advancing cutter is much higher than the in-situ confining pressure. Also, the failure mechanism ahead of a cutter is more similar to shear-enhanced compaction than shear localization. Both these observations suggest that the mechanical properties of rock should be simulated to pressures significantly higher than the in-situ pressure.
[0034] FIGS. 2 a and 2 b show PFC models of rock cutting at the two extremes of atmospheric and high pressure conditions. The cutter, as it would be mounted to a fixed cutter or “drag” bit or other earth-boring tool in practice. is shown in outline by a black line as back raked to 15° and exhibiting a 45° chamfer at the cutting edge proximate the formation being cut, and is moving from left to right. As shown in FIG. 2 b , the balls having a dot in their centers and located at the outer surface of the compacted material against the cutting face and edge and along the side of the cutter, as well as against the formation itself, represent the boundary on which confining pressure is applied. Note that the mechanisms evident in these models are analogous to real life descriptions above. At atmospheric pressure large cracks are driven into the elastic rock matrix and large elastic chips fly off, as shown in FIG. 2 a . In the high pressure case of FIG. 2 b , the cutting is composed of completely crushed material, having a saw tooth shape and held together by pressure. As shown, the reconstituted cutting is extruding up the face of the cutter.
DEM Cutting Results
[0035] Quantitative agreement between cutting forces generated by PFC models and measured cutting forces is elusive because the PFC model employed is a two-dimensional model, (PFC2D) while actual rock cutting in the real world is, of course. effected in three dimensions. It has been shown that cutting in a groove has a significant effect on the cutting forces that cannot be accounted for using PFC2D. P. V. Kaitkay. 2002, Modeling of Rock Cutting Using Distinct Element Methods , Kansas State University Master's Thesis.
[0036] There is, however a wide range of qualitative agreement between rock cutting tests conducted at high pressure and PFC models. For example, cutting becomes less efficient with increasing back rake, just like in real cutting tests. FIG. 3 shows a 30° back rake cutter, modeled in the same manner and under the same simulated conditions as FIG. 2 b , which shows a 15° back rake cutter. The 30° back rake case required 45% more normal force to maintain the same depth of cut, which is in accordance with actual rock cutting tests.
[0037] Another qualitative agreement between actual rock cutting tests and DEM modeling is that specific energy required to cut rock increases with decreasing depth of cut. That is, cutting becomes less efficient at lower depths of cut, just like it does in actual drilling. Whatever mechanisms govern this reduction in efficiency in real life are evidently reproduced in the model. Other qualitative agreements have also been observed to exist.
[0038] PFC indicates that one of the most significant mechanisms governing cutting efficiency is flow of the crushed formation material under the cutter. This mechanism is not widely recognized in the literature. Detournay and his students have observed and modeled this flow at atmospheric pressure. E. Detournay and A. Drescher, 1992, Plastic flow regimes for a tool cutting a cohesive-frictional material, in Pande & Pietrusczak (eds) Numerical Models in Geomechanics , pp. 367-376, Rotterdam: Balkema; H. Huang, 1999, Discrete Element Modeling of Tool - Rock Interaction , University of Minnesota Ph.D Thesis; T. Richard, 1999, Determination of Rock Strength from Cutting Tests , University of Minnesota Master's Thesis. Gerbaud and his colleagues at the Ecole des Mines de Paris have performed lab tests that indicate some material must be flowing under the cutter. L. Gerbaud, S. Menand, and H. Sellami, 2006, PDC Bits: All Comes from the Cutter Rock Interaction, IADC/SPE 98988, presented at the IADC/SPE Drilling Conference, Miami. However, the effects Gerbaud predicts in empirical equations are not as profound as those indicated by PFC.
[0039] One significant fact that PFC models reveal is that the presence of a third material, the crushed rock, plays a key role in the cutting process. Cutters do not bear directly on the virgin elastic rock that we seek to excavate. Rather, there is always the presence of this third material between the cutter and the elastic rock. While publications have shown this third material in illustrations, the mechanical properties of the crushed material are almost always ignored in mathematical models of formation cutting, probably because it has been presumed that this crushed rock is rather weak. However, while the crushed material has no elastic strength, it has been determined by the inventor to have significant strength due to hydrostatic compression under the confining borehole pressure.
[0040] To be an effective tool in predicting cutter and drill bit performance, the constitutive properties of this crushed material must be determined. As the strength of a rock cutting is predominantly a function of differential pressure, the strength must he determined under pressure. Notably, as soon as the cutting is created, it begins imbibing filtrate from the drilling mud, which alters its strength. The strength, therefore, must be evaluated immediately after the cutting is created. One embodiment of the invention comprises a test to provide a first order approximation of the cutting strength.
[0041] For calibration purposes, a special rotary drag bit using polycrystalline diamond compact (PDC) cutters was built, the cutters being spaced far enough apart that chips of formation material cut by the PDC cutters and flowing on each blade would not interact with each other. 3.17 mm (⅛ inch) diameter rods were mounted rotationally behind each PDC cutter, protruding from the blade, in the path of the cutting from a given cutter. Rods of different material, including copper, bronze and steel, were placed in the path of the cuttings to determine which rods the cuttings are able to bend and, thus, obtain an estimate of their strength. However, in tests with Catoosa shale at 41.4 MPa (6,000 psi) bottom hole pressure and drilling at 60 RPM with a depth of cut of 0.51 mm/rev (0.2 in/rev), the cuttings bent all the rods. A blade of the bit and bent rods is shown from frontal and side perspectives in FIG. 4 a . A partially split cutting that was bearing against one of the rods is shown in FIG. 4 b.
[0042] Knowing how much force is required to bend these rods, a lower bound of cutting strength was estimated, on the same order of magnitude as the original strength of the Catoosa shale.
Inelastic Rock Properties Govern Rock Cutting
[0043] PFC can show how much energy is partitioned in elastic strain in the balls, elastic strain in the bonds, friction between the balls, kinetic energy and damping. PFC indicates that during cutting under pressure. fifty times more energy is dissipated in friction (the sum of ball to ball and ball to wall friction) than is stored in elastic energy. This observation appears to be accurate because: (1) the crushed rock material is strong and large forces are required to deform it; (2) the volume of the crushed material being deformed at any instant is larger than the volume of the highly stressed elastic front ahead of the crushed rock; (3) the strain of the crushed rock is very high; (4) in a high strain elastic-plastic deformation, substantially more energy is dissipated in plastic deformation than elastic deformation. This last conclusion is illustrated in FIG. 5 , which shows a stress/strain curve of Bonne Terre Dolomite from an actual test. This stress/strain curve is from a triaxial test conducted at 41 MPa (6,000 psi) confining pressure strained to 10% strain. Even at this comparatively low strain, the plastic energy represents the large majority of the energy dissipation.
[0044] Since the majority of the energy expended in cutting under pressure is apparently dissipated in friction, then the elastic properties of the rock are largely immaterial. As an experiment, a PFC cutting test was run in a manner identical to that shown in FIG. 2 b , but with all elastic ball-to-ball bonds deleted. The rock with bonds (shown in FIG. 2 b ) had a UCS of 55 MPa (8,000 psi). The rock with no bonds in the parallel test (shown in FIG. 6 ) was identical but had a cohesion of zero; this PFC material may be characterized to be like loose sand. Both of these PFC tests were conducted under a hydrostatic pressure of 20.7 MPa (3,000 psi) during cutting. The cutting forces required to cut the unbonded material of the parallel test were nearly identical to the cutting forces required to cut the bonded material. Real life experiments drilling on loose sand strengthened by borehole pressure have yielded similar results. R. A. Cunningham and J. G. Eenink, 1958, Laboratory Study of the Effects of Overburden, Formation and Mud Column Pressures on Drilling Rates of Permeable Formations, Presented at the 33 rd Annual Fall Meeting of the Society of Petroleum Engineers, Houston.
[0045] In an embodiment of the invention, particular mechanical properties were selected for measurement in a triaxial test that would characterize this highly plastic process of rock cutting.
[0046] The area under the stress/strain curve is a measure of energy dissipated during deformation, and is also a measure of the specific energy. However, a particular strain level should be selected to quantify this area. Ideally, this area would be measured to the level of strain experienced by the rock during cutting. However, it is not possible to identify one strain level imposed on the rock during cutting because there is such a large variance in the strain field. It is possible, however, to define an “effective” strain during cutting for modeling purposes by extending the strain until the area under the stress/strain curve substantially equals the specific energy consumed in a real test. This approach seems to indicate that the effective strain is in the multiple hundreds of percent. Thus, if one were to compare the specific energy of two drag bits, differences in specific energy between them is related to differing amounts of strain imparted to the rock. More efficient bits are those which remove an equivalent volume of rock under the same conditions with less strain.
[0047] Winters and Warren proposed to measure the area under the stress/strain curve twenty years ago and Kolle reaffirmed this point. W. J. Winters and T. M. Warren, 1987, Roller Cone Bit Model With Rock Ductility and Cone Offset, SPE 16696, presented at the 62 nd Annual Technical Conference and Exhibition Dallas. However, to the knowledge of the inventor this proposal has not been developed. Perhaps one reason is because implementation is more difficult than it sounds. As discussed above, it is presently unknown to what strain a triaxial test should be conducted and, if known, it would not be possible to conduct a triaxial test to such high strain. A much harder question, and one which is not susceptible to an accurate answer, is at what confining pressure for the crushed formation material should the area under the stress/strain curve be evaluated? As there is a wide variance in the hydrostatic component of stress in the stress field ahead of the cutter, it is likely that the differences in hydrostatic component of stress are great enough that some parts of the rock arc strain softening and others are simultaneously strain hardening.
[0048] Another contemplated measure of rock drillability in a triaxial test might simply be the stress difference at high strain. The stress difference at high strain is a measure of the stress required to deform rock detritus. At very high strain, the stress difference tends to approach a steady value (like perfect plasticity). The area under the stress/strain curve at high strain approximates a long rectangle. Strain softening or strain hardening in the early part of the stress/strain curve has a negligible effect on the total area under a stress/strain curve measured to high strain. The height of the stress/strain curve. combined with an effective strain, defines the majority of the area.
[0049] Thus, it is contemplated to be constructive to create something like a “failure Envelope” of the stress difference required to deform detritus at high strain. FIG. 7 shows such an envelope, which may be termed a “flow envelope,” superimposed over a yield surface, or failure envelope. These data were taken from triaxial tests conducted to 10% strain at confining pressures ranging from 3.4 MPa (500 psi) to 207 MPa (30,000 psi). The flow envelope in fact represents the position of the classical yield surface after strain softening and strain hardening have occurred. A measure of strength based on the flow envelope is believed to correlate better with actual drillability than confined compressive strength (CCS) of the rock, since the stress required to deform rock detritus goes up more rapidly with pressure than the stress to fail elastic rock.
[0050] FIG. 8 of the drawings depicts a PFC model of a tooth of a roller cone of a rotating cutter bit indenting a rock formation with some degree of “skidding” as the tooth as it would be mounted to or formed on the roller cone moves right to left in the drawing figure, simulating the combined, well-known rotation and sliding motion of a tooth of a roller cone in an actual drilling operation as the bit is rotated and the cone rotates, under weight on bit. As with previous examples describe above, the contiguous dark balls at the outer surface of the virtual rock formation represent the boundary on which confining pressure is applied. The “skidding” is evident from the build up of rock material to the left of the tooth. Behavior of virtual rock under impact of a cutting structure of a percussion bit may, likewise, be simulated.
CONCLUSIONS
[0051] DEM is a good tool for modeling rock cutting. Large strain and crack propagation are handled naturally. DEM materials exhibit a transition from shear localization to shear-enhanced compaction in virtual triaxial tests like real rocks do. Particle Flow Code gives good qualitative agreement between rock cutting tests and models of those tests.
[0052] Inelastic properties have a stronger influence on rock drillability than elastic properties. Inelastic parameters that characterize rock may be identified and used as analysis tools in DEM. Rock should be evaluated at higher strain levels than previously realized to identify new fundamental mechanical properties that govern drilling.
[0053] The area under the stress/strain curve may be a good parameter with which to quantify rock drillability, due to its correlation with specific energy. Thus, there are opportunities to use the area under the stress/strain curve to understand how to apply DEM at high pressure. It is believed that the stress difference at high strain may also be employed as a practically attainable measure that will correlate with rock cutting and rock drillability.
[0054] While the present invention has been described in terms of certain embodiments, those of ordinary skill in the art will recognize that it is not so limited, and that variations of these embodiments are encompassed by the present invention. Accordingly, the present invention is limited only by the scope of the Claims which follow, and their legal equivalents.
[0055] The disclosure of each of the documents referenced in the foregoing specification is hereby incorporated in its entirety by reference herein.
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Discrete Element Modeling (DEM) of rock subject to high confining pressures, such as in a subterranean drilling environment, may be used to predict performance of cutting structures used in drill bits and other drilling tools, as well as of the tools themselves. DEM may also be used to create “virtual” rock exhibiting specific drillability characteristics with or without specific reference to any actual rock, for purposes of assessing cutting efficiency of various cutting structure configurations and orientations, as well as of drilling tools incorporating same.
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CROSS REFERENCE TO RELATED APPLICATION
This application claims the priority of German Application No. P 44 38 884.5, filed Oct. 31, 1994.
BACKGROUND OF THE INVENTION
This invention relates to an apparatus for measuring the sliver thickness in a drawing frame, particularly in a regulated drawing frame. The apparatus includes a sliver guiding device for guiding a plurality of simultaneously inputted fiber slivers at the inlet of the drawing frame. At least parts of the inner wall faces of the guiding device converge such that the side-by-side running slivers are brought together to form a sliver assembly in which the slivers assume a side-by-side contacting relationship in a single plane. Downstream of the guiding device, as viewed in the direction of sliver run, a roller pair is arranged which defines a nip through which the sliver assembly passes. By virtue of the frictional engagement in the nip, the roller pair pulls the sliver assembly through the sliver guiding device. Downstream of the roller pair the slivers diverge from one another. The sliver guiding device is associated with a biased, movable sensor element which, together with an operationally stationary counterelement (wall element), constitutes a constriction for the throughgoing sliver assembly. The sensor element executes excursions as the thickness of the sliver assembly changes. The displacements of the sensor element are applied to a transducer which, in response, generates control pulses. The counterelement situated opposite the sensor element may be adjusted and immobilized in its adjusted position.
In a known arrangement of the above-outlined type the counterelement is shiftable towards or away from the sensor element and may be immobilized in its adjusted position by a setscrew. The purpose of such an adjustment is to adapt the sliver guiding device to different fiber batches, particularly when the type of fiber is changed or the number of the parallel running slivers is altered.
SUMMARY OF THE INVENTION
It is an object of the invention to provide an improved apparatus of the above-outlined type in which the sliver guidance between the sensor element and the counterelement is improved.
This object and others to become apparent as the specification progresses, are accomplished by the invention, according to which, briefly stated, the apparatus for measuring sliver thickness in a drawing frame includes a sliver guiding device having converging inner wall faces for bringing a plurality of simultaneously introduced slivers together to form a sliver assembly constituted by side-by-side positioned running slivers arranged in a plane. The apparatus further includes a sensor element and a counterelement laterally contacting the sliver assembly from opposite sides. The counterelement is so supported that it may pivot parallel to the plane of the sliver assembly-for purposes of adjustment and immobilization. The sensor element is urged into a resilient contact with the sliver assembly whereby the sensor element undergoes excursions upon variation of thickness of the sliver assembly. The sensor element and the counterelement together define a constriction through which the sliver assembly passes. A transducer converts excursions of the sensor element into electric pulses. A withdrawing roller pair supported downstream of the sliver guiding device pulls the sliver assembly through the sliver guiding device.
By virtue of the fact that the counterelement is rotatable, the guidance of the slivers in case of change in the type or number of slivers is improved. The alteration of the angle between the counterelement and the lateral wall surfaces of the guiding device permits an adaptation when a change in the processing of the slivers occurs.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1a is a schematic side elevational view, with block diagram, of a regulated drawing frame, incorporating the invention.
FIG. 1b is an enlarged top plan view of a component illustrated in FIG. 1a, showing further details.
FIG. 2 is a sectional top plan view of the component illustrated in FIG. 1b, showing further details.
FIG. 3a is a sectional top plan view of a preferred embodiment, showing structural details and illustrating the construction in a first setting.
FIG. 3b is a view similar to FIG. 3a, illustrating the construction in a second setting.
FIG. 4 is a sectional top plan view of a preferred embodiment, showing structural details and illustrating the construction in a third setting by virtue of component replacement.
FIG. 4a is an enlarged top plan view of a detail of FIG. 3a.
FIG. 5 is a perspective view of a sliver guiding device according to a preferred embodiment of the invention.
FIGS. 6a and 6b are sectional top plan views of another preferred structural embodiment of the invention, showing two different operational positions.
FIGS. 7a and 7b are sectional top plan views of yet another preferred structural embodiment of the invention, showing two operational positions.
FIGS. 8, 9 and 10 are schematic sectional top plan views of three additional preferred embodiments of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1a illustrates a high production drawing frame which may be, for example, an HS 900 model, manufactured by Trutzschler GmbH & Co. KG, Monchengladbach, Germany. A plurality of slivers 3, paid out from non-illustrated coiler cans, enter a sliver guiding device 2, through which they are drawn and further advanced by a pair of cooperating withdrawing rollers 4 and 5. In their travel through the sliver guiding device, the slivers 3 move past a measuring member 6. The drawing frame 1 includes an upper inlet roller 7 and a lower inlet roller 8 which are associated with the pre-drawing zone 9 delimited at the downstream end by the upper predrawing roller 10 and the lower predrawing roller 11. Between the roller pair 10, 11 as well as a roller pair formed of the upper main drawing roller 13 and the lower main drawing roller 15 the main drawing zone 12 extends. The lower main drawing roller 15 is associated with a second upper main drawing roller 14. Such an arrangement is referred to as a four over three drawing system.
The drafted slivers 3, after passing through the roller pair 14, 15, reach the inlet of a sliver guide 16 and are drawn through a sliver trumpet 17 arranged at the downstream end of the sliver guide 16 by cooperating delivery rolls 18, 18'. In the sliver trumpet 17 the slivers are combined into a single sliver deposited into a non-illustrated coiler can. The main drawing rollers 13, 14, 15 and the delivery rollers 18, 18' are driven by a main motor 19 controlled by a computer 21. The signals generated by the measuring member 6 at the sliver guiding device 2 are applied to the computer 21 and are converted into control signals which are applied to a regulating motor driving the withdrawing rollers 4, 5 as well as the rollers 7, 8, 10 and 11 of the pre-drawing zone 9. According to the signals of the measuring unit 6, representing the fluctuating thickness values of the sliver assembly formed of the slivers 3, the computer 21 sends control signals to the regulating motor 20 which accordingly varies the rpm's of the rollers 4, 5, 7, 8, 10 and 11.
Turning to FIG. 1b, in the top plan view illustrated therein the upper withdrawing roller 4 is not shown for clarity. The slivers 3 are brought together in the sliver guiding device 2 to form the sliver assembly in which the individual slivers are in a mutually contacting relationship and extend in a single plane. The measuring unit 6 symbolically shown in FIG. 1a includes a sensor element 22 which is rotatably supported by a bearing 30 for swinging motions in a direction parallel to the single plane in which the slivers 3 of the sliver assembly lie. The structure and function of the sensor element 22 will be described later.
Opposite the sensor element 22 a counterelement 34 is provided which is adjustable to vary, in cooperation with the sensor element 22, the passage width of a constriction 23 at the outlet end of the sliver guiding device 2. As will be described later, the counterelement 34 is adjustable by swinging it about a pivot 36 in a direction parallel to the single plane in which the slivers 3 of the sliver assembly lie. The counterelement 34 may be immobilized in its adjusted position, as will also be described later.
FIG. 2 shows how the individual slivers 3 are brought together by the sliver guiding device 2 to assume therein a side-by-side contacting relationship to form the sliver assembly and how they are sensed in the constriction 23 by means of the sensor element 22. The sensor element 22 has a lever arm 31a which is exposed to the pulling force of a tension spring 32 and is coupled with a measuring element 33 which may be a plunger-and-solenoid arrangement. Another lever arm 31b laterally continuously engages with its free end the sliver assembly formed of slivers 3. Thickness changes in the throughgoing fiber quantities of the slivers 3 are thus sensed as volume changes. Departing from FIG. 1b, the withdrawing rollers 4 and 5 are arranged vertically, that is, the slivers are laterally clamped by the nip 26 of the rollers 4 and 5.
FIGS. 3a, 3b and 5 show the apparatus for measuring the thickness of a sliver assembly formed of slivers 3. The guiding device 2 has four walls 2a, 2b, 2c and 2d, of which at least two oppositely located walls converge towards one another in the downstream direction, that is, in the sliver advancing direction L. The walls 2a-2d cause the slivers 3 to converge and assume a side-by-side position in a single plane to form the sliver assembly. As the sliver assembly exits from the device 2, it enters the withdrawing rollers 4 and 5 after which the sliver assembly is dissolved as the individual slivers 3 assume a divergent course. In the downstream zone of the sliver guiding device the pivotal sensor element 22 is arranged which, together with the facing counterelement 34 forms the constriction 23 for the sliver assembly. The change in position of the sensor element 22 caused by a thickness variation of the sliver assembly applies mechanical signals to a transducer 33 which, accordingly, emits electric control pulses.
The counterelement 34 is pivotal in the direction of the arrows A, B about the axis of a rotary bearing (pivot pin) 36 parallel to the plane in which the slivers 3 are arranged side-by-side. The rotary bearing 36 is arranged at the outlet end of the guide wall 2c, as best seen in FIG. 3a and supports the counterelement 34 at an end 34' thereof. The counterelement 34 may be adjusted and immobilized in the adjusted position, for example, by a setscrew 35 having a stem 37 engaging the counterelement 34 at a location spaced from the pivot pin 36. The setscrew 35 is held in a support bracket 35'. The support bracket 35' and the rotary bearing 36 are secured in threaded bores 42 in a base plate 40 by means of screws 41a, 41b, and are laterally shiftable to new adjusted positions as indicated by the arrows C and D. The sensor element 22 and the counterelement 34 project through the lateral walls 2b and 2c. By means of the setscrew 35 the counterelement 34 is rotated about the rotary axis 36, for example, when the processed silver type is changed (the drawing frame 1 is inoperative during such changing operation), so that the distance between the counterelement 34 and the sensor element 22 is, in the constriction 23, changed from the distance a (FIG. 3a) to the distance b (FIG. 3b). At the same time, the angle α between the wall 2c and the counterelement 34 is also changed. The sensor element 22 biased by the spring 32 engaging the lever arm 31a of the sensor element 22 reacts to all changes of thicknesses of the throughgoing slivers 3, as a result of which the distance between the sliver engaging tip of the sensor element 22 and the finely adjusted counterelement 34 varies as a function of the thickness fluctuations. As it may be observed in FIGS. 3a and 3b, the silver-engaging surface of the counterelement 34 is such that in any pivotal position of the counterelement 34, the sliver assembly passes smoothly from the walls of the device 2 onto the sliver-engaging surface of the counterelement 34.
As seen in FIG. 3a, the sliver guiding device 2 has two opposite, converging side walls 2b, 2c having an inlet width c and an outlet width d. The side wall 2b lies with its outer face against a web-like holding element 38 which, as best shown in FIG. 5, is secured to a base plate 39. The holding element extends perpendicularly to the base plate 39 and parallel to the side wall 2b.
In the construction shown in FIG. 4, the sliver guiding device 2 of the earlier described embodiment is replaced by a sliver guiding device 2' having a greater inlet width c' and a greater outlet width d' than the respective dimensions c and d of the sliver guiding device 2. The converging walls of the sliver guiding device 2' are inclined at a different angle than in the sliver guiding device 2. As an alternative, it may be feasible to nest a smaller sliver guiding device in a permanently attached sliver guiding device of larger dimensions. A replacement of a sliver guiding device 2' for a sliver guiding device 2 is effected, for example, because of a change in the type of the sliver to be processed by the drawing frame.
Reverting to FIG. 5, the guide wall 2a in the zone of the constriction 23, that is, in the zone of the outlet of the sliver guiding device 2 for the fiber slivers 3, has a zone 2a' which faces a zone 2d' of the guide wall 2d. The lateral walls 2b and 2c include a slot in the zone of the constriction 23 so that the sensor element 22 and the counterelement 34 may project therethrough and may engage, under pressure, laterally opposite sides of the sliver assembly composed of the side-by-side arranged slivers 3. The base surface 2d' merges into the base plates 39 and 40 situated externally of the sliver guiding device 2.
Turning to FIGS. 6a and 6b, the sensor element 22 is a lever pivotal about the bearing 30 and has lever arms 31a and 31b extending in opposite directions from the bearing 30. The lever 31 is swingable as indicated by the arrows E and F. At the end of the lever arm 31a, the sensor element 22 is engaged by a tension spring 32, whose other end is secured to a single-arm adjusting lever 43 which is rotatable about a pivot 44 in the direction of the arrows G and H. The free outer end of the lever 43 may form a manually engageable handle. The pivot 44 is secured to the base plate 39. In case the setting lever--which may be immobilized by detents--is moved from its position shown in FIG. 6a in the direction of the arrow H into the position shown in FIG. 6b, the securing location of the spring 32 is changed, whereby the bias and thus the spring force exerted on the sensor element 22 is altered. The base plate 39 has detents 45 and 46 such as slots and bolts for determining positions for the setting lever 43.
FIGS. 7a and 7b show a single-arm pivotal lever 47 which is swingable in the direction of the arrows I and K about a pivot 48 secured to the base plate 39. One end of a tension spring 50 is connected to the pivotal lever 47 at a location 51, while the other end of the tension spring 50 is secured to a stationary spring support 52. On the pivot lever 47 a carrier element, for example, a pin 53 is provided which is connected with the lever arm 31a of the lever 31 forming the sensor element 22. In case the pivot lever 47 is moved from its position shown in FIG. 7a in the direction of the arrow I into the position shown in FIG. 7b, then by virtue of the pressure by the pin 53 the lever arm 31a is shifted, as a result of which the distance between the sensor element 22 and the counterelement 34 is increased from a (FIG. 7a) to e (FIG. 7b). In this manner, the opening in the zone of the fiber outlet is significantly increased to what may be termed as a servicing opening e. The servicing opening e facilitates a thread-in operation for the slivers 3 upon a start of operation or readily permits a cleaning of the inner surfaces of the sliver guiding device 2. The immobilizing or detent devices for the pivot lever 47 (such as wall apertures) are designated at 54 and 55.
In FIG. 8, the rotary bearing 36 supporting the counterelement 34 and the setting device including the setscrew 35 are mounted on a shifting element 56, whose position may be changed and which may be immobilized by screws received in threaded bore holes 42 of the base plate 40, as shown in FIG. 3a. Between the side walls 2b and 2c of the sliver guiding device 2 on the one hand and the sensor element 22 and the counterelement 34 on the other hand, respective rubber seals 62 and 61 are arranged, as also shown in FIG. 3a.
According to FIG. 9, the counterelement 34 is rotatably mounted on the bearing 36.
Turning to FIG. 10, the counterelement 34 is provided with a slot 57 through which a screw 58 extends. This arrangement provides for both a pivotal and a linear shifting motion of the counterelement 34. The screw 58, in addition to functioning as a pivot and a linear guide, also serves for immobilizing the counterelement 34 in its set position.
It will be understood that the above description of the present invention is susceptible to various modifications, changes and adaptations, and the same are intended to be comprehended within the meaning and range of equivalents of the appended claims.
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An apparatus for measuring sliver thickness in a drawing frame includes a sliver guiding device having converging inner wall faces for bringing a plurality of simultaneously introduced slivers together to form a sliver assembly constituted by side-by-side positioned running slivers arranged in a plane. The apparatus further includes a sensor element laterally contacting the sliver assembly; and a counterelement laterally contacting the sliver assembly. The counterelement is so supported that it may pivot parallel to the plane of the sliver assembly for purposes of adjustment and immobilization. The sensor element is urged into a resilient contact with the sliver assembly whereby the sensor element undergoes excursions upon variation of thickness of the sliver assembly. The sensor element and the counterelement together define a constriction through which the sliver assembly passes. A transducer converts excursions of the sensor element into electric pulses. A withdrawing roller pair supported downstream of the sliver guiding device pulls the sliver assembly through the sliver guiding device.
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LIST OF PRIOR ART REFERENCE
The following reference is cited to show the state of the art:
(1) G. Smarandoin et al., "An all -MOS Analog to Digital Converter Using a Constant Slope Approach": IEEE Journal of Solid-State Circuits, June, 1976.
BACKGROUND OF THE INVENTION
1. FIELD OF THE INVENTION
This invention relates to an analog-to-digital Converter (hereinafter referred to as an ADC) which is important for an interface between the analog and the digital circuits, and more particularly to an integrating type ADC as used in the field of welfare equipments, home electric apparatus and instrumentation, etc.
2. DESCRIPTION OF THE PRIOR ART
In a prior art ADC, A-D conversion is done by discharging the charge corresponding to an input signal by a discharging circuit after it is charged in a strorage means, and counting the number of clock pulses by a counter during the discharging time T which is equal to a period that a level of the charge reaches a constant detection level V T . An example is described in an article entitled "An All-MOS Analog to Digital Converter Using a Constant Slope Approach", IEEE Journal of Solid State Circuits, June 1976 by G. Smarandoin et. al.
However, in such a circuit construction of the prior art, if an input signal voltage is less than the detection level V TH , the discharge time T cannot be detected, and thus A-D conversion is impossible. In another word, in the prior art circuit, the A-D conversion is possible in a limited range of the input signal.
SUMMARY OF THE INVENTION
One object of this invention is to extend the range of input signal for A-D conversion in an ADC, wherein charges corresponding to an analog input signal are stored in a storage means and then the stored charges are discharged so that a discharge time until a momentarily changing voltage of said storage means reaches a certain detection level is counted by a counter.
Another object of this invention is to provide a circuit construction effective to form an ADC in an IC.
In order to attain these objects, the ADC according to this invention has such a construction that a predetermined bias voltage is connected to the voltage of the storage means (since this voltage is usually equal to an input signal voltage, it is assumed to be the input signal voltage hereinafter) at the discharging to increase the discharge starting voltage and that the discharge time until the discharge voltage reaches said detection level is counted. Thus, even if the input signal voltage is below the detection level V TH , the discharge starting voltage is made larger than the bias voltage by a suitable setting of the bias voltage, whereby counting of discharge time or the A-D conversion of a very small analog signal becomes possible.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a drawing showing the schematic circuit construction of the prior art ADC of exponential slope type.
FIG. 2 is a waveform diagram for explanation of the operation of the circuit construction of FIG. 1.
FIG. 3 is a drawing showing the schematic circuit construction of an ADC of exponential slope type according to one embodiment of this invention.
FIGS. 4a and 4b are waveform diagrams for explanation of the operation of the circuit construction of FIG. 3.
FIGS. 5a and 5b are concrete circuit diagrams showing a bias voltage supply means in the circuit construction of FIG. 3.
FIG. 6 is a drawing showing the schematic circuit construction according to another embodiment of this invention.
FIG. 7 is a waveform diagram for explanation of the operation of the circuit diagram of FIG. 6.
FIGS. 8a and 8b are drawings showing the essential portion of a circuit construction improving the embodiment of FIG. 6.
FIG. 9 is a drawing showing the schematic circuit construction of an ADC of constant slope type according to another embodiment of this invention.
FIG. 10 is a drawing showing the concrete circuit construction of a constant current discharge circuit in the circuit construction of FIG. 9.
FIG. 11 is a waveform diagram for explanation of the operation of the circuit construction of FIG. 9.
FIG. 12 is a drawing showing the schematic circuit construction of an example of modifying the connection point of the bias voltage supply means used in this invention.
DESCRIPTION OF THE PRIOR ART
Prior to a detailed description of this invention with reference to the drawings, an explanation of an example of the prior art ADC of exponential slope type will be made with FIG. 1. The literature already indicated demonstrating an ADC of constant slope type should be referred to also.
In FIG. 1, 1 denotes an input terminal to which an input signal is supplied, and 2 denotes a storage means comprising a switch 21 (SW1) and a capacitive element 22. 3 denotes a discharging circuit comprising a resistance element 31 and a switch 32 (SW2). 4 is a level detecting circuit and 5 is a counter whose terminals 51, 52 and 54 receive clock pulses to be counted, set and clear pulses respectively.
FIG. 2 is a waveform diagram for explanation of the operation of the circuit construction of FIG. 1. When an input signal voltage V I is supplied to the input terminal 1 and the switch 21 (SW1) is turned on at a time shown in FIG. 2(b), the output terminal voltage V or the voltage at one terminal of the capacitive element 22 of the storage means 2 becomes equal to the input signal voltage V I . That is, the analog input signal voltage V I is stored in the storage means. After a time to, when the switch 21 (SW1) is turned off and the switch 32 (SW2) of the discharging circuit 3 is turned on as shown in FIG. 2(c), an electric charge is discharged with an exponential slope through the resistive element 31, as shown in FIG. 2(a). When the voltage V drops to a constant detection level V TH , the level detection circuit 4 is turned off, as shown in FIG. 2(d), giving a reset pulse for the counter 5. Since the set pulse for the counter 5 was applied at the terminal 52 at the discharge starting time or when the switch 32 (SW2) was turned on, the counter 5 counts the number of clock pulses supplied to the terminal 51 during the period T I o as shown in FIG. 2(e). After the end of counting, the count value is sent out to a processing circuit as shown by an arrow 53.
Following equations hold for the count value N I o , the frequency f of clock pulses, the capacitance C of the capacitive element 22, and the resistance R of the resistance element.
V.sub.I =V.sub.TH exp (T.sub.I.sup.o /CR), (1)
N.sub.I.sup.o =fT.sub.I.sup.o =f·CR·ln (V.sub.I /V.sub.TH). (2)
As apparent from these equations, if V I ≦V TH , the value of N I o becomes zero. That is, in the circuit construction shown in FIG. 1, when the input signal voltage V I is less than the detection level V TH , the output of counter 5 is zero, which means that the A-D conversion is not possible. It is seen therefore that the A-D conversion of the prior art circuit is limited.
This is also the same with an ADC of constant slope type using a constant current circuit in the discharging circuit. Putting the count value N IC o , the period T IC o and the current value of the constant current circuit I o , we have the following equations corresponding to eqs. (1) and (2).
V.sub.I =(I.sub.o /C)T.sub.IC.sup.o +V.sub.TH, (3)
N.sub.IC.sup.o =(f.sub.C /I.sub.o)(V.sub.I -V.sub.TH) . (4)
It is clear that unless V I >V TH the count value N IC o is not obtained.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 3 shows the first embodiment of this invention, in which this invention is applied to an ADC of exponential slope type. In the figure, the same reference numeral designates the same element. 6 denotes a bias voltage supply means having a function of connecting a bias voltage V B to the capacitive element 22. 61 and 62 are switches (SW3) and (SW4) respectively. 63 is a bias voltage source. A parallel circuit comprising the switch 61 or (SW3), the switch 62 or (SW4) and the bias voltage source 63 is connected in series with the capacitive element 22.
Explanation will be made of the operation of the embodiment with reference to FIGS. 4a and 4b, showing the waveforms at the output of the storage means 2 of FIG. 3. FIG. 4a shows the waveform when the input signal voltage V I is less than the detection level voltage V TH while FIG. 4b shows the waveform when V I is larger than V TH . In FIG. 4a, under the condition of switch 21 (SW1) on; switch 32 (SW2) off; switch 61 (SW3) on; and switch 62 (SW4) off, an input signal voltage V I less than V TH is applied at the input terminal 1. Corresponding charge is stored in the capacitive element 22 and the voltage V at the output of the storage means becomes V I . Next, when the switches 21 (SW1) and 32 (SW2) are turned off and on respectively and, at the same time the switches 61 (SW3) and 62 (SW4) are turned off and on respectively to connect a bias voltage V B to the capacitive element 22 to cause discharging, the voltage V at the output of the storage means 2 is shifted to (V I +V B ). In this case, the bias voltage V B should of course satisfy the condition V I +V B >V TH . The period T I in which the voltage V at the output of the storage means 2 drops to V TH is counted by a counter 5 to obtain a count value N. Here, the following equations corresponding to eqs. (1) and (2) hold.
V.sub.I =V.sub.TH exp (T.sub.I /CR)-V.sub.B, (5)
N.sub.I =fCRln ((V.sub.I +V.sub.B)/V.sub.TH). (6)
Thus, even if the input signal voltage V I is smaller than V TH , the A-D conversion is effected only by adding a bias voltage source with a suitable value and an additional switch. FIG. 4b shows the waveform when the condition of switch 61 (SW3) on; switch 62 (SW4) off is kept at the discharging time since the input signal voltage V I is larger than V TH . It is noted that the waveform of FIG. 4b is entirely the same as that of FIG. 2a.
Although in the above description the bias voltage V B was connected to the capacitive element 22 prior to the discharging and the voltage V at the output of the storage means 2 was made (V I +V B ), a bias voltage V B with V B >V TH may be connected to the capacitive element 22 before the discharging regardless of whether V I is less than V TH or not. By this method, the circuit can be easily constructed, because no circuit for discriminating whether V I is larger or smaller than V TH is necessary.
Next, explanation will be made of effective elements for constructing the embodiment of FIG. 3 in an IC. As the switches (SW1) to (SW4), single channel (n or P channel) MOSFET or C-MOS analog switches may be used. The level detection circuit 4 can be formed by MOSFET, since it works satisfactorily by multistage connection of conventional logic gates such as inverters.
A concrete example of V B , V TH , and V I will be briefly described here. When the level detection circuit 4 is constituted by multistage connections of inverters, V TH may be set at 0.5 V to 1.5 V. If V TH is set around 1.3 V and the bias voltage V B is set around 2.0 V, all the input signal voltage V I above OV can be A-D converted.
FIGS. 5a and 5b show concrete examples of the bias voltage supply means 6 in FIG. 3. In FIG. 5a, the switches 61 (SW3) and 62 (SW4) of FIG. 3 are constituted by MOSFET's, with 64 and 65 being control terminals for them. FIG. 5b shows a bias voltage supply means 6' realized by a conventional inverter of MOSFET's, with 66 and 67 being V DD supply and control terminals respectively. The voltage difference between the low and high levels of the inverter corresponds to the bias voltage V B . Namely, the inverter is at the low level at the charging time while at the high level at the discharging time. Usually, the low level is grounded.
FIG. 6 shows a modification of the embodiment of FIG. 3. In this embodiment, a reference voltage terminal 7 is connected in parallel with the input terminal 1 to which the input signal voltage V I is supplied, and furthermore switches 23 (SW5) and 24 (SW6) are added to the switch 21 (SW1). Influence of irregularity and age variation of the circuit elements are thus eliminated by the introduction of the reference voltage V R as one of the input voltages of ADC. In FIG. 6, the level detection circuit 4 is drawn by a multiple connection of inverters 4. The inverters 4 may be those, as shown in FIG. 5b.
Explanation of the operation of the circuit construction of FIG. 6 will be made next with reference to FIG. 7. FIG. 7(a) shows the output voltage V of the storage means 2. FIGS. 7(b), (c), (d), (e) show ON-OFF operations of the switches (SW6), (SW1), (SW5) and (SW2) respectively. FIG. 7(f) shows the output of the level detection means 4 while FIG. 7(g) shows the operation timing of the counter 5. Although the application time of bias voltage V B is not shown, V B is applied simultaneously with the ON of the switch 32 (SW2) while its application is stopped simultaneously with the ON of the switch 24 (SW6). Initially, when the switch 24 (SW6) is turned on and the zero voltage is A-D converted, the counter 5 gives a count value No. Next, when the switch 21 (SW1) is turned on and the input voltage V I is A-D converted, the counter 5 gives a count value N I . Lastly, when the switch 23 (SW5) is turned on and the reference voltage V R is A-D converted, the counter 5 gives a count value N R . In this case, the following equation hold.
0=V.sub.TH exp (N.sub.o /fCR)-V.sub.B, (7)
V.sub.I =V.sub.TH exp (N.sub.I /fCR)-V.sub.B, (8)
V.sub.R =V.sub.TH exp (N.sub.R /fCR)-V.sub.B. (9)
From eqs. (7), (8) and (9), we have ##EQU1## Thus, V I is free from the influence of C, R, and V TH .
However, since the bias voltage V B is obtained from the high level of the inverter, variation of V B and age variation become serious. FIG. 8 shows the essential portion of a circuit construction solving these problems. FIG. 8a shows a construction which counts a count value N B corresponding to the bias voltage V B . In comparison with FIG. 5, an inverter 8 with the same characteristic as that of the inverter 6' for the bias voltage supply means, an input terminal 9 to which the high level voltage V B ' is applied, and a switch 25 (SW7) for supplying this voltage to the storage means (2) are added. In this circuit, assuming the count value for V B ' with V B '=V B as N B , we have ##EQU2## Thus, the influence of V B is eliminated. If the variation of V B and V B ' can not be neglected, the embodiment as shown in FIG. 8b may be useful, in which two kinds of reference voltage are used. Let reference voltages V R and V R ' be applied to the inputs 7 and 7' respectively and count values N R and N R ' be obtained by the counter 5. Assuming the count values for the input voltage V I and the zero voltage as N I and N o respectively, we obtain ##EQU3## where τ" may be obtained from ##EQU4## In FIG. 8b, the switch 23' (SW5') serves to select the reference voltage V R '.
The above description referring to FIGS. 3 to 8 has been made on the embodiments of ADC of exponential slope type. Next, explanation will be made of an embodiment of ADC of constant slope type with reference of FIG. 9. A difference from the exponential slope type is that a constant current discharging circuit 3' is employed as a discharging means. In addition, SW1, SW5 and SW9 are designated to be MOSFET's.
FIG. 11 shows the waveform diagrams of the circuit construction of FIG. 9. FIG. 11(a) shows the voltage V at the output of the storage means 2; FIG. 11(b) shows the ON states of (SW1), (SW5), and (SW6); FIGS. 11(c), (d) and (e) show the ON and OFF states of (SW2), (SW3) and (SW4) respectively; FIG. 11(f) shows the output of the level detection circuit 4; and FIG. 11(g) shows the counting period of the counter 5. Although the times of ON-OFF of switches (SW1) to (SW6) are shown to coincide with each other, the switch 61 (SW3) is turned off a little later than the OFF time of switches 21 (SW1), 23 (SW5) and 24 (SW6). The switch 62 (SW4) is then turned on at a later time, and the switch 32 (SW2) is turned on at a further delayed time. Morerover, it is necessary to provide a certain time gap between the OFF time of switch 62 (SW4) and the On time of switch 61 (SW3). The control of the switch group is done by a signal from a control circuit (not shown).
As apparent from the waveform of FIG. 11(a), when the switches 62 (SW4) and 61 (SW3) are turned off and on respectively, the voltage V at the output of the storage means 2 becomes minues, say-(V B -V TH ). If the circuit of this invention is constructed by IC, since the p-n junctions between the substrate and the drain regions of the switches 21 (SW1), 23 (SW5) and 24 (SW6) is forwardly biased, the IC could be destructed due to an excessive current. One desirable method to avoid this is to turn on the switch 61 (SW3) and the switch 24 (SW6) simultaneously after the switch 62 (SW4) is turned off, as shown in the embodiment of FIGS. 6 and 7, to bring the both terminals of the capacitive element 22 to zero voltage.
Denoting the constant current value in the discharging time of the constant current discharging circuit 3' by I o , eqs. (3) and (4) hold. Therefore, the circuit of FIG. 9 operates in accordance with the operation waveform shown in FIG. 11. If the count values for the reference voltage V R , the input signal voltage V I and the zero voltages V o are N RC , N IC and N DC respectively, we have ##EQU5## In the above equation, C and V B do not appear. Various kinds of circuits built in an IC are pablicly known. However, as compared with them, the circuit construction as shown in FIG. 10, for example, is favorable, which was filed by the applicant as a specification of Japanese Patent Application No. 87417/77 on July 22, 1977. In FIG. 10, 33 is a V DD supply terminal and 34 is a control terminal for supplying a control pulse to the gate of a MOSFET switch 32 for operating the constant current circuit and discharging it. In the constant current circuit, there is utilized the fact that the drain current in the saturation region of the enhancement type MOSFET is substantially constant independently of the drain voltage. This constant current circuit consists of a constant current output circuit 35 and its bias circuit 36. The constant current output circuit 35 comprises two enhancement type MOSFET's 351 and 352 connected in series between the output terminal and the earth. The bias circuit 36 operates the enhancement type MOSFET's 351 and 352 in the saturation region, and is formed by a first voltage division circuit consisting of the depletion type MOSFET 361 and the enhancement type MOSFET 362 and a second voltage division circuit consisting of the depletion type MOSFET 363 and the enhancement type MOSFET 364. The constant voltage of the first voltage division circuit is applied to the gate of the enhancement type MOSFET 352, while the constant voltage of the second voltage division circuit is applied at the gate of the enhancement type MOSFET 351. These constant voltages are set to operate the enhancement type MOSFET's 351 and 352 in the saturation region. The variation of the voltage at the connection point of MOSFET's 351 and 352 appears opposite to that of the drain currents of them so that the drain voltage of FET 352 becomes always constant, thereby obtaining a constant current circuit of high precision.
Usually, while the discharge circuit of constant slope type is more complicated than that of exponential slope type, count of a required digital value from a count value N is very easy.
Next, explanation of a modification of the circuit elements in the above embodiments will be made. For the level detection circuit 4, a multistage connection of digital gate circuits such as inverters is most suitably be built in an IC, but the use of analog comparators and operational amplifiers is also favorable. Furthermore, as the connection position of the bias voltage supply means 6, such a position as shown in FIG. 12 is also allowed, as is evident from its function.
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An analog-to-digital converter comprising a capacitive element for storing an analog input signal, a discharge means for discharging the charge stored in said capacitive element, a means for counting the number of clockpulses between the time of discharge starting and the time at which the voltage at the output of said capacitive element reaches a certain detection level, and a bias voltage supply means for supplying a bias voltage in order to bring the voltage at the output terminal of said capacitive element at the discharge starting time above said detection level.
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This application is a divisional application of U.S. patent application Ser. No. 14/038,942, filed Sep. 27, 2013 by Daniel W. Tam et al., for an invention entitled “Seawater Faraday Cage”. The '942 application is assigned to the same assignee as the present invention.
FEDERALLY-SPONSORED RESEARCH AND DEVELOPMENT
This invention (Navy Case No. 103889) is assigned to the United States Government and is available for licensing for commercial purposes. Licensing and technical inquires may be directed to the Office of Research and Technical Applications, Space and Naval Warfare Systems Center, Pacific, Code 72120, San Diego, Calif. 92152; voice (619) 553-5118; email ssc par T2@navy.mil.
FIELD OF THE INVENTION
The present invention pertains generally to the design of Faraday cages. More specifically, the present invention pertains to methods for designing Faraday shields that use conductive fluids to protect vessel communications and sensors from the damaging effects caused by radiation and natural lightning.
BACKGROUND OF THE INVENTION
A Faraday cage is a shield formed by conducting material such as metal to protect the enclosure from external electromagnetic radiations. When an external electrical field is present, the Faraday cage prevents the electric field from penetrating within the cage. If the cage is grounded, the excess charge will flow to ground instead of residing on its outer surface. Traditionally Faraday cages are made of copper, aluminum foil or other metals.
Typically, the effectiveness of the Faraday cage in prevent electromagnetic radiation from passing through is dictated by the conductivity of the cage material and the thickness of the metal. Because Faraday cages are typically made of metal, and/or a metal mesh incorporated within a matrix, they are bulky and difficult to move around. Furthermore, it is not practical to implement a traditional Faraday cage on a ship to shield the whole ship and its antennas due to size and weight constraints. Additionally, a Faraday cage will prevent the passage of electromagnetic radiation through the cage in both directions, both inbound and outbound. Although there are times when a vessel may want to protect itself from inbound electromagnetic radiation, there is also a need for a vessel to selectively emit radio waves, radar emissions, etc. in the conduct of its daily operations. Thus, it is also desirable to have a Faraday cage which can be selectively activated and deactivated.
In view of the above, it is an object of the present invention to provide a Faraday cage and method for deployment, which uses seawater to provide the shielding effect. Another object of the present invention is to provide a Faraday cage and method for deployment that is extremely lightweight relative to the amount of area/volume it is designed to protect. Still another object of the present invention is to provide a Faraday cage and method for deployment that can be selectively activated and deactivated. Another object of the present invention is to provide a Faraday cage and method for deployment where the size and corresponding area of coverage can be adjusted during operation of the Faraday cage. Yet another object of the present invention is to provide a Faraday cage whose protective properties can be adjusted according to the level of electromagnetic radiation desired by the user. Another object of the present invention is to provide a Faraday cage and method for deployment that is easy to use in a cost-efficient manner.
SUMMARY OF THE INVENTION
A method for deploying a lightweight, flexible Faraday cage around a device can include the initial steps of establishing a flow of conductive fluid, and directing the conductive fluid flow in a manner that causes a shroud of conductive fluid to form over the device. In some embodiments, a flexible material such as canvas can be spread over an umbrella-like skeletal structure, and the conductive fluid can be sprayed onto the flexible material to form the shroud around the device. The shroud of conductive fluid can have a thickness to thereby establish the attenuation or shielding effect with respect to the device.
The flexible material can also be divided up into portions, which can be placed over the device, so that a first portion is over the device and a larger second portion of flexible material is over the first portion. A flow of conductive fluid can then established over both the first portion and the second portion to form multiple shrouds having first and second thickness, so that the shrouds can appear to be concentric when viewed in plan view. In still other embodiments, a plurality of nozzles can be placed around the perimeter of the device, and the nozzles can be directed at a predetermined point over the device. When conductive fluid flow is established through the nozzles, the streams can meet at the predetermined point and collide to thereby establish the conductive shroud for the device.
For all of the above embodiments, the shroud(s) can have a thickness, which can be chosen according to the desired frequency of electromagnetic radiation to be blocked. Typically, the thickness(s) can be from one to one hundred millimeters (1-100 mm). The shroud can be formed from any conductive fluid, such as tap water, saltwater, seawater or distilled water, for example.
BRIEF DESCRIPTION OF THE DRAWINGS
The novel features of the present invention will be best understood from the accompanying drawings, taken in conjunction with the accompanying description, in which similarly-referenced characters refer to similarly-referenced parts, and in which:
FIG. 1 is a diagram showing the relationship between an incident power wave, P inc , reflected power wave, P ref , and transmitted power wave, P trans at normal angle between two semi-infinite mediums: air and seawater;
FIG. 2 is a graph of the attenuation loss for a propagating wave in seawater;
FIG. 3 is a graph of the transmission loss from a power wave traveling from an air medium to seawater;
FIG. 4 is a graph of the total loss for various distances into the seawater;
FIG. 5 is a top plan view of a seawater Faraday cage of the present invention, according to several embodiments;
FIG. 6 is a side elevational view of the seawater Faraday cage of FIG. 5 ;
FIG. 7 is a side elevational view of an alternative embodiment of the seawater Faraday cage of FIG. 5 ;
FIG. 8 is a top plan view of still another alternative embodiment of the seawater Faraday cage of the present invention; and,
FIG. 9 is a block diagram, which illustrates steps that can be taken to practice the methods of the present invention according to several embodiments.
DETAILED DESCRIPTION OF THE EMBODIMENTS
In brief overview, the seawater Faraday cage of the present invention according to several embodiments can take advantage of the electrical conductivity of the sodium and chloride ions in seawater to create a flexible type of Faraday cage or shield. The conductivity of the seawater can determine the performance of the shielding effectiveness. By using a seawater Faraday cage instead of a traditional metal shielding cage, the weight can be significantly reduced. The seawater Faraday cage can also be selectively activated and deactivated to avoid interfering with other operations (outward electromagnetic emissions such as radar and radio waves). The fact that seawater can be easily accessed from ocean can render a seawater Faraday cage very useful for Naval vessel applications.
In cases where it can be desirable to block electromagnetic radiation from impinging on a ship (or any other device or structure), a flow of conductive fluid can be manipulated to establish a shroud of seawater, which can cover the whole ship or any sections thereof, or any device 10 that is mounted on the skin of the ship, and can prevent any damaging effect due to incoming electromagnetic radiation. The shroud of seawater can create the Faraday cage. The thickness of the shroud required can depend on the electrical properties of seawater. The electrical properties of seawater vary in frequency, temperature, and salinity.
FIG. 1 is an illustration showing a power wave traveling in air at normal incidence that encounter a seawater interface. At incidence, a fraction of the power wave will reflect back into the air and the other part will be transmitted into the seawater. The power wave transmitted into the seawater will be attenuated by the properties of seawater as the power wave propagates through the medium. This power loss is known as the attenuation loss and the loss due to the reflected power is known as the transmission loss. The ratio of the power transmitted into the seawater and the incident power in air is given by equation (1):
P trans P inc = ⅇ ( - 2 α z ) ︸ Attenuation Loss T 2 η 1 Re ( 1 η 2 * ) ︸ Transmission Loss . ( 1 )
where α is the attenuation constant in Nepers per meter (Np/m), Re is the real number component, η 1 , is the intrinsic impedance of air (ohms), η 2 is the intrinsic impedance of seawater (ohms), z is the distance inside the seawater (m), and T is the transmission coefficient. The transmission coefficient is calculated by equation (2):
T = 2 η 1 η 1 + η 2 . ( 2 )
The intrinsic impedance is given by
η = j2 π f μ σ + j 2 π f ɛ , ( 3 )
Where j is the imaginary component part, f is the frequency in Hz, μ is the permeability, ε is the permittivity, and σ is the conductivity. The permeability can be expressed as the product of the permeability of free space and the relative permeability of the material, μ=μ 0 ×μ r , where μ 0 =4π×10 −7 l H/m and μ r is the relative permeability. For air and seawater, μ r =1. The permittivity can be expresses as the product of the permittivity of free space and the relative permittivity of the material, ε=ε 0 ×ε r , where ε 0 =8.854×10 −12 f/m and ε r is the relative permittivity. For air ε r =1 and ε r varies for seawater. Air is a dielectric and therefore has a conductivity of zero while the conductivity of seawater varies. The intrinsic impedance of air, η 1 , is therefore, 377Ω. The attenuation constant is calculated using equation (4):
α = 2 π f μ 2 ɛ 2 { 1 2 [ 1 + ( σ 2 2 π f ɛ 2 ) - 1 ] } 1 / 2 . ( 4 )
The conductivity and permittivity of sea water vary, however, using a typical conductivity value of 4 Siemens per meter (S/m, where a Siemen is the inverse of an Ohm, S=1/Ω) and relative permittivity value of 81, the attenuation loss and transmission loss is calculated to demonstrate the blockage effect for seawater.
FIG. 2 is a plot of the attenuation loss in dB/cm versus frequency. The plots shows that the attenuation loss increases as the frequency increases and the amount of attenuation may be controlled by varying the shroud wall thickness. FIG. 3 is a plot of the transmission loss versus frequency. As can be seen from FIG. 3 , the transmission losses decrease as the frequency increases. These plots can be used to design the shroud wall thickness required for various frequencies and required shielding effect (it should be appreciated that the same analysis could be conducted for salt water, tap water, distilled water or any other conductive fluid, provided the conductivity and permittivity of the conductive fluid is known). FIG. 4 is a plot showing the total loss (absorption and transmission) for various distances inside the seawater. In addition to this analysis, surface roughness and additional transmission loss due to the finite thickness of the shroud needs to be considered in enactment.
In cases where multiple shrouds can be envisioned, the spacing between each shroud can also determine the effectiveness of the Faraday shield, in addition to the thickness of respective multiple shrouds. However, the gap between the concentric shrouds is needed to form multiple layers to establish the attenuation effect and achieve a complete Faraday shield.
Referring now to FIGS. 5-7 , the seawater Faraday cage 50 of the present invention according to several embodiments is shown and is illustrated. As shown, the cage 50 can include a flexible material 52 , which can be draped over a collapsible, umbrella-like framework 53 (shown in phantom in FIG. 5 ). Collapsible framework 53 can be large enough to cover device 10 , or even ship 59 in FIG. 5 . Or, multiple collapsible frameworks 53 can be used to cover the entire ship 59 . For clarity, only one framework 53 is shown in FIG. 5 . A flow of conductive fluid can establish a shroud 54 of conductive fluid, which can cover all or part of the ship and/or device 10 to be protected.
In some embodiments, and as can be seen from FIGS. 6-7 , the flexible material 52 (such as canvas, for example) can be divided into a first portion 52 a and a second portion 52 b , which can be arranged over respective collapsible framework 53 a , 53 b so that first portion 52 a is over device 10 and second portion 52 b is over first portion 52 a . As shown second portion 52 b can have a surface area that can be greater than that of first portion 52 a . With this configuration, when flow of conductive fluid is established, the corresponding shrouds 54 a and 54 b can be established so that first portion 52 a would be over device, shroud 54 a would enclose the device, second portion 52 b would be over shroud 54 a (and device) and shroud 54 b would enclose shroud 54 a (and device 10 ). Moreover, shrouds 54 a and 54 b would appear to be concentric when viewed in plan view. To accomplish the seawater flow as described above, a pump 56 can direct conductive fluid through piping 58 and through openings (not shown) above frameworks 53 a and 53 b . For the embodiment shown in FIG. 6 , there can be a single run of piping 58 . Alternatively, piping 58 could branch in a manner that allows for a fraction of conductive to flow over first portion 52 a and second portion 52 b , with sufficient flow rate to establish thickness 60 a and 60 b for corresponding shrouds 54 a and 54 b.
Referring now to FIG. 8 , several alternative embodiments of the present invention can be illustrated. As shown, a plurality of nozzles 62 a through 62 N, can be established around the perimeter of ship 59 and/or or device 10 to be protected. The nozzles 62 can be constructed with steel, copper or brass in a variety of diameters and heights to accommodate the requirement, and the nozzles 62 can be oriented to direct a flow of conductive fluid to a predetermined point 64 . Point 64 can be chosen so that when the streams for nozzles 62 collide, the shroud is established. These embodiments can obviate the need for a framework 53 and flexible material 52 to create shroud 54 . Or, the nozzle arrangement could be used in conjunction with framework 53 and flexible material 52 in FIG. 5 , instead of piping. Point 62 could be chosen above flexible material 52 and can also be at the geometric center of flexible material 52 (when viewed in top plan, as illustrated in FIG. 5 ) to thereby establish the shroud 54 .
With the above configurations, the seawater Faraday cage of the present invention can be flexible and light weight, when compared to a traditional metal Faraday cages. The seawater Faraday cage of the present invention according to several embodiments can be selectively activated with a flip of switch. In addition, seawater can be used as an inexhaustible supply of conductive fluid without requiring a return line of fluid, i.e. the seawater Faraday cage of the present invention can be an open system in some embodiments, as seawater can be obtained easily from the ocean, the Faraday cage of the present invention can be established, and the seawater can drain overboard during the operation of the seawater Faraday cage, which can be very desirable for Naval applications. It should also be appreciated that the structure and cooperation of structure described above could also be used to provide a fluid Faraday cage over a building or home, providing a conductive fluid source (most likely public works fireman pressure) is available.
Referring now to FIG. 9 , a block diagram 100 is provided to illustrate steps that can be taken to accomplish the methods of the present invention. As shown, the methods can include the initial step 102 of establishing a flow of conductive fluid 102 , using the structure and cooperation of structure described above. The methods can further include the additional optional step of spreading a flexible material over the device to be protected, as shown by step 104 . The flexible material can be selectively divided into portions and the flow can be divided as described above to establish concentric shrouds, or it can be spread as a single unitary sheet over collapsible framework, as described above.
The methods of several embodiments can further include the step 106 of directing the conductive fluid to establish a shroud 54 over the device 10 . Step 106 can be accomplished using the arrangement of piping 58 described above, or the aforementioned plurality of nozzles 62 can be directed at point 64 (with or without flexible material 52 and framework 53 ), also as described above. Step 106 can be accomplished to establish a shroud, or multiple shrouds, that can have thickness, which can be further selected according to the desired frequency of electromagnetic radiation that can be desired to block.
The use of the terms “a” and “an” and “the” and similar references in the context of describing the invention (especially in the context of the following claims) is to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. The terms “comprising,” “having,” “including,” and “containing” are to be construed as open-ended terms (i.e., meaning “including, but not limited to,”) unless otherwise noted. Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided herein, is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention unless otherwise claimed. No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the invention.
Preferred embodiments of this invention are described herein, including the best mode known to the inventors for carrying out the invention. Variations of those preferred embodiments may become apparent to those of ordinary skill in the art upon reading the foregoing description. The inventors expect skilled artisans to employ such variations as appropriate, and the inventors intend for the invention to be practiced otherwise than as specifically described herein. Accordingly, this invention includes all modifications and equivalents of the subject matter recited in the claims appended hereto as permitted by applicable law. Moreover, any combination of the above-described elements in all possible variations thereof is encompassed by the invention unless otherwise indicated herein or otherwise clearly contradicted by context.
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A method for deploying a lightweight, flexible Faraday cage around a device can include the step of directing the conductive fluid flow in a manner that causes a shroud to form over the device. In some embodiments, a flexible material such as canvas can be deployed over the device and the conductive fluid can be sprayed onto the flexible material to form the shroud. In other embodiments, a plurality of nozzles can be placed around the perimeter of the device, and the nozzles can be directed at a predetermined point over the device. The streams can meet at the predetermined point, collide and thereby provide the conductive shroud for the device. The shroud can have a skin depth, which can be chosen according to the desired frequency of electromagnetic radiation to be blocked, typically from one to one hundred millimeters (1-100 mm).
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TECHNICAL FIELD
This invention relates to a stent pusher assembly, and to a delivery system having a rapid-exchange configuration for deploying a self-expanding stent at a stenting site within a human or animal body.
BACKGROUND AND CONTENT OF THE INVENTION
EP-A-1 095 634 (EP 634) discloses all features of the preamble of independent claims 1 and 11 . EP 634 discloses a system in which the soft atraumatic distal tip of the system is at the leading end of the inner catheter. The outer sheath of the delivery system has a distal end which stops proximally short of the atraumatic tip.
Stents to be deployed at a stenting site within a human or animal body expand radially in the course of delivery, from a radially compact delivery disposition to a radially larger deployed disposition. In self-expanding stents made of stainless steel, the deformation of the stent is below the elastic limit, the stent until its deployment being radially confined and under elastic stress and typically released by proximal withdrawal of a confining sheath while the stent is itself prevented from moving proximally with the confining sheath by abutment with a stop on the distal end of a catheter shaft which suffers axial compressive stress while the surrounding sheath is proximally withdrawn.
By contrast, stainless steel stents which are relaxed in a radially compact disposition suffer plastic deformation when expanded into their deployed disposition by inflation of a balloon within the lumen of the stent.
An early example of stainless steel self-expanding stents is Gianturco U.S. Pat. No. 4,580,568 and an early example of the balloon expansible stainless stent is Palmaz EP-A-221 570.
A third category of stent is the memory metal stent, made of a biologically compatible nickel-titanium shape memory alloy with martensitic and austenitic phases. At body temperature, the stent “seeks” to revert to the austenitic phase. Typically it is confined within a surrounding sheath and again released at the stenting site by proximal withdrawal of this sheath.
The present invention offers improvements in systems to deliver those stents which are brought to the stenting site within a confining surrounding sheath.
In the technical field of stenting, there is a desire to reduce the transverse dimensions of the stent delivery system. In this field, the widely used measure of transverse cross-section is the unit of “French”, often abbreviated to “F” which is a one third part of a millimeter. Thus, a 6F (six French) delivery system has a diameter of 2 millimeters.
For any particular stenting operation, one has to select a particular stent and a particular delivery system. There is a large choice in both of these elements. Accordingly, it would be an advantage for manufacturers of stents and their delivery systems to achieve a degree of modularity in the design and construction of stents and their delivery systems. For example, there is a wide range of stents which could be delivered by a six French delivery system and it would therefore be convenient for the manufacturer of a stent delivery system to be able to tailor a basic six French system to fit any particular stent which would be compatible with a six French delivery system. This would reduce costs, to the advantage of patients, while retaining full flexibility for medical practitioners to optimise their choice of stent for any particular patient.
Like many catheter systems, a stent delivery system is often used with a flexible guidewire. The guidewire is preferably made of metal, and is slidably inserted along the desired body passage. The delivery system is then advanced over the thus pre-placed guidewire by “backloading” or inserting the proximal end of the guidewire into a distal guidewire port leading to a guidewire lumen defined by the delivery system.
Many conventional delivery systems define guidewire lumens that extend along the entire length of the outer sheath. These delivery systems are described as “over-the-wire” delivery systems, in that the delivery system is guided to the site of the stenosis over the guidewire, the guidewire thereby exiting the delivery system at the proximal end of the delivery system. “Over-the-wire” delivery systems provide several advantages, including improved trackability, the ability to flush the guidewire lumen while the delivery system is inside the patient's body, and easy removal and exchange of the guidewire while the delivery system remains in a desired position in the patient.
In some circumstances, however, it may be desirable to provide a “rapid exchange” delivery system, which offers the ability more easily to remove and exchange the delivery system while retaining the guidewire in a desired position within the patient. In a rapid-exchange delivery system, the guidewire occupies a lumen located only in the distal portion of the delivery system. The guidewire exits the delivery system through a proximal guidewire port, closer to the distal end of the delivery system than to its proximal end, and extends in parallel along the outside of the proximal portion of the delivery system.
Because a substantial length of the guidewire is outside the delivery system, it may be manually held in place close to the point where it passes the entry point on the body of the patient, as the delivery system is removed. This facilitates handling, removal and exchange of the delivery system for the practitioner for the following reasons.
With a guidewire lumen that is much shorter than the full catheter length a single physician can insert and remove a stent delivery system into and from the patient's body. Whereas over-the-wire delivery systems require a guidewire having a length at least double the length of the outer catheter, the rapid-exchange configuration allows the use of much shorter guidewires which enable a single physician to handle the proximal end of the guidewire at the same time as the catheter at the point of its entry into the body of the patient.
Accordingly, the present invention advantageously provides a stent delivery system having a rapid-exchange configuration for delivering and deploying a self-expanding stent.
Stents themselves cannot be directly seen during their journey to the stenting site, nor can one directly see whether the stent is exactly located as desired within the stenting site. Rather, indirect means have to be used to follow the progress of the stent through the body and make sure that it is correctly located before it is deployed. Thus, a stent delivery system is used during deployment to carry radiopaque contrast or marker fluid to the stenting site so that the target stenosis can be seen through the reduced amount of radiopaque fluid in the bodily lumen at the stenosis. This radiopaque fluid is generally injected through an injection port at the proximal end of the delivery system and through an annular space between an outer sheath of the delivery system and a proximal portion of an inner catheter shaft. The visibility of the stenosis is adversely affected when the lumen, through which radiopaque contrast fluid is injected, is too small to deliver a strong pulse of contrast fluid. As pulses of fluid are used for visualisation, the effectiveness of visualisation depends on the volume flow in each pulse. This in turn depends on the ease of flow of the fluid along the full length of the delivery system, from the point of injection at the proximal end, to the stenosis beyond the distal end of the delivery system.
Thus, delivery systems which offer a large cross-section and unimpeded lumen for contrast fluid will be favoured by radiologists, other things being equal. The visibility can additionally be increased by further reducing the resistance of the system to pulses of contrast fluid. It is therefore an object of the present invention to provide good visualisation with contrast fluid, without sacrifice of other important performance aspects of the delivery system, including pushability and low overall diameter. By increasing “pushability” we mean the capability to be advanced longer distances along narrower and more tortuous bodily lumens.
Furthermore, the delivery system invariably carries at least one radiopaque marker at a known location relative to the length of the stent, so that radiologists can be sure of the location of the ends of the stent, on the basis of their knowledge of the location of the radiopaque marker. Even if the stent is rendered sufficiently radiopaque for it to be seen, it is still useful to have a radiopaque marker on the distal end of the delivery system, to reveal successful separation of the stent from the delivery system.
Thus, in our example of a six French delivery system, to be used for delivering stents of various lengths, there will be a wish to provide radiopaque markers within the delivery system at two spaced-apart locations on the axis of the delivery system, corresponding to the opposite ends of the stent (until the stent is deployed out of the system). One object of the present invention is to offer a degree of modularity in this design aspect.
With delivery systems having a rapid-exchange configuration, just as with over-the-wire systems, the stent delivery system is advanced over the guidewire, itself normally within a guide catheter, in order to bring the distal tip and stent to the stenting site. Depending on the application, different diameter guidewires are specified. Two commonly used guidewire diameters are 0.46 mm/0.018 inches and 0.89 mm/0.035 inches (commonly known as 18 thou or 35 thou guidewires). Thus, a further degree of modularity can be achieved by offering a delivery system which is compatible with a range of guidewire diameters, specifically, both 18 thou and 35 thou guidewires.
It would be an advantage for any new stent delivery system to be able straightforwardly to take the place of those previous delivery systems which individual practitioners have grown to be comfortable using. One such system uses in its proximal portion a metallic rod, which can be either solid or hollow, made of stainless steel.
Good design for stent delivery systems is indicated by manufacturing steps which can be performed with high precision and reliability, yet with acceptable cost levels. This is yet another objective of the present invention.
Finally, for any system which is extremely long in proportion to its diameter, and features at least three co-axial elements, the cylindrical surfaces of these co-axial elements need to be so composed and conformed that friction between them is low enough that the co-axial elements can be moved tolerably easily axially relative to each other. It is yet another object of the present invention to provide systems which enable bringing these friction levels down to advantageously low levels.
Another consideration when a self-expanding stent is released progressively by successive proximal stepwise movements of the outer confining sheath results from the delivery system typically being extremely long in proportion to its cross-sectional dimensions, and constructed predominantly or wholly from synthetic polymeric materials which have substantial elasticity and marked kinetic aspects to their deformation characteristics. In such a case, any particular rate of strain imposed on the proximal end of the outer sheath is likely to be experienced at the distal end of the same sheath in a somewhat different strain rate. For example, a fast squeeze of the trigger of a deployment system at the proximal end of the sheath will likely result in a somewhat slower resulting proximal advancement of the distal end of the same sheath. Furthermore, a pull on the sheath will impose compressive stresses along the length of the inner shaft, likely leading to a proximal movement of the stent which then relaxes back to the original, more distal, position of the stent as the tensile stress in the outer sheath eases back towards zero. In its own delivery systems, present applicant has observed what happens at the distal end of a stent delivery; system during successive squeezes of the trigger of a delivery system which pulls the outer sheath proximally in a series of steps. The appearance at the stent end of the system is as if the system were “breathing” in that it, and the stent, moves axially first proximally, then distally, with each squeeze of the trigger.
This “breathing” phenomenon is of course a complicating factor when it comes to precision of placement of the stent within any particular stenting site. It is yet another object of the present invention to ameliorate this problem.
SUMMARY OF THE INVENTION
According to one aspect of the present invention there is provided a pusher assembly for a delivery system for a self-expanding stent, the pusher assembly constituting a catheter shaft with a proximal pusher end to receive an end-wise compressive force and a distal pusher end to deliver said force to a stent to be delivered, the pusher assembly comprising a pusher strand extending from the proximal pusher end to a distal strand end which is nearer the distal pusher end than the proximal pusher end; a pusher element which abuts the stent in use to deliver said force to the stent; and a transfer shaft having a proximal and a distal end, the proximal end being connected to the distal tube end and the distal end being connected to the pusher element and characterised in that the pusher element defines a guidewire path, and the transfer shaft lies to one side of said path.
By contrast, in earlier systems such as that of EP 634 in which the atraumatic tip is carried on the inner catheter, the pusher element is mounted on a tube which has a guidewire lumen and extends distally all the way to the tip.
According to another aspect of the present invention, there is provided a stent delivery system having a rapid exchange configuration for a self-expanding stent which provides improved visualisation through an increased volume flow in each pulse. The volume flow in each pulse is increased in the present invention due to a simplified and reduced internal structure of the delivery system.
The scheme of a simplified delivery system is represented in FIG. 1 which shows the essential features of a basic delivery system including an outer sheath 4 confining the stent 6 in a radially compressed state and a pusher element 8 preventing proximal movement of the stent when the outer sheath 4 is proximally withdrawn. The pusher element is carried on an inner catheter shaft 3 . Here, the delivery system is inserted over a guidewire 2 into a lumen of a human or animal body.
In one of its aspects, the present invention employs a short inner catheter shaft so that its distal end is relatively close to the proximal guidewire lumen exit port. In conventional delivery systems, the inner catheter shaft 3 extends beyond the distal end of the stent 6 to provide a tapered tip, for ease of insertion of the delivery system into the patient's body and for reducing trauma whenever the catheter is advanced distally. Above-mentioned EPO 634 discloses a stent delivery system which conforms to this conventional model.
In the present invention, using the pusher element to define at least a short distal guidewire lumen, and providing the system tip taper on the distal end of the outer sheath, renders redundant an inner catheter within the stent and distal of the stent. Therefore, the internal structure of the delivery system is more open, which consequently enhances ease of flow and the volume of contrast fluid that can be ejected from the distal end of the delivery system with each successive pulse imposed from the proximal end of the delivery system. Hence, visualisation is improved.
In another aspect of the invention the manufacturing and assembling steps required to get the delivery system of the present invention ready for use are minimised due to the simplified internal structure. There exists no longer the need for keeping the stent at a fixed position on the inner catheter shaft while the outer sheath is fitted over the stent. Also, the risk of advancing the stent too far distally and out of the distal opening of the outer sheath during assembly of the delivery system is minimised, since the outer sheath in the present invention comprises the tapered tip which acts as a distal stopper for the stent during assembly.
The introduction of a stent using the stent delivery system of the present invention, and subsequent removal of the delivery system, is facilitated especially in tortuous vessels and other body lumens having a relatively narrow diameter because, once the stent has been placed at a desired site inside the patient's body, there need be no component of the delivery system which is radially inwardly located from the stent and which has to be proximally withdrawn through the stent lumen. Especially in narrow and sharply curved body vessels, this might introduce a risk that the distal tip being withdrawn through the stent lumen interferes with bodily tissue protruding radially inwardly through the interstices of the stent and into the stent lumen. The delivery system of the present invention avoids this problem by providing the tapered tip on the distal end of the outer sheath so that, during removal of the delivery system out of the patient's body, there need be no system components which travel proximally within the stent lumen and are likely to engage with the inner surface of the stent.
In one preferred embodiment, the pusher element is a cylinder which has a distal-facing end face at the distal end of the cylinder to push on the proximal end of the stent. Thus, the end face will likely be flat and transverse to the axis of the cylinder. The pusher element can serve as, and preferably does serve as, a radiopaque marker.
If desired, the pusher element can also serve as a mount for a distal marker carrier tube cantilevered distally forward from the pusher element to lie within the space that will correspond to the lumen of the stent to be deployed by the system. This is useful when it is required to have on the delivery system a radiopaque marker for the distal end of the stent. This radiopaque marker can be placed on the carrier tube at a position at or towards the distal end of the carrier tube and corresponding to the distal end of the stent. For stents of different lengths, the length of the carrier tube can easily be varied to correspond to the stent length, prior to fixing the distal marker on the carrier tube.
It will be appreciated that the carrier tube requires relatively little strength, so can be made thin and flexible, thereby reducing the risk of its interfering with tissue protruding through the stent during its withdrawal from the stenting site.
As the carrier tube is a relatively simple and isolated part of the delivery system, and conveniently made of a synthetic polymeric material, it will be a relatively simple matter to change the length of the carrier tube to suit any particular stent destined to be carried on the system. If desired, the carrier tube can be extended backwardly proximally from the pusher element and given a bell end or flared end outwardly proximally. This flared end provides security against the possibility of unwanted distal slippage of the carrier tube distally through the pusher element and of being left behind in the body when the delivery system is withdrawn. It may also be useful to guide the guidewire through the system whenever there is need to introduce the distal end of the guidewire from the proximal end of the system.
In yet another aspect of the invention, the modular construction of the delivery device results in fewer steps during manufacturing and assembly of the stent delivery system. The device may be modularized by using a transfer shaft connecting the rod or inner catheter with the pusher element. This can be set to any desired length, to accommodate stents of different length in a delivery system which features standard length catheter components such as the sheath, rod or inner catheter and pusher tube. It may be convenient to use a welded joint to fasten one or both of the two ends of the transfer shaft to the pusher element and rod, respectively.
For a better understanding of the various aspects of the present invention, and to show more clearly how its several features can be carried into effect, individually or in selected combinations reference will now be made, by way of example, to the accompanying drawings of embodiments of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows in longitudinal axial section the distal portion of a prior art delivery system;
FIG. 2 is a cross-section of the distal portion of a delivery system having a rapid-exchange configuration in accordance with a preferred embodiment of the present invention;
FIG. 3 shows an isometric view of the adapter having two lumens effecting the rapid exchange configuration;
FIG. 4 shows a cross-section of the proximal portion of the delivery system, the pull-back device used to proximally retract the outer sheath, in accordance with a preferred embodiment of the present invention;
FIG. 5 shows a cross-sectional view of the distal portion of an over-the-wire pusher assembly according to a second embodiment of the invention;
FIG. 6 shows a cross-sectional view of the distal portion of another over-the-wire pusher assembly according to a third embodiment of the invention;
FIG. 7 shows a cross-sectional view of the distal portion of yet another over-the-wire assembly, being a fourth embodiment of the invention;
FIG. 8 shows at larger scale the distal tip portion of the FIG. 7 embodiment; and
FIG. 9 shows at the scale of FIG. 8 a part of the FIG. 7 distal portion which is proximal of the tip shown in FIG. 8 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The following description of the preferred embodiments of the present invention is merely illustrative in nature, and as such does not limit in any way the present invention, its application, or uses.
FIG. 2 shows a cross-section of the distal portion of a delivery system having a rapid-exchange configuration in accordance with a preferred embodiment of the present invention.
In FIG. 2 , a guidewire 2 extends beyond the distal end of the distal portion of the delivery system along which the stent delivery system is advanced to the site of the stenosis inside the patient's body. The stent 6 is held in a radially compressed state by means of an outer sheath 4 the distal end of which constitutes the distal end of the stent delivery system. The distal tip 4 A of the outer sheath 4 , as shown in FIG. 2 , is tapered in order to facilitate advance of the stent delivery system along a bodily lumen. Furthermore, the outer sheath 4 comprises a radiopaque marker 27 the position of which is indicative for the distal end of the stent until deployment of the stent. The guidewire 2 extends all the way through the outer sheath lumen and exits the distal portion of the stent delivery system at a proximal guidewire port 24 .
A pusher element 8 abutting the stent 6 in use of the delivery system prevents proximal movement of the stent 6 when the outer sheath 4 is withdrawn proximally to release the stent. The pusher element 8 , which at the same time serves as a proximal radiopaque marker, is connected to a transfer shaft 12 . The pusher element 8 is preferably laser-welded to the distal end of the transfer shaft 12 . For ease of connection the distal end of the transfer shaft 12 is tapered and embedded in a respective slot provided in the proximal end of the pusher element 8 . The distal end of the transfer shaft 12 is tapered, and the transfer shaft 12 is corresponding oblate at its distal end, so that the distal end of the transfer shaft 12 can be fitted into a respective slot of the adjacent pusher element 8 , with the circumferential surface over a specific arc length of the oblated end being flush with the circumferential surface of the pusher element 8 . The slot provided in the proximal end of the pusher element 8 has an axial length which extends from the proximal end of the pusher element 8 beyond midway along the axial length of the pusher element 8 . This ensures a sufficiently rigid connection of the transfer shaft 12 with the pusher element 8 . Such shaping of the distal end of the transfer shaft 12 and the pusher element 8 optimises the flow of injected contrast fluid F, since the fluid does not meet any unnecessary barrier when travelling along the length of the transfer shaft 12 . In this way, the flow resistance of the injected contrast fluid F is minimised.
The transfer shaft 12 is capable of receiving an endwise compressive force C and transmitting the force C to the proximal end of the stent 6 , thereby preventing proximal movement of the stent 6 when the outer sheath 4 is withdrawn proximally by imposition of tensile force T on the sheath 4 . The arrows in FIG. 2 are indicative for the direction of the respective forces T and C.
A connection piece 14 , such as a tube, at the proximal end of the transfer shaft 12 , as shown in FIG. 2 , enables the accommodation of different stent lengths in an unchanged sheath 4 by an appropriate adjustment in the length of the transfer shaft 12 in accordance with the length of the respective stent 6 .
The cut-to-length transfer shaft end within the connection tube 14 is glued or soldered to the connection tube 14 . The proximal end of the transfer shaft 12 is directly connected to the distal end of the rod 16 by means of a solder joint or glue. Otherwise, the connection tube 14 can be no more than a collar into which two adjacent ends of separate transfer shaft portions are inserted end-to-end and approximated, such that both abutting ends of the transfer shaft 12 portions are in physical contact with each other inside the collar. Therefore, there is no relative axial movement of the two adjacent ends of the transfer shaft 12 portions within the collar. Thus, the longitudinal force transmission between the proximal end of the tube 16 receiving the endwise compressive force C to the proximal end of the stent 6 is optimised.
The proximal end of the distal portion of the stent delivery system, as shown in FIG. 2 , comprises an adaptor 20 having two lumens 22 , 24 for effecting the rapid-exchange configuration. The guidewire 2 exits the distal portion of the stent delivery system through a guidewire port 24 of the adaptor 20 , so as to be exposed outside the stent confining sheath 4 to enable the rapid exchange. The guidewire port 24 is preferably off-centre of the adapter 20 . The orifice of the second lumen 22 is defined by a pipe 18 .
Referring to FIG. 2 , a rod 16 being part of the pusher assembly and preferably made of metal abuts at a distal end thereof the proximal end of the transfer shaft 12 inside the connection piece 14 . Its proximal end extends beyond the proximal end of the pipe 18 . The rod 16 extends distally from the distal portion of the delivery system through the second lumen 22 of the adapter. At its proximal end it receives the endwise compressive force C.
In a further embodiment of the present invention, not shown, the rod 16 can be provided as a tube with a lumen running from the proximal end of the system to the lumen of the pipe 18 .
In both embodiments, the pipe 18 is connected to the adaptor 20 and furthermore, the adaptor 20 is connected to the outer sheath 4 . The integrity of this connection is somewhat crucial for the proper functioning of the delivery system, since the outer sheath 4 is usually made of a polymeric material whereas the adaptor 20 , the rod 16 (or tube), and the transfer shaft 12 are preferably made of metal, such as stainless steel. Metal-to-polymer connections are normally made by means of an adhesive.
To permit sufficient rigidity and to provide a rupture-resistant connection of the pipe 18 through the adaptor 20 to the outer sheath 4 , the pipe 18 is advantageously welded into a recess of the adaptor 20 . Tension studs 20 A, as shown in FIG. 3 , are provided in the proximity of the distal end of the adapter 20 to engage along the entire circumference of the adapter 20 with individual strands of a braid 43 encapsulated by the polymeric material of the outer sheath 4 . The tension studs 20 A protrude radially outwardly into the interstices of the braid 43 to reduce the dependence on glue to prevent rupture of the connection between the adapter 20 and the outer sheath 4 . The stud to braid link between the pipe 18 and the outer sheath 4 via the adapter 20 feature metal all the way from one end of the system to the other so that the risk that the adhesive joint between the adapter 20 and the outer sheath 4 may break is reduced and the strain suffered by the system in releasing a stent is also kept small. Other type of connections will be apparent to those skilled in the art and an explicit explanation thereof is therefore omitted.
When using the stent delivery system, a tensile force T acts on the pipe 18 , thereby proximally displacing the outer sheath 4 to release the stent 6 , and at the same time a compressive force C is received by the tube or the rod 16 at its proximal end and is transmitted to the transfer shaft 12 in order to prevent proximal displacement of the stent 6 during stent deployment.
Since the pusher element 8 provides a lumen for the guidewire, abuts the stent 6 in use and is supported axially by the transfer shaft 12 , and since the stent 6 is self-expanding and so is pressing radially outwardly on the sheath 4 , there is no need for an inner catheter to extend beyond the proximal end of the stent 6 . The tapered tip 4 A of the sheath 4 facilitates advance of the catheter system through a tortuous lumen of the patient's body. The tapered tip 4 A also resists inadvertent or premature distal movement of the stent 6 relative to the sheath 4 , such as when the delivery system is introduced into a narrow vessel inside the patient's body. In this way, the tapered tip 4 A of the outer sheath 4 can act a distal stopper for the stent.
For a detailed description of such tapered tips and their use, see Applicant's WO 01/34061.
A distal marker carrier 10 , itself carried on the pusher element 8 , exhibits a length sufficient to project distally beyond the stent 6 and defines a lumen for the guidewire 2 . In use, the guidewire 2 extends along an axial path which lies side by side with the transfer shaft 12 , which shaft 12 is off the axis of the outer sheath 4 . The proximal end of the distal marker carrier 10 is attached, conveniently by glue, to the inner surface of the pusher element 8 to fix its axial position. The proximal end of the distal marker carrier 10 has a flared end or shows some sort of tulip-shape which facilitates distal advancement of the guidewire 2 through the pusher assembly of the delivery system. The fixing established by the glue and the flared ends also reduces the likelihood of separation of the carrier tube 10 from the pusher element 8 .
The distal marker carrier 10 carries a distal marker 26 , such as a radiopaque marker, indicating the position of the distal end of the stent 6 . The inner surface of the distal marker 26 is flush with the inner surface of the distal marker carrier 10 for undisturbed elative axial movement of the guidewire 2 . Preferably, a particular heat treatment is employed to attach the distal marker 26 to the distal marker carrier 10 , so that the distal marker is partially fused together with the distal marker carrier 10 . It is also conceivable to embed or swage the distal marker 26 into the distal marker carrier 10 because the material used for the distal marker carrier 10 is relatively soft, preferably a resin tube.
The distal marker carrier 10 is a polymeric tube whereas the pusher element 8 , the transfer shaft 12 , and rod 16 or tube 16 are made of metal, conveniently stainless steel. It is also conceivable to use other material combinations for these parts, such as nickel titanium shape memory alloy for the transfer shaft 12 and a composition of platinum/iridium (90/10) for the pusher element 8 .
The outer sheath 4 may also carry a marker band such as one 27 on its inner luminal surface just proximal of its tapered tip 4 A for marking the distal end of the outer sheath 4 .
Some applications require a thicker guidewire 2 , such as a 35 thou guidewire. In such cases, one may choose to omit the distal marker carrier 10 . Otherwise, one may choose to locate the marker 26 distal of the distal end of the stent in the free volume 40 between the stent and the tip 4 A, thereby minimising the consumption of lumen cross-section inside the stent lumen. The remaining structure of the pusher assembly can remain the same. Hence the versatility of the pusher assembly is increased because of its usefulness with guidewires of different diameters.
FIG. 3 shows an isometric view of the adapter 20 , preferably made of metal, such as stainless steel, effecting the rapid exchange configuration. The adapter comprises two lumens 22 , 24 one of which is a guidewire lumen 22 and the other one of which permits the rod 16 or tube to exit the adapter. Lumen 24 of the adapter is defined by two opposing arcuate segments 23 A and 23 B. The pipe 18 is introduced into lumen 24 of the adapter 20 from the proximal end of the adapter which has the shape of a mushroom until it abuts the distal end of a recess (not shown). In this manner, the adapter does not need to have a circumferential side wall which encloses lumen 24 by 360°. Hence, the lateral dimensions are minimised. Furthermore, as shown in FIG. 3 , tension pins (studs) 20 A are provided on the outer circumferential surface of the distal portion of the adapter 20 engaging with the braid 43 which is encapsulated by the polymeric material of the outer sheath 4 . Lumen 24 which is a guidewire lumen is located off-centre of the adapter 20 and allows the guidewire 2 to exit the delivery system to effect the rapid-exchange configuration. The adapter is preferably made of metal, such as stainless steel, but the use of other alloys is conceivable.
Referring now to FIG. 4 , a cross-sectional view of the proximal portion of the stent delivery system is shown. The proximal portion is part of a pull-back device used for proximally retracting the outer sheath 4 to release the stent 6 . The pipe 18 which is connected to the sheath 4 via the adapter 20 is linked to an adapter ring 36 . A welded joint is preferably be used for the link but other types of joints may be used, such as glue or an interference fit etc. The adapter ring 36 is joint to a polymeric sleeve 38 fitted into the distal portion of a distal hub 40 . As the distal hub is successively pulled back proximally with every squeeze on the trigger of the pull-back device (not shown), a proximal hub 46 at the proximal end of the rod 16 or tube is held stationary at the same time by a compressive force being transmitted from the proximal hub 46 via rod 16 and transfer shaft 12 to the pusher element 8 . In this way, controlled release of the stent at a desired position inside the patient's body is achieved.
The proximal portion of the stent delivery system further provides the possibility to insert contrast fluid through the Luer-adapter 42 into the annulus between the distal hub 40 and a supporting member 44 being sealed by an O-ring 48 and connected to rod 16 . The contrast fluid passes beyond the distal end of the distal hub 40 , creeps through the gap between the adapter ring 36 and the rod 16 and emerges from the distal end of the pipe 18 finally to reach the distal end of the outer sheath 4 to get squirted out into the vessel of the patient's body.
The Luer-valve assembly 42 also comprises a safety lock for locking the axial movement of rod 16 , (the subject of Applicant's PCT/EP02/06782 and earlier British Patent Application No. 0114939.2), which ensures safe transport of the packaged delivery system without the risk of inadvertent release of the stent and to enable the physician to interrupt the stent deployment process, when needed, without having to be concerned with the displacement of the stent whilst the physician is not holding the delivery system in his/her hands.
The pusher assembly, as shown in FIG. 5 , is destined to be used for an 18 thou guidewire 20 . The entire pusher assembly is enclosed by an outer catheter 4 of an over-the-wire stent delivery system prior to deployment of the stent 6 . In this condition the stent 6 is held in a radially compressed configuration by the same outer catheter 4 . For deployment of the stent 6 , the outer catheter 4 is withdrawn until the distal tip 63 is proximal of the proximal end of the stent 6 .
The pusher assembly incorporates a catheter shaft 66 , the distal end of which is connected to a transfer shaft 64 . A pusher element 68 is connected to the distal end of the transfer shaft 64 . During the course of stent deployment the distal end 69 of the pusher element 68 abuts the proximal end of the stent 6 . Thus, the pusher element 68 serves as a stop for the stent 6 during stent deployment, to prevent proximal movement of the stent as the outer catheter 4 is withdrawn proximally.
The proximal end of the pusher element 68 is laser-welded to the distal end of the transfer shaft 64 and the same manner of connection is used for connecting the proximal end of the transfer shaft 64 to the distal end of the catheter shaft 66 .
For ease of connection, both the distal and the proximal ends of the transfer shaft are tapered and embedded in respective slots provided in the proximal end of the pusher element 6 and the distal end of the catheter shaft 66 . The ends of the transfer shaft 64 are tapered such that the circular cross-section of the transfer shaft 64 between its ends is oblate at its ends, so that both ends can be fitted into respective slots of the adjacent pusher element 68 and catheter shaft 66 , with the circumferential surfaces over a specific arc length of both oblated ends being flush with the circumferential surface of the pusher element 68 and the catheter shaft. The slot provided in the proximal end of the pusher element 68 has an axial length which extends from the proximal end of the pusher element beyond mid-way along the axial length of the pusher element 68 . The length of the slot in the distal end of the catheter shaft 66 is much the same length, and long enough to ensure that a sufficient connection between the transfer shaft 64 and the catheter shaft 66 is obtained. Such shaping of the two ends of the transfer shaft and the pusher element 68 and the catheter shaft 66 maximises the flow of injected contrast fluid, since the fluid does not meet any unnecessary barrier when travelling along the length of the transfer shaft. In other words, the resistance to the flow of the injected contrast fluid is minimised.
A connection piece such as a tube 78 at an intermediate position of the transfer shaft 64 enables the accommodation of different stent lengths in an unchanged sheath 4 and catheter shaft 66 , by an appropriate adjustment in the length of the transfer shaft portions in accordance with the length of the respective stent. The two cut-to-length transfer shaft portion ends bridged by the connection tube 78 are either glued or soldered to the connection tube 78 . The connection tube 78 can be no more than a collar into which the two adjacent ends of the separate transfer shaft portions are inserted and approximated, such that both ends of the transfer shaft are in physical contact with each other inside the collar. Therefore, there is no relative axial movement of the two adjacent ends of the transfer shaft portions within the collar.
A distal marker carrier 74 , itself carried on the pusher element 68 , exhibits a length sufficient to project distally beyond the stent 6 and defines a lumen for the guidewire 20 . In use, the guidewire 20 extends along an axial path which lies side-by-side with the transfer shaft 64 which is off the axis of the outer sheath 4 . The proximal end of the distal marker carrier 74 is attached, conveniently by glue, to the inner surface of the pusher element 68 to fix its axial position. The proximal end of the distal marker carrier 74 has a flared end or shows some sort of tulip-shape for undisturbed distal advancement of the guidewire 20 through the pusher assembly of the delivery system. The fixing established by the glue and the flared end also reduces the likelihood of separation of the carrier tube 74 from the pusher element 68 . The distal marker carrier 74 carries a distal marker, such as a radiopaque marker 72 , indicating the position of the distal end of the stent.
The distal marker carrier 74 is a polymeric tube whereas the pusher element 68 , the transfer shaft 64 , the catheter shaft 66 and the connection tube 78 are made of metal, conveniently stainless steel. It is also conceivable to use other material combinations for these parts, such as nickel titanium shape memory alloy for the transfer shaft and a composition of platinum/iridium (90/10) for the pusher element 68 .
The distal marker 72 can be embedded or swaged into the distal marker carrier 74 because the material used for the distal marker carrier 74 is relatively soft, preferably a resin tube.
Some applications require a thicker guidewire 20 , such as a 35 thou guidewire. In such cases, the distal marker carrier 74 may need to be omitted, as shown in FIG. 6 . The remaining structure of the pusher assembly can remain the same. Hence, the versatility of the pusher assembly is increased because of its usefulness with guidewires of different diameters.
Reverting to the embodiment shown in FIG. 5 , however, a thicker guidewire can be accommodated if the distal marker 72 is moved to a position just distal of the distal end of the compressed stent 6 . To resist bowing of the pushing wire 64 , it can be bonded to an additional short length of tube mounted distally to the catheter shaft 66 . The bonding could be with glue. The mounting could be a telescopic mounting within the distal open end of the shaft 66 , the tube length glued to the said distal end and extending, cantilevered, distal of the distal end with the pushing wire glued to its outside cylindrical surface. Denial of bowing of the pushing wire within the lumen of the outer catheter should eliminate any substantial “lost motion” when the outer catheter is initially pulled back proximally, and the pushing wire 64 goes into compression, in the initial stages of stent release.
Drawing FIGS. 7 , 8 and 8 show another embodiment of the invention which is, in some respects, a hybrid of the embodiments of FIGS. 5 and 6 .
In FIG. 7 there is an inner catheter 140 of polymeric material, glued inside the stainless steel shaft 116 and extending distally to a distal tip zone 142 which lies distal of the stent 6 . Swaged around this distal tip zone is a distal marker 112 , lying just distal of a distal end of the stent 6 . For the remaining distal tip portion 142 of the inner catheter 140 , lying distal of the distal marker 112 , the diameter is slightly increased, as can best be seen in
FIG. 8 , which increases the security with which the marker 112 is retained on the inner catheter shaft 140 , with corresponding reduced likelihood of loss of the marker 112 by slipping off the distal end of the catheter 140 . As can be seen, the guidewire 20 extends through the shaft 116 and inner catheter 140 , being a relatively snug fit within this lumen.
Lying on the outside cylindrical surface of the inner catheter 140 is a transfer shaft 114 and connector 118 . With a sequence of glue spots 144 , the transfer shaft 114 is bonded to the inner catheter shaft 140 , thereby preventing any tendency for the transfer shaft 114 to bow when it is put in longitudinal compressive tension for release of the stent 6 .
As shown in FIG. 8 , at the distal end of the transfer shaft 14 is the pusher 108 and this carries, on its outside cylindrical surface, an additional thin platinum/iridium radiopaque marker band 146 . A further marker 148 is integrated in the thickness of the outer catheter wall 4 , just distal of the stent 6 , overlying the marker 112 on the inner catheter 140 . During progressive deployment of the stent, by proximal withdrawal of the outer catheter 4 , the radiologist will be able to observe the progressive movement of the outer catheter marker 48 , proximally away from the distal stent marker 112 and towards through and beyond the proximal marker 146 .
In the following, some of the advantages of the subject pusher assembly are elucidated.
Since the catheter shaft tube 116 , the pusher element 108 and the guidewire 20 are all of metal, friction between the guidewire and the stent delivery system is low, and so PTFE or other special low-friction coatings can be omitted, thereby saving manufacturing costs.
During release of the stent, the transfer shaft remains under a more or less constant compressive strain once it has undergone a certain amount of bowing within the lumen of the outer catheter sheath 4 as a result of the proximal withdrawal of the outer sheath. This bowing typically reduces the distance between the pusher element 108 and the catheter shaft 114 by approximately 5 mm. The compressive strain suffered by the transfer shaft 14 remains constant throughout the deployment of the stent for as long as the outer catheter 4 is in axial tension. Hence, a precise placement of the stent with respect to the stenting site can be achieved and no significant “breathing”, as mentioned above, to be observed.
The simplified internal structure of the distal portion of the delivery system enables improved visualisation of the stenosis due an increased volume flow of contrast fluid with each pulse.
During release of the stent, virtually no proximal movement of the stent is seen, while the outer sheath is being withdrawn proximally. The present invention provides a metal structure all the way from the proximal end of the pull back unit receiving the endwise compressive force to the pusher element to keep the stent in place during stent deployment. Therefore, no adverse bowing of the force transmitting components is caused during stent release. Furthermore, the component that is withdrawn proximally, including the outer sheath 4 , can also exhibit metal-to-metal connections end-to-end.
As shown in the illustrated embodiments, the length of the transfer shaft, which preferably amounts to a maximum of 3 cm, is relatively short compared to its diameter, so that appreciable bowing is suppressed. In addition, the transfer shaft confined by the outer sheath and lying side-by-side to the guidewire inside the lumen of the outer sheath has nowhere to go when it seeks to bend under compression during stent release, thereby preventing shortening of the distance between the pusher element and the distal end of the rod. Hence, more precise placement of the stent with respect to the stenting site can be achieved. Furthermore, assembly of the system is facilitated and manufacturing cost are reduced.
The system is further adaptable to guidewires of different diameters, which enhances the versatility of the system and its acceptability to the practitioner.
The delivery system may be used in connection with a guiding catheter. The physician attempting to bring a stent to a stenosis site inside the patient's body uses an outer guide catheter to be first introduced in the patient's body. Once the guide catheter has been properly placed, a guidewire is introduced through the guide catheter lumen along which the delivery system is advanced to the site of the stenosis in a next step. Here, the contrast fluid to be used to visualise the stenosis can be injected, if the physician prefers to do so, through the gap between the internal surface of the guide catheter and the external surface of the delivery system. Hence, the annulus between the pipe 18 and the rod 16 or tube, shown in FIG. 2 , can be further reduced in order to minimise the transverse dimension of the delivery system, which is advantageous in terms of both, the recovery of the patient and the handling comfort for the physician.
Prior to use of the delivery system, as is the case for any devices used to inject fluids into the human body, the delivery system needs to be vented and primed, i.e. the system is flushed with a biocompatible solution, such as a sodium chloride solution, until all the air confined inside the system has been driven out of the system. The delivery system of the present invention may be flushed with such a solution from the distal tip of the delivery system prior to use. This may enhance the practical usefulness of the delivery system, since the guidewire is also inserted into the delivery system from the distal end of the system, so that the physician can carry out the flushing and the guidewire insertion almost in one go. This allows the physician to choose the alternative with which he/she has grown most comfortable and which is best suited for the specific circumstances.
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A pusher assembly for a delivery system for a self-expanding stent ( 6 ) which is delivered by proximal withdrawal of a sheath ( 4 ) radially surrounding the stent has a stent pusher element ( 8 ) which defines a lumen for a guidewire ( 2 ), a pusher strand ( 16 ) that extends to the proximal end of the delivery system and bears an end-wise compressive stress during release of the stent. A transfer shaft ( 12 ) links the distal end of the pusher strand ( 16 ) to the pusher element ( 8 ) and lies side-by-side with the guidewire ( 2 ). In a rapid exchange version, an adapter ( 20 ) provides two lumens side-by-side, one ( 22 ) carrying the pusher strand ( 16 ) and the other ( 14 ) defining a proximal guidewire part. To the adapter is mounted the proximal end of the stent sheath ( 4 ). The system allows modular ( 14 ) construction, a tapered tip ( 4 A) on the sheath, and an uncluttered internal configuration which facilitates passage of pulses (F) of liquids from the proximal to the distal end of the system.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent application Ser. No. 15/149,425, entitled, “Devices, Systems and Methods for Medicament Delivery,” filed May 9, 2016, which is a continuation of U.S. patent application Ser. No. 14/581,693, now U.S. Pat. No. 9,352,091, entitled “Devices, Systems and Methods for Medicament Delivery,” filed Dec. 23, 2014, which is a continuation of U.S. patent application Ser. No. 13/866,296, now U.S. Pat. No. 8,920,377, entitled “Devices, Systems and Methods for Medicament Delivery,” filed Apr. 19, 2013, which is a continuation of U.S. patent application Ser. No. 13/353,769, now U.S. Pat. No. 8,425,462, entitled “Devices, Systems and Methods for Medicament Delivery,” filed Jan. 19, 2012, which is a continuation of U.S. patent application Ser. No. 12/794,014, now U.S. Pat. No. 8,105,281, entitled “Devices, Systems and Methods for Medicament Delivery,” filed Jun. 4, 2010, which is a continuation of U.S. patent application Ser. No. 12/138,987, now U.S. Pat. No. 7,731,690, entitled “Devices, Systems and Methods for Medicament Delivery,” filed Jun. 13, 2008, which is a divisional of U.S. patent application Ser. No. 10/515,571, now U.S. Pat. No. 7,416,540, entitled “Devices, Systems and Methods for Medicament Delivery,” filed Nov. 23, 2004, which is a national stage filing under 35 U.S.C. §371 of International Patent Application No. PCT/US2004/039386, entitled “Devices, Systems and Methods for Medicament Delivery,” filed Nov. 23, 2004, each of which is incorporated herein by reference in its entirety.
BACKGROUND
[0002] Exposure, such as via ingestion, inhalation, and/or injection, to certain allergens, toxins, and/or other substances can cause profound reactions for some and/or all people and/or animals. For example, certain people are highly allergic to certain substances, such as peanuts, shellfish, particular drugs, certain proteins, bee venom, insect bites, etc. The allergic response to the exposure can lead to anaphylactic shock, which can cause a sharp drop in blood pressure, hives, and/or substantial breathing difficulties caused by severe airway constriction. As another example, inhalation of certain nerve agents can cause severe physiological trauma. Responding rapidly to such exposures can prevent injury and/or death. For example, in response to an exposure leading to anaphylactic shock, an injection of epinephrine (i.e., adrenaline) can provide substantial and/or complete relief from the reaction. As another example, injection of an antidote to a nerve agent can greatly reduce and/or eliminate the potential harm of the exposure. As yet another example, rapid injection of certain drugs, such as a beta blocker, blood thinner, nitroglycerine, antihistamines, insulin, and opioids, etc., can provide substantial relief from various dangerous medical conditions.
[0003] Thus, certain exemplary embodiments provide systems, devices, and/or methods for rapidly injecting a medicament.
SUMMARY
[0004] Certain exemplary embodiments comprise an apparatus, comprising: a compressed gas container; a plurality of vials adapted to store a liquid medicament, each vial defining a longitudinal axis, the longitudinal axes of the plurality of vials parallel and non-co-axial, the plurality of vials fluidly coupleable to an actuating portion of a contents of the gas container; and a plurality of pistons, each piston adapted to move within a corresponding vial from the plurality of vials, the plurality of pistons adapted to, in response to discharge of the actuating portion of the contents of the compressed gas container, transfer at least a portion of the liquid medicament from the plurality of vials and through a needle that is extendable into a patient. Certain exemplary embodiments comprise a method comprising a plurality of activities, comprising: discharging an actuating portion of a contents of a compressed gas container, the compressed gas container contained within an apparatus; in reaction to said discharging activity, moving a piston within a vial, the vial one of a plurality of vials contained within the apparatus, each vial adapted to store a liquid medicament, each vial defining a longitudinal axis, the longitudinal axes of the plurality of vials parallel and non-co-axial, the plurality of vials fluidly coupleable to a contents of the gas container; and transferring a liquid medicament from the vial and through a needle that is extendable into a patient.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] A wide variety of potential embodiments will be more readily understood through the following detailed description of certain exemplary embodiments, with reference to the accompanying exemplary drawings in which:
[0006] FIG. 1 is a perspective view of an exemplary embodiment of a system 1000 ;
[0007] FIG. 2 is a front view of an exemplary embodiment of a system 1000 ;
[0008] FIG. 3 is a side view of an exemplary embodiment of a system 1000 ;
[0009] FIG. 4 is a cross-sectional view taken along lines A-A of FIG. 3 of an exemplary embodiment of a system 1000 in a first operative position;
[0010] FIG. 5 is a cross-sectional view taken along lines A-A of FIG. 3 of an exemplary embodiment of a system 1000 in a second operative position;
[0011] FIG. 6 is a cross-sectional view taken along lines A-A of FIG. 3 of an exemplary embodiment of a system 1000 in a third operative position;
[0012] FIG. 7 is a cross-sectional view taken along lines A-A of FIG. 3 of an exemplary embodiment of a system 1000 in a fourth operative position;
[0013] FIG. 8 is a cross-sectional view taken along lines A-A of FIG. 3 of an exemplary embodiment of a system 1000 in a fifth operative position;
[0014] FIG. 9 is a cross-sectional view taken along lines A-A of FIG. 3 of an exemplary embodiment of a system 1000 in a sixth operative position;
[0015] FIG. 10 is a flowchart of an exemplary embodiment of a method 10000 ;
[0016] FIG. 11 is a perspective view of an exemplary embodiment of system 1000 ;
[0017] FIG. 12 is a perspective cross-sectional view taken along lines B-B of FIG. 11 ;
[0018] FIG. 13 is a perspective view of an exemplary embodiment of actuation stick 2200 ;
[0019] FIG. 14 is a cross-sectional view of an exemplary embodiment of gas venting mechanism 8000 taken along lines A-A of FIG. 3 .
DETAILED DESCRIPTION
[0020] When the following terms are used herein, the accompanying definitions apply:
actuating portion—that part that puts something into action. actuation lock—a device adapted to prevent actuation, such as, for example a pivotable, translatable, keyed, squeezable, and/or removable lock. actuator—a mechanism that puts something into action. adapted to—suitable or fit for a particular purpose. apparatus—a mechanism and/or device. arm—an elongated structural member, which need not be solely linear. can—is capable of, in at least some embodiments. channel—a conduit for one or more fluids. compressed gas—a substantially pressurized substance, such as helium, nitrogen, and/or carbon dioxide, etc., in a gaseous form. comprising—including but not limited to. contain—to hold within. contents—a contained compressed gas. credit card—a card (usually plastic) that assures a seller that the person using it has a satisfactory credit rating and that the issuer will see to it that the seller receives payment for the merchandise and/or services delivered. Typically measuring in size from approximately 3 to approximately 4 inches in length, such as approximately 3.40 inches, 3.375 inches, 85 millimeters, etc., and from approximately 1.75 to approximately 2.75 inches in width, such as approximately 2.10 inches, 2.2125 inches, 2.5 inches, 55 millimeters, etc. discharge—to release from confinement; to emit. eject—to expel. escape port—an opening for the exit of a gas. expulsion pressure—a force applied over an area of a liquid, the force sufficient to expel the liquid in a predetermined manner. extend—to move out and/or away from. extendable—able to move out and/or away from. fluid—a gas and/or liquid. fluidly coupleable—able to be related via a fluid. frangible—a device that is capable of being broken and/or penetrated to allow fluid to flow therethrough. housing—something that covers, protects, holds, and/or supports. in reaction to—responding indirectly and/or directly to. indicate—to show, mark, signify, denote, evidence, evince, manifest, declare, enunciate, specify, explain, exhibit, present, reveal, disclose, and/or display. indicator—a device and/or substance that indicates. liquid medicament—a medicine, medication, drug, pharmaceutical, prescriptive, antidote, anti-venom, hormone, stimulant, vasodilator, anesthetic, and/or nutritional supplement in a substantially liquid form. may—is allowed to, in at least some embodiments. needle—a hollow, slender, sharp-pointed instrument used for injection. Includes cannulas. non-co-axial—not having co-linear axes. patient—a receiver of a liquid medicament, such as a human, mammal, animal, etc. piston—a sliding piece which either is moved by, or moves against, fluid pressure. pivotable—capable of pivoting. plurality—the state of being plural and/or more than one. predetermined—established in advance. puncturer—a device adapted to penetrate using a substantially sharp and/or tapered point, tip, edge, or the like. pusher—a device adapted to convert fluid pressure to mechanical movement. retract—to pull inward. reservoir—a receptacle or chamber for storing and/or directing movement of a fluid. spring—an elastic device, such as a coil of wire, that regains its original shape after being compressed or extended. status—a state or condition. substantially—to a great extent or degree. system—a collection of mechanisms, devices, data, and/or instructions, the collection designed to perform one or more specific functions. tip—a terminal end. transfer—to convey from one place to another. translatable—capable of being transferred from one place to another and/or of being moved with respect to something else. valve—a device that regulates flow through a pipe and/or through an aperture by opening, closing, and/or obstructing a port and/or passageway. vent—to release from confinement. vial—a closable vessel.
[0070] FIG. 1 is a perspective view, FIG. 2 is a front view, and FIG. 3 is a side view, of an exemplary embodiment of a system 1000 , which can comprise a housing 1100 , which, in certain operative embodiments, can comprise a handheld portion 1800 separated via an actuation guard 1200 from an actuation bar 1300 . Actuation guard 1200 can prevent accident activation of system 1000 . Housing 1100 can be constructed of a durable material, such as stainless steel, aluminum, polycarbonate, etc., to protect a compressed gas container, medicament, injection apparatus and/or user of system 1000 . The injection apparatus can be actuated by a fluid pressure, such as pressure provided by the compressed gas, which upon completion of its actuation duties can escape housing 1100 via gas escape opening, such as via status indicator 1400 .
[0071] A status of a system 1000 can be determined via status indicator 1400 , which can provide a view, such as via a UV blocking, photo-sensitive, and/or translucent window, into an interior of housing 1100 . Viewable through the window can be a status of medicament carried by housing 1100 , a location of a needle and/or injection apparatus for the medicament, and/or an activation status of system 1000 . For example, if the medicament has aged to the point of discoloration, which aging might or might not render the medication useless, harmful, etc., status indicator 1400 can allow that situation to be determined. In certain exemplary embodiments, gas can escape housing 1100 via status indicator 1400 and/or another opening in housing 1100 .
[0072] Certain exemplary embodiments of system 1000 can provide a compact medicament delivery mechanism that can efficiently and/or rapidly deliver a prescribed dose. The length (L) and width (W) of system 1000 can be similar to that of a credit card, and the thickness (T) can be less than one inch. Thus, certain exemplary embodiments of system 1000 can provide a conveniently carried, easy-to-use, easy to activate drug delivery apparatus that can require little to no training to safely carry, use, and/or dispose of.
[0073] To assist a user in positioning system 1000 in a correct orientation for injection, system 1000 and/or housing 1100 can provide various tactile clues. For example, a top 1110 of housing 1100 can be rounded, and a bottom 1120 of actuation bar 1300 of housing 1100 can be flat. Other tactile clues are also possible, such as bulges, ribs, grooves, gaps, roughened surfaces, indentations, etc.
[0074] FIG. 4 is a cross-sectional view taken along lines A-A of FIG. 3 of an exemplary embodiment of a system 1000 in a first operative position. FIGS. 5, 6, 7, 8, and 9 show system 1000 of FIG. 4 in second, third, fourth, fifth, and sixth operative positions, respectively.
[0075] System 1000 can comprise a housing 1100 , handheld portion 1800 , actuation guard 1200 , and/or actuation bar 1300 . System 1000 can comprise system actuator 2000 , gas reservoirs 3000 , medicament actuator 4000 , medicament storage assembly 5000 , medicament carrier 9000 , needle assembly 6000 , use indicator 7000 , and/or gas vent mechanism 8000 , etc.
[0076] Upon removal, release, rotation, and/or relocation of actuation guard 1200 , system actuator 2000 can be adapted to rapidly discharge an actuating portion of a contents of a compress gas container. For example, system actuator 2000 can comprise a compressed gas container 2400 , which initially can contain a compressed gas 2500 , an actuating portion of which can be released from container 2400 by penetration of a gas port 2600 via a point of a puncturer 2700 . Upon removal and/or relocation of actuation guard 1200 , actuation bar 1300 can be moved closer to and/or in contact with handheld portion 1800 . Upon removal and/or relocation of actuation guard 1200 , gas container 2400 can be brought into contact with puncturer 2700 via extension of a pre-compressed spring 2300 and/or movement of an actuation stick 2200 . Thus, actuation guard 1200 can prevent accident activation of system 1000 and/or unintended discharge of an actuating portion of the contents 2500 of gas container 2400 .
[0077] Once gas port 2600 has been punctured, an actuating portion of compressed gas 2500 can escape from container 2400 and flow via gas reservoirs 3000 , such as gas channel 3100 . The flowing gas can meet and/or apply gas pressure to medicament actuator 4000 , which can comprise a pusher 4100 , which can travel within a sleeve 1500 defined by walls 1520 . Sleeve 1500 can be constructed of metal, stainless steel, aluminum, plastic, polycarbonate, etc. Seals 4200 , such as o-rings, can resist gas leakage, such as past pusher 4100 and/or out of housing 1100 . Thus, pusher 4100 can function as a piston traveling within a cylinder, although it is not necessarily required that the cross-sectional shape of sleeve 1500 be round.
[0078] Medicament actuator 4000 can interface with medicament storage assembly 5000 . For example, medicament actuator 4000 can comprise a plurality of plungers 4300 , each of which can be capped with a piston 4400 which can sealingly slide and/or move within a corresponding vial 5100 containing a liquid medicament 5200 . For example, in response to pressure applied by an actuating portion of the contents 2500 of compressed gas container 2400 , pusher 4100 can cause plungers 4300 and/or pistons 4400 to simultaneously move. The number of corresponding sets of plungers 4300 , pistons 4400 , and/or vials 5100 can be 2, 3, 4, 5, 6, or more. Pistons 4400 can be constructed of a resilient, durable, and/or sealing material, such as a rubber. Each plunger 4300 from the plurality of plungers can define a longitudinal axis, the longitudinal axes (e.g., axes 4310 , 4320 , 4330 , 4340 ) of the plurality of plungers parallel, non-coaxial, and/or co-planar.
[0079] Each vial 5100 from the plurality of vials can be substantially cylindrical with a substantially round and/or substantially elliptical cross-sectional shape. Thus, each vial 5100 can define a longitudinal axis, the longitudinal axes of the plurality of vials parallel, non-coaxial, and/or co-planar. The longitudinal axis of each vial can be co-axial with the longitudinal axis of its corresponding plunger.
[0080] Each vial can be capped at one end with a frangible 5300 , which can be burst when piston 4400 generates sufficient pressure upon medicament 5200 , thereby allowing at least a portion of medicament 5200 to flow out of vial 5100 and into medicament carrier 9000 . Thus, the plurality of vials can be fluidly coupleable to the actuating portion of the contents 2500 of gas container 2400 .
[0081] Medicament carrier 9000 can hold each of vials 5100 and can travel within sleeve 1500 . Medicament carrier 9000 can comprise a plurality of channels 9200 adapted to receive medicament 5200 as it exits its respective vial 5100 , and direct medicament 5200 to a common conduit 9300 . Medicament carrier 9000 can interface with needle assembly 6000 and/or use indicator 7000 .
[0082] From common conduit 9300 , medicament 5200 can enter needle assembly 6000 , such as into a single needle 6100 via which medicament can approach needle tip 6200 . As medicament actuator 4000 and/or medicament carrier 9000 are driven toward actuator bar 1300 , needle tip 6200 can penetrate an end 6400 of needle sheath 6300 and exit actuator bar 1300 at needle port 1340 .
[0083] Referring to FIG. 5 , upon movement of actuation bar 1300 closer to handheld portion 1800 , sheath seat 1330 can come in contact with sheath tip 6400 , thereby causing sheath 6300 to buckle and/or crumble. As actuator bar 1300 comes in contact with handheld portion 1800 , bar stop 1320 can approach medicament carrier stop 9400 , while carrier spring 1600 is compressed.
[0084] Referring to FIG. 6 , as at least a portion of contents 2500 of gas container 2400 escapes, it can flow through channel 3100 . The gas, which can still be relatively pressurized, can begin to accumulate behind pusher 4100 to form an expanding gas chamber 3200 and to cause medicament actuator 4000 , medicament storage assembly 5000 , and medicament carrier 9000 to slide together within sleeve 1500 . As medicament actuator 4000 , medicament storage assembly 5000 , and medicament carrier 9000 slide closer to actuator bar 1300 , spring 1600 becomes increasingly compressed between bar stop 1320 and medicament carrier stop 9400 . As medicament actuator 4000 , medicament storage assembly 5000 , and medicament carrier 9000 slide closer to actuator bar 1300 , needle tip 6200 can extend further from actuator bar 1300 and sheath 6300 can become further compressed and/or deformed. At its ultimate extension point, needle tip 6200 can extend from housing 1100 from approximately 0.25 millimeters to approximately 20 millimeters, including all values and subranges therebetween, such as up to approximately 2 millimeters, greater than approximately 5 millimeters, from approximately 5.13 millimeters to approximately 9.98 millimeters, etc.
[0085] Referring to FIG. 7 , as gas chamber 3200 continues to expand, medicament carrier 9000 can be driven until medicament carrier stop 9400 contacts actuator bar stop 1300 thereby resisting further travel of medicament carrier 9000 . At that point, additional expansion of gas chamber 3200 can cause medicament actuator 4000 , pusher bar 4100 , plungers 4300 , and/or pistons 4400 to initiate travel with respect to medicament storage assembly 5000 , thereby generating an expulsion pressure in vials 5100 , and/or thereby rupturing frangibles 5300 and allowing medicament 5200 to enter medicament carrier 9000 , and begin flowing through medicament channels 9200 , medicament conduit 9300 , needle 6100 , and/or out needle tip 6200 and into a patient. Alternatively, frangibles 5300 can be replaced and/or augmented by a frangible located at or near where medicament conduit 9300 couples to needle 6100 . Frangibles 5300 can be constructed of a thin, taught, resilient, durable, and/or sealing material potentially having a predetermined yield strength, such as a rubber, such as chromo butyl rubber, and/or of a relatively brittle material potentially having a predetermined yield strength, such as ceramic, certain plastics, such as polystyrene, etc.
[0086] As medicament carrier stop 9400 contacts actuator bar stop 1300 , medicament carrier hooks 9600 can engage with engagement receivers 7100 in use indicator 7000 .
[0087] Referring to FIG. 8 , as gas chamber 3200 continues to expand, medicament actuator 4000 , pusher bar 4100 , plungers 4300 , and/or pistons 4400 can continue moving until they complete their travel within medicament storage assembly 5000 , thereby expelling a predetermined dose of medicament 5200 from vials 5100 , out of needle assembly 6000 , external to housing 1100 , and/or into the patient. As gas chamber 3200 reaches its maximum size, medicament actuator 4000 , pusher bar 4100 , plungers 4300 , and/or pistons 4400 can continue moving until they complete their travel with respect to medicament carrier 9000 , thereby causing gas release actuator 9700 to engage with gas release valve 8200 . Engagement of gas release actuator 9700 with gas release valve 8200 can cause within gas chamber 3200 to exit gas chamber 3200 , discharge away from pistons 4400 , and/or exhaust from system 1000 and/or housing 1100 , such as via status indicator 1400 and/or a gas escape port located on housing 1100 ).
[0088] Referring to FIG. 8 and FIG. 9 , as sufficient gas is vented from gas chamber 3200 , the pressure applied by the gas in gas chamber 3200 can decrease until the force applied by the gas on medicament actuator 4000 is less than the force of compressed spring 1600 . Thus, spring(s) 1600 can begin to expand, thereby moving medicament carrier 9000 , vial assembly 5000 , and medicament actuator 4000 away from actuator bar 1300 and helping to exhaust gas from gas chamber 3200 . As medicament carrier 9000 moves, use indicator 7000 can travel with it, due to the engaged relationship of medicament carrier hooks 9600 and engagement receivers 7100 and/or engagement catches 7200 in use indicator 7000 . As use indicator 7000 moves away from actuation bar 1300 , sheath 6300 can travel with it, thereby creating a gap between sheath tip 6400 and needle port 1340 , and thereby exposing a previously non-visible colored portion 1350 of actuation bar 1300 and/or providing an indication that system 1000 has been used (and likely substantially exhausted of its medicament), thereby discouraging any further attempts to use system 1000 .
[0089] As medicament carrier 9000 moves away from actuator bar 1300 , needle 6100 can retract into sheath 6300 which un-buckles and/or un-deforms towards its original shape. Eventually, needle 6100 can retract completely within the boundaries of housing 1100 , thereby tending to prevent accidental needle sticks after the initial injection and/or potentially reducing and/or eliminating a sharps hazard.
[0090] In certain exemplary embodiments, system actuator 2000 can comprise a finger triggered, twistable, pivotable, and/or lever-operated mechanism. For example, system actuator 2000 can comprise a twistable handle that can screw into gas port 2600 . In certain exemplary embodiments, system actuator 2000 can be a finger trigger located on a side of the housing.
[0091] FIG. 10 is a flowchart of an exemplary embodiment of a method 10000 for operating a medicament delivery apparatus. At activity 10100 , an actuation lock for the apparatus is released. At activity 10200 , an actuating portion of the contents of a compressed gas container are released. At activity 10300 , via pressure provided by the released gas, a needle is extended from the apparatus. At activity 10400 , via pressure provided by the released gas, a piston applies pressure to a medicament stored in one of a plurality of vials. At activity 10500 , a frangible containing the medicament in the vial is burst. At activity 10600 , the medicament flows from the vial, through the needle, and into a patient. At activity 10700 , once a predetermined dose is expelled and/or injected, the needle is withdrawn from the patient and/or retracted into the pre-use bounds of the apparatus. At activity 10800 , the apparatus is rendered unusable for additional injections and/or indicated as previously utilized.
[0092] FIG. 11 is a perspective view of an exemplary embodiment of system 1000 , showing actuation guard 1200 removed from housing 1100 , so that actuation guard 1200 no longer separates actuator bar 1300 from handheld portion 1800 . Actuation guard 1200 can comprise a grippable portion 1220 that can be gripped by a user to pull actuation guard 1200 away from housing 1100 , thereby allowing system 1000 to be activated, such as via slapping actuator bar 1300 against a thigh of the user. Actuation guard 1200 can comprise an actuation stick separator portion 1240 , that can keep separate actuation stick prongs 2240 when actuation guard 1200 is installed on housing 1100 . Actuation guard 1200 can comprise a guard portion 1260 that can separate actuator bar 1300 from handheld portion 1800 when system 1000 is not in use and/or when system 1000 has not been used.
[0093] FIG. 12 is a perspective cross-sectional view taken along lines B-B of FIG. 11 , and FIG. 13 is a perspective view of an exemplary embodiment of actuation stick 2200 . Referring to FIGS. 12 and 13 , system 1000 can comprise housing 1100 , actuation bar 1300 , and system actuator 2000 , which can comprise prong squeezer 1390 , actuation stick 2200 , prong retainer 2100 , spring 2300 , upper spring retainer 2260 , gas container 2400 , gas port 2600 , and/or puncturer 2700 . When actuation bar 1300 is pressed firmly against a user's body, such as via slapping housing actuation bar against the user's thigh, buttocks, and/or arm, prong squeezer 1390 can urge prong tips 2220 of prongs 2240 of actuation stick 2200 toward one another. Note that prong tips 2200 can have a triangular, wedge, angular, and/or frustro-conical shape. As prongs tips 2220 slide along the angled V-groove of prong squeezer 1390 , prong catches 2230 can substantially loose contact with prong retainer 2100 . This can allow compressed spring 2300 to rapidly urge actuation stick 2200 and gas container 2400 toward puncturer 2700 , which can penetrate gas port 2600 , thereby allowing gas to escape from gas container 2400 . Although any of many different types of gas containers can be utilized, an exemplary gas container can be obtained from Leland Limited, Inc. of South Plainfield, N.J.
[0094] FIG. 14 is a cross-sectional view of an exemplary embodiment of gas venting mechanism 8000 of system 1000 taken along lines A-A of FIG. 3 . System 1000 can comprise handheld portion 1800 , actuator bar 1300 , sleeve 1500 . As pistons 4440 near the limit of their travels, medicament 5200 can be expelled along medicament path 5900 , which can extend past frangible 5300 , through medicament channels 9200 , medicament conduit 9300 , and needle 6100 , and into the body of a user, such as subcutaneously, intramuscularly, and/or at a depth of from approximately 0.25 millimeters to approximately 20 millimeters, including all values and subranges therebetween, such as up to 2 millimeters, greater than 5 millimeters, etc.
[0095] As pistons 4440 near the limit of their travels, engagement of gas release actuator 9700 with gas release valve 8200 can cause compressed spring 8300 to move valve arm such that o-ring 8400 is urged away from its seat 8500 . This movement can reveal a passage 8600 , via which gas can exit gas chamber 3200 along gas exhaust path 8900 , which can extend between sleeve inner walls 1520 and outer walls 9100 of medicament carrier 9000 . Eventually, gas exhaust path 8900 can extend between handheld portion 1800 and actuator bar 1300 . Likewise, an alternative embodiment of valve 8200 , made of rubber or any other resilient material, can be placed across seat 8500 to provide a seal that, once gas release actuator 9700 interacts with valve 8200 , allows valve 8200 to bend or flap upwards away from seat 8500 , causing the gas to escape via passage 8600 .
[0096] Still other embodiments will become readily apparent to those skilled in this art from reading the above-recited detailed description and drawings of certain exemplary embodiments. It should be understood that numerous variations, modifications, and additional embodiments are possible, and accordingly, all such variations, modifications, and embodiments are to be regarded as being within the spirit and scope of this application. For example, regardless of the content of any portion (e.g., title, field, background, summary, abstract, drawing figure, etc.) of this application, unless clearly specified to the contrary, there is no requirement for the inclusion in any claim herein or of any application claiming priority hereto of any particular described or illustrated activity or element, any particular sequence of such activities, or any particular interrelationship of such elements. Moreover, any activity can be repeated, any activity can be performed by multiple entities, and/or any element can be duplicated. Further, any activity or element can be excluded, the sequence of activities can vary, and/or the interrelationship of elements can vary. Accordingly, the descriptions and drawings are to be regarded as illustrative in nature, and not as restrictive. Moreover, when any number or range is described herein, unless clearly stated otherwise, that number or range is approximate. When any range is described herein, unless clearly stated otherwise, that range includes all values therein and all subranges therein. Any information in any material (e.g., a United States patent, United States patent application, book, article, etc.) that has been incorporated by reference herein, is only incorporated by reference to the extent that no conflict exists between such information and the other statements and drawings set forth herein. In the event of such conflict, including a conflict that would render invalid any claim herein or seeking priority hereto, then any such conflicting information in such incorporated by reference material is specifically not incorporated by reference herein.
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An apparatus includes a housing, a medicament container, an actuator, and a biasing member. The actuator is configured to move the medicament container within the housing when the actuator is moved from a first configuration to a second configuration. The actuator includes a gas container and a puncturer. When the actuator is in the first configuration, a portion of the puncturer is disposed apart from the gas container. When the actuator is in the second configuration, the portion of the puncturer is disposed within the gas container. The gas container has a longitudinal axis offset from a longitudinal axis of the medicament container. The biasing member is configured to bias the actuator toward the second configuration.
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TECHNICAL FIELD
This invention relates to processes for developing quinone diazide positive-working photoresists, particularly high contrast resists used in the fabrication of integrated circuits on single-crystal wafers.
BACKGROUND ART
Quinone diazide positive-working photoresists, and similar positive-working compounds used in the preparation of lithographic printing plates, are described in U.S. Pat. No. 4,464,461, issued to Guild on Aug. 7, 1984, particularly from column 3, line 39 to column 7, line 16. The foregoing patent is hereby incorporated herein by reference. Commercial photoresists of this kind include OFPR-800; other photoresists sold by the Dynachem division of Morton Thiokol, Inc., Tustin, Calif.; and products sold by Shipley Company, Inc., Newton, Mass.; Eastman Kodak Company, Rochester, N.Y.; and others.
A positive-working photoresist functions by being coated on a suitable substrate, image-wise exposed to actinic radiation, then subjected to a development process which removes those portions of the photoresist which were previously exposed to radiation, leaving the unexposed portions of the resist intact. The developed photoresist pattern protects the corresponding portions of the substrate from a further operation performed on the substrate, such as ion implantation, etching, plating, or the like. (In the case of printing plates, the residual portions of the photoresist have a different affinity for ink than the exposed portions of the substrate.) The known developers for quinone diazide positive-working photoresists comprise an aqueous solution of an alkali. The concentration of alkali is chosen to provide a developer which will selectively attack the exposed portion of the photoresist under the exposure and development conditions which have been selected.
While some commercially available developers contain metal salts such as sodium carbonate, sodium hydroxide, and others as alkaline agents, the art has recently chosen to avoid metal ion containing alkaline materials, or other metal ion sources, in photoresist developers. A concern has developed that residual metal ions left by the developer might form conductive paths in the finished device. Because of this avoidance of metal ion containing developers, the preferred alkaline materials are now tetraalkylammonium hydroxides, and particularly tetramethylammonium hydroxide (TMAH). TMAH based developers are discussed in U.S. Pat. No. 4,423,138, issued to Guild on December 27, 1983; U.S. Pat. No. 4,464,461, issued to Guild on Aug. 7, 1984; European Patent Application No. 0,062,733, filed by Cawston et al on Jan. 28, 1982 and published on Oct. 20, 1982, based on a corresponding U.S. patent application filed Apr. 10, 1981; Grieco et al, "Photoresist Developer Compounds", IBM Technical Disclosure Bulletin, Volume 13, Number 7 (December, 1970); "Improved Resist Developer," Research Disclosure 22713, March, 1983, pages 98-99; and others.
Several prior patents show the possibility of using an alkanolamine, particularly ethanolamine, in photoresist developers. According to its English language abstract, Japanese patent application No. 59-119105, believed to have been published December 26, 1985, teaches the use of either an inorganic alkali or an organic amine such as monoethanolamine or ethylenediamine as an alkaline agent in a photoresist developer. U.S. Pat. No. 4,464,461, column 1, lines 40-43 indicates that developers containing, for example, alkanolamines are "well known". U.S. Pat. No. 4,530,895, issued to Simon et al on July 23, 1985, at column 1, lines 59-62, suggests use of a developer containing an alkaline substance such as diethylamine, ethanolamine, or triethanolamine as a photoresist developer. U.S. Pat. No. 4,411,981, issued to Minezaki on Oct. 25, 1983, discloses from column 3, line 46 to column 4, line 8, the use of a developing and etching solution for a photoresist containing various organic bases such as TMAH, monoethanolamine, diethanolamine, and triethanolamine, among many other basic reacting compounds. None of these references suggests any reason to mix a quaternary ammonium compound and an alkanolamine to correct any shortcoming of either material used alone as a developer.
As will be shown in comparative examples, TMAH used alone as a photoresist developer causes what appears to be a deposit of flaky residue along the upper and lower edges of lines of developed photoresists, particularly high contrast photoresists. The presence of this residue in exposed areas (which are intended to be free of photoresist) suggests potential problems.
Alkanolamines by themselves are not suitable as developers for high contrast photoresists of the type exemplified herein, as they develop lines with poor resolution, fail to develop them altogether, or strip the photoresist. High concentrations of these developers also roughen the upper, normally smooth surfaces of developed photoresist lines.
One continuing challenge, as circuit geometries shrink and quality standards are maintained or raised, is how to maximize line width uniformity. Good line width uniformity means that lines of developed photoresist have nearly the same nominal line width and other dimensions as the mask lines and that these dimensions don't vary significantly depending on the location of the line on the wafer, the location of the wafer in a boat in which a batch of wafers are immersion processed together, or the order in which wafers are spray processed.
Another continuing challenge in photoresist developer research is how to achieve the desired line width uniformity despite variations in development conditions from the nominal conditions selected for development. A developer composition having this property is said to have wide process latitude.
It is further desirable that a photoresist developer not cause the side walls of the developed photoresist to become less vertical.
SUMMARY OF THE INVENTION
One object of this invention is to solve the residue problem of TMAH or similar photoresist developers while retaining or improving line width uniformity and process latitude of such developers. A further object is to accomplish the preceding object with a developer which is usable in commercial automated equipment, especially spray equipment which demands that a developer be easily sprayable.
One aspect of the invention is a method for developing an exposed quinone diazide positive-working photoresist without forming irregular deposits on the edges of unexposed portions of the photoresist. The method comprises the steps of providing an exposed photoresist for development; providing the developer previously defined above; developing the photoresist with the indicated developer until the pattern is cleared; and rinsing the developer from the photoresist.
The developer consists essentially of an aqueous solution of an alkali and an alkanolamine. The alkali is a tetraalkylammonium hydroxide, and is present in the composition in an amount sufficient to enable the composition to develop the photoresist. The alkanolamine has the following structure: ##STR2## In the above structure, n is 0 or 1, and each R is independently selected from hydrogen methyl, or ethyl.
The amounts of the alkali and the alkanolamine to be used can be variously expressed to accomplish different objectives. First, the alkanolamine component is present in the composition in an amount sufficient to reduce formation of the previously mentioned irregular deposits on the edges of unexposed portions of the photoresist during development of the photoresist. Second, the alkanolamine can be present in an amount sufficient to increase the C p value of the composition, as defined later in this specification. Third, the alkanolamine can be present in an amount sufficient to increase the process latitude of the composition, as defined later in this specification.
In a preferred aspect of the invention, about 0.7 to about 1.6% by weight of the tetraalkylammonium hydroxide is present, and the ratio of the hydroxide to the alkanolamine is less than or equal to about 1:9 by weight. The composition can optionally contain from about 0 to 0.05% by weight of a surfactant to improve the sprayability of the composition and to avoid the problem of dewetting the resist during development.
A second aspect of the invention is a similar method in which enough of the previously stated alkanolamine is present in a developer to provide a C p value of at least about 1.33 for the developer as used to develop a quinone diazide positive-working photoresist.
BRIEF DESCRIPTION OF DRAWINGS
FIGS. 1 through 6 are each a perspective fragmentary photographic view of a developed two micron (nominal mask dimension) photoresist line, also illustrating the surrounding substrate and a portion of the adjacent line. Each photograph was taken at a magnification of 20,000 diameters, at an energy of 23 KV, using a scanning electron microscope. FIGS. 1 through 6 show lines developed according to Examples 35 through 40, respectively. FIG. 6 represents the state of the art prior to the present invention, and FIG. 5 shows development using an alkanolamine not within the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Photoresist developers according to the present invention consist essentially of a solvent, a primary alkali, an alkanolamine as defined herein, and optionally a surfactant and various other minor ingredients.
While various organic solvents are used in some photoresist developers, for the present purpose the preferred solvent is deionized water. The amount of water used is dictated by the amounts of other ingredients. While the amount of water is not generally critical, the compositions described herein contain from about 60% to about 94% by weight water.
The primary alkali, referred to elsewhere herein simply as the alkali, is the primary ingredient which dissolves exposed portions of the photoresist when the photoresist is developed. Various tetraalkylammonium hydroxides have been used or suggested as suitable primary alkaline compounds; the use of any of these well known compounds is contemplated in the broadest aspect of the present invention. Although various of these compounds have been selected for different purposes, the most common selection is tetramethylammonium hydroxide (TMAH). The art has largely adopted TMAH to the exclusion of other tetraalkylammonium hydroxides as the primary alkali of choice.
It should be noted that the alkanolamines described below are also alkaline in water solution, and the prior art has suggested their use as alkaline materials in photoresist developers. Consequently, inclusion of substantial amounts of these materials will contribute to the alkalinity of the developer, and thus reduce the amount of primary alkali which is necessary.
The amount of alkali useful herein is most broadly more than 0.5% by weight, preferably from about 0.7 to about 2% by weight, more preferably from about 0.8 to about 1.6% by weight, and most preferably from about 0.9 to about 1.1% by weight. The amount of primary alkali used in a particular formulation must be adjusted to account for the influence of the other ingredients thereof.
The alkanolamines useful herein are those specified previously in the Summary. Table I which follows recites all the alkanolamines within the previously stated generic formula:
TABLE I______________________________________Alkanolamine SpeciesSpecies # Name______________________________________ 1 1-amino-2-hydroxyethane 2 1-amino-2-hydroxypropane 3 1-amino-2-hydroxybutane 4 1-hydroxy-2-aminopropane 5 2-amino-3-hydroxybutane 6 2-amino-3-hydroxypentane 7 1-hydroxy-2-aminobutane 8 2-hydroxy-3-aminopentane 9 3-amino-4-hydroxyhexane10 1-amino-3-hydroxypropane11 1-amino-3-hydroxybutane12 1-amino-3-hydroxypentane13 1-amino-2-methyl-3-hydroxypropane14 1-amino-2-methyl-3-hydroxybutane15 1-amino-2-methyl-3-hydroxypentane16 1-amino-2-ethyl-3-hydroxypropane17 2-hydroxy-3-aminomethylpentane18 3-aminomethyl-4-hydroxyhexane19 1-hydroxy-3-aminobutane20 2-amino-4-hydroxypentane21 2-amino-4-hydroxyhexane22 2-amino-3-hydroxymethylbutane23 2-amino-3-methyl-4-hydroxypentane24 2-amino-3-methyl-4-hydroxyhexane25 2-amino-3-hydroxymethylpentane26 2-amino-3-(1-hydroxyethyl)-pentane27 3-hydroxy-4-(1-aminoethyl)-hexane28 1-hydroxy-3-aminopentane29 2-hydroxy-4-aminohexane30 3-amino-5-hydroxyheptane31 2-hydroxymethyl-3-aminopentane32 2-hydroxy-3-methyl-4-aminohexane33 3-amino-4-methyl-5-hydroxyheptane34 3-amino-4-hydroxymethylhexane35 2-hydroxy-3-ethyl-4-aminohexane36 3-amino-4-ethyl-5-hydroxyheptane______________________________________
As the comparative examples provided below will illustrate, several compounds structurally related to the alkanolamines specified above either interfere with the development process or do not provide the benefits of the present invention. Thus, diols such as propylene glycol; diamines such as ethylenediamine; and di- or trialkanolamines have been found not to be useful herein.
The preferred alkanolamines are species 1, 2, and 10 as stated in Table I. These alkanolamines are all suitable for photoresist development by immersion. Most preferred is species 10, which has also been found to be suitable for spray development of photoresists.
The proportion of alkanolamine contemplated herein is determined largely by the ratio of the primary alkali to the alkanolamine by weight. This ratio is no more than 1:9, preferably 1:12 to 1:38, and most preferably about 1:15 if the alkanolamine is 1-hydroxy-3-aminopropane. The lower limit is provided in the preferred range of ratios because when the indicated maximum proportion of alkanolamine is exceeded, the surfaces of developed lines will be roughened. The upper limit of the range of ratios is specified to provide a noticeable reduction in the amount of residue formed. The most preferred ratio has been found to minimize the residue problem at minimal cost while avoiding the roughening effect of excess alkanolamine. These ratios will be found to vary with the proportion and selection of primary alkali and with the choice of a particular alkanolamine.
The desired amount of alkanolamine will typically be from about 10% to about 40% by weight of the composition. A preferred range is from about 14% to about 21% by weight.
The present compositions may optionally contain a surfactant, in particular a nonionic surfactant, to improve the sprayability and wetting properties of the formulation. In some spray development equipment, some of the present compositions will emerge from the spray nozzle as a cohesive stream of fluid, rather than as finely atomized droplets. The result can be that the developer is not adequately distributed during the spray step. The addition of certain alkanolamines, particularly in large amounts, has been found to reduce the sprayability of the compositions. This effect is believed to result from changes in the viscosity or the surface tension of the compositions.
Another fault which some of the indicated developers have is a tendency to dewet, or withdraw from, the photoresist pattern during development. This reduces the amount of time the photoresist pattern is exposed to the developer, and thus inhibits development. The presence of a nonionic surfactant alleviates this problem too.
The preferred nonionic surfactants are the polyethylene oxide condensates of alkyl phenols. These compounds include the condensation products of alkyl phenols having an alkyl group containing from about 6 to 12 carbon atoms, in either a straight chain or branched chain configuration, with ethylene oxide in amounts equal to 5 to 25 moles of ethylene oxide per mole of alkyl phenol. The alkyl substituent in such compounds can be derived, for example, from polymerized propylene, diisobutylene, octene, or nonene. Examples of compounds of this type include nonylphenol condensed with about 9.5 moles of ethylene oxide per mole of nonylphenol, dodecyl phenol condensed with about 12 moles of ethylene oxide per mole of phenol, dinonyl phenol condensed with about 15 moles of ethylene oxide per mole of phenol, and diisooctylphenol condensed with about 15 moles of ethylene oxide per mole of phenol. One particular surfactant which has proven useful herein is TRITON X-100, marketed by Rohm and Haas Co., Philadelphia, Pa. The useful amount of surfactant is limited by the tendency of such surfactants to degrade the optimal vertical wall structure of the developed lines of photoresist. The preferred composition, therefore, contains no more than about 0.05% by weight of a nonionic surfactant. Some compositions require no surfactant at all.
Other components, such as preservatives for TMAH, dyes, wetting agents, cosolvents, buffers, and the like may be added to developers according to the present invention. The preferred additives are essentially free of metal cations.
For purposes of the present specification, an amount of the primary alkali effective to develop the photoresist is determined experimentally by providing a proposed composition and varying the amount of alkali to find a concentration which will develop the photoresist without stripping it. The necessary amount of the primary alkali will be determined by many factors, including the presence of an alkanolamine and any other alkaline constituents of the developer; exposure energy; line geometries; development mode and conditions; and temperature. The examples in this specification provide specific compositions which have been found to perform well. One of ordinary skill in the art can readily formulate a developer having an appropriate amount of the primary alkali to develop the selected photoresist.
Similarly, the amount of the alkanolamine which is sufficient to reduce formation of irregular deposits on the edges of unexposed portions of the photoresist during development will depend on the developer formulation, process conditions, the photoresist used and how it is applied, and other factors. An amount of alkanolamine sufficient to reduce formation of irregular deposits is determined qualitatively by examining scanning electron microscope photomicrographs of photoresists developed with various developers to select the optimal developer for a given task. When the amount of the alkanolamine is expressed as an amount sufficient to increase the C p value of the composition, C p values of the composition under the desired development conditions are measured. The amount of alkanolamine is adjusted to maximize the C p in a particular formulation. Preferred compositions provide a C p value under the desired development conditions of at least about 1.33 when one micron lines are developed.
If the amount of alkanolamine is expressed as an amount sufficient to increase the process latitude of the composition, process latitude values of the composition are measured. The amount of alkanolamine is adjusted to maximize the process latitude in a particular formulation. Preferred compositions provide a process latitude of at least about 1.33 under the development conditions specified in the Examples.
In the method inventions defined herein, the primary novel element is selection of a developer composition according to the previously stated composition invention. It is not evident from any prior art known to the inventors that selection of this developer will allow a photoresist to be developed under high contrast conditions without forming irregular deposits on the edges of unexposed portions of the photoresist, providing a C p value and a process latitude for the developer of at least about 1.33.
Various modes of development are contemplated within the scope of the present invention. In immersion development, the coated and exposed wafers, either alone or in a boat of wafers, are supported in a bath of the selected developer for a sufficient time to develop the photoresists. In spray process development individual wafers coated with the photoresist are transported to a development site and developed by one or a sequence of operations including streaming the developer onto the surface of the photoresist; spinning the wafer to remove excess material, particularly fluid, from its surface; spraying the developer over a wide surface of the wafer; and puddling, which is done by allowing residual developer to remain as a meniscus or puddle covering the surface of the stationary wafer. Automated spray development equipment can be programmed to provide the desired sequence of development steps, and to develop each wafer in a batch according to the desired program.
EXAMPLE
The following examples are provided to illustrate practice of the present invention, including the best mode. The claims, and not the examples, define the scope of the present invention.
Photoresist samples were prepared as follows. The substrate was a silicon wafer with a polyoxide surface coating, pre-treated with hexamethyldisilane to promote adhesion. EPR-5000, a novolak resin-based composition sold by the Dynachem division of Morton Thiokol, Inc., Tustin, California, was coated onto the substrate using conventional automated spin-coating equipment. The coating thickness was about 13,000 Angstroms (1.3 microns), plus or minus about 300 Angstroms, and was measured for each wafer individually. The coatings were dried and conditioned in the usual manner, providing sensitized substrates typical of those used in the industry.
For all experiments, the sensitized substrates were exposed through an exposure mask on a step-and-repeat exposure tool with ultraviolet radiation provided by a high pressure mercury vapor lamp. The size of the exposed image (24 millimeters by 14 millimeters) allowed several exposures (18 or less) to be distributed on the surface of the substrate without overlapping. It was possible either to incrementally increase exposure energies at each exposure, or to repeat one exposure energy several times across the surface of the substrate.
Developer solutions were prepared by mixing the ingredients recited below to provide one-gallon batches.
In the immersion testing, an entire batch of each developer solution was poured into a large dish, forming a bath deep enough to completely immerse a wafer being developed. The exposed substrates were developed by manually immersing each one in the dish of developer. The immersion time was one minute (60 seconds). Then, the substrates were removed from the dish of developer and rinsed by placing them in a cascade tank fed from the bottom with deionized water.
For spray/puddle development testing the development and rinsing steps were performed using conventional automated spray development equipment sold by Silicon Valley Group, San Jose, California. In each program several sequential steps were completed. For each step, the wafer was rotated at the indicated rate while the indicated material was applied in the indicated manner for the indicated amount of time, according to one of the schedules in Table II.
Film speed of the developer was evaluated by observing through an optical microscope at 400× magnification the radiation dose necessary to resolve one micron lines of resist.
Linewidth uniformity (Critical Dimension Uniformity) is evaluated using several exposures at the same dose across the surface of the substrate. Linewidth measurements are made at each of these exposures, the measurements are averaged, and the standard deviation is calculated. A value called "C p ", can be calculated from this data according to the following formula:
C.sub.p =delta L/6 sigma
Delta L is the difference between the minimum and maximum acceptable linewidths of a line defined in the photoresist by a 1 micron line on the exposure mask. Sigma is one standard deviation.
For a 1 micron nominal linewidth, the acceptable range of linewidths is defined to be from 0.9 to 1.1 microns; delta L is thus (1.1-0.9) microns, or 0.2 microns. An acceptable value of sigma is defined herein to be less than or equal to 0.025 microns. Presenting the same information in terms of the C p , an acceptable value for C p is defined herein to be less than or equal to 1.33 microns.
Process latitude is a measure of a developer's ability to function satisfactorily despite defined variations in process parameters. For present purposes process latitude is satisfactory if, at exposure energies of from 220 to 260 mJ/cm 2 ; a resist thickness of 1.3 microns (plus or minus 0.1 microns) of EPR-5000 resist; a (resist) soft bake temperature of from 115° C. to 120° C.; a developer temperature of 15° C. (plus or minus 1° C.), or alternately a developer temperature of 18° C. (plus or minus 1° C.); and an exposure tool focus on the top of the resist (plus or minus 1.0 microns); C p exceeds 1.33 microns. Process latitude can be reported quantitatively as the minimum value of C p over the defined range of exposure energies. The developers according to the present invention have better process latitude than conventional resists which do not contain alkanolamines.
In Examples 1-4, monoethanolamine, abbreviated "MEA", was used as an alkanolamine according to the present invention. The proportions of ingredients and other information are set out in Table III. In the Tables, development mode "I" indicates immersion development. "Spray 1" indicates spray development according to Program 1 set forth in Table II. The abbreviation "mJ/cm 2 " indicates the radiation exposure in millijoules per square centimeter. "Result" provides a qualitative indication of the result of the experiment. LR indicates low resolution or a lack of resolution, meaning that the developer did not selectively remove the exposed portions of the photoresist while refraining from attacking the unexposed portions thereof. "Poor spray" means that the composition was not properly atomized by the spray nozzle. "Poor develop" means that exposed portions of the photoresist were not removed or were removed inadequately. The "ratio" is a recapitulation of the ratio of TMAH to the alkanolamine, here MEA, providing a ready comparison of the development result with the ratio of these ingredients.
Looking at Table III, it will be evident that examples 1 and 2 provide good development in an immersion mode, while in Example 3 the spray pattern provided during spray development was considered poor, indicating that the material was developed but that irregular development is potentially present. Eample 4, in which only 0.5% TMAH and 80.0% MEA is employed as a developer, demonstrates that this is too little TMAH to provide proper development, even in the presence of 80% monoethanolamine. Example 4 also establishes that monoethanolamine by itself, even at high concentrations, is not a suitable developer for the present photoresist.
Table IV, in which the alkanolamine is 1-amino-2-hydroxypropane (species 2 of Table I, identified in Table IV as 1,2-MPA), shows the results of Examples 5-8. In this Table and subsequent Tables, "X-100" indicates TRITON X-100 nonionic surfactant, identified previously in the specification. "Spray 2" in the development mode line indicates Spray Develop Program 2 in Table II. In the result column, "res." indicates that a residue was present on the edges of developed lines of the photoresist.
1-amino-2-hydroxypropane sometimes provides a residue (Examples 5 and 8) and sometimes does not (Examples 6 and 7). It is better in an immersion developer than in a spray developer; a poor spray pattern was noted during spray development. The best result is obtained at a ratio of 1:18 as in Example 7, in which no residue was noted on the developed lines.
Examples 9-18 in Tables V and VI show development with 1-amino-3-hydroxypropane, abbreviated in Tables V and VI as 1,3-MPA. This is species 10 of Table I. Looking first at Table V, Examples 9 and 10 are essentially identical runs, but in Example 9 a residue was noted at a ratio of 1:12, while in Example 10 no residue was noted. This indicates that this is a marginally acceptable formulation. Similarly, Examples 11 and 12 are essentially identical runs. In one case a residue was provided, and in the other case no residue was observed. Examples 9-12 were all run at a ratio of 1:12, which therefore is less preferred than the 1:15 ratio of Example 13. A 1:15 ratio has been found in this and other examples to almost never leave residue on the edges of the developed resist lines. Thus, a ratio of 1:15 is preferred to provide optimal development with minimal amounts of the alkanolamine.
Examples 14-18 show ratios of TMAH to 1,3-MPA of 1 to 15 or lower. Examples 14-16, using spray development, illustrate that the 1:15 composition of 1,3-MPA can be sprayed successfully and provides residue free development. The compositions of Examples 14-16 all contain TRITON X-100 surfactant, in increasing amounts. In Example 16 0.05% of this surfactant was too much, as it caused developed resist line sidewalls to slope or otherwise deviate from the optimal vertical sidewalls. Thus, 0.05% of this surfactant is more than the preferred maximum amount under the other conditions of this example. Example 17 showed a ratio of 1:20 and good development despite the presence of less TMAH than in the other formulations. Example 18 illustrates that at extremely low ratios, even when the amount of TMAH is minimized, the developed resist has a rough surface. Roughness is believed to be caused by the presence of a large amount of the alkanolamine. While some roughness can be tolerated, it is not desirable, so a minimum ratio of about 1 to 38 is preferred herein.
Tables VII, VIII, and IX embody the results of comparative Examples 19-34, using various similar compounds in place of the alkanolamines of the present invention.
In Table VII, Examples 19-23, the alkanolamine was replaced with ethylene diamine (abbreviated EDA in the table) in ratios of from a maximum of 1:3 to a minimum of 1:37.8. In all cases immersion development was used. The relatively large proportion of TMAH in the high ratio of Example 19 stripped both developed and undeveloped portions of the resist from the substrate. The remaining examples all show the formation of residue or heavy residue, and the lowest ratio of TMAH (and highest ratio of EDA) provides a heavy residue and lack of resolution which do not constitute suitable development. The inventors conclude from this example that a wide range of different proportions and ratios of ethylene diamine does not exhibit the beneficial properties of the present invention.
Table VIII provides comparative examples 24-27 in which the alkanolamine is replaced with ethylene glycol (EG). Over a wide range of ratios and proportions of ethylene glycol, the result is again a residue on the developed lines of photoresist, in either the immersion or the spray mode of development. Example 28 is prior art, and illustrates that a formulation containing just TMAH in a proportion sufficient to develop the photoresist provides a residue, and thus is not an optimal developer according to the present invention. As noted previously, Example 4 shows the contrary situation in which a large amount of an alkanolamine according to the present invention is present (80%) and an insufficient proportion of TMAH is present. Comparing these examples, it is evident that neither TMAH alone nor an alkanolamine alone provides proper development, but the other examples show that the combination of these two ingredients improves development unexpectedly.
In Table IX, Examples 29 and 30 show the use of diethanolamine (abbreviated: DEA); comparative Examples 31 and 32 show the use of triethanolamine (abbreviated: TEA); and comparative examples 33 and 34 employ diethylethanolamine (abbreviated: DEEA) in place of the present alkanolamines. In all these comparative examples, each in two different proportions employing the immersion development mode, development was hindered by the additive. In Examples 29-32, despite a high maximum exposure, only a latent image was produced. This means that the exposed portions of the photoresist were not removed by this formulation. In Examples 33 and 34 the developed and undeveloped portions of the photoresist were both stripped.
The comparative examples illustrate that the class of additives which prevent residue formation without disturbing the function of the resist developer is narrow. Ethylene diamine differs from the presently claimed monoethanolamine by substitution of a second amine for a hydroxy group. Ethylene glycol of comparative Examples 24-28 is different from monoethanolamine only by the substitution of a second hydroxyl group for the amine group. In short, a structure with an amine group on one end and a hydroxyl group on the other works, but respective structures with two amine groups or two hydroxyl groups in the same positions do not work. The additives of comparative examples 29-34 differ from the present invention, and specifically from monoethanolamine, by the substitution of alkyl or ethanol moieties for the amine hydrogen atoms of the present generic formula. Diethanolamine has two ethanol moieties instead of the single ethanol moiety of monoethanolamine according to the present invention. Triethanolamine has three ethanol moieties in place of the single ethanol moiety of the present invention. Diethylethanolamine has two ethyl groups in place of the amine hydrogens of monoethanolamine. These substitutions all provide a compound which does not function in the advantageous manner of the present alkanol amines.
The formulations and data for Examples 35-40 are reported in Table X. Exemplary two micron lines of each developed resist were photographed with a scanning electron microscope at a magnification of 20,000 diameters and an energy of 23 KV. FIGS. 1 through 6 respectively correspond to Examples 35 through 40.
In FIG. 1 and Example 35, the developer was 1-amino-2-hydroxypropane at a ratio of 1:12. FIG. 1 illustrates some residue, particularly along the upper edges of the resist, but no roughness. (The slight roughness or grain shown in the photographs on the top surface of each resist line and on the substrate between the resist lines is a combination of noise in the microscope and photographic grain.) FIG. 1 shows a reduction of the residue problem, but not a complete solution.
In FIG. 2 and Example 36, the formulation contained 1-amino-3-hydroxypropane at a ratio of 112. The result shown in FIG. 2 is similar to that shown in FIG. 1.
In FIG. 3 and Example 37, a 1:15 ratio of 1-amino-3-hydroxypropane was used; the formulation contained 1.00% of TMAH, and is considered optimal. As FIG. 3 shows, the developed lines have smooth upper surfaces and no visible residue. (The regular, horizontal striations on the sidewalls of the lines are artifacts of standing waves in the exposure radiation, and are not residue.)
In Example 38 and FIG. 4, the ratio of TMAH to 1-amino-3-hydroxypropane is 1:37.9. The line is clearly developed and has no residue, but the entire top and side surfaces of the line are roughened; this is considered less than optimal development, although the advantages of the present invention other than absence of roughness are obtained in this example.
In Example 39 and FIG. 5, ethylene diamine is added to the developer at a ratio of 1:20. Heavy residue is present on the edges of the top surface. The vertically oriented ridge-and-valley irregularity of the sidewalls is also related to the presence of the residue problem:
Example 40 and FIG. 6 illustrate development with a prior art formulation of 2.0% by weight TMAH and no other additives. FIG. 6 thus illustrates that without an alkanolamine a heavy residue is observed.
TABLE II______________________________________Spray Development Programs Wafer Material DurationStep Rotation Applied Mode of Step______________________________________Spray Develop Program 11 50 rpm Developer Spray 42 sec.2 1,000 rpm DI water Stream 10 sec.3 4,000 rpm None Dry 10 sec.Spray Develop Program 21 1,000 rpm DI water stream 2 sec.2 1,000 rpm Developer spray 10 sec.3 400 rpm Developer spray 5 sec.4 0 rpm Developer spray 2 sec.5 0 rpm None puddle 15 sec.6 1,000 rpm DI water stream 10 sec.7 4,000 rpm None dry 10 sec.Spray Develop Program 31 450 rpm Developer spray 7 sec.2 50 rpm Developer spray 4 sec.3 0 rpm None puddle 15 sec.4 50 rpm Developer spray 4 sec.5 0 rpm None puddle 15 sec.6 50 rpm Developer spray 4 sec.7 0 rpm None puddle 15 sec.8 1,000 rpm DI water stream 10 sec.9 5,000 rpm None dry 10 sec.______________________________________
TABLE III______________________________________MEA, Examples 1-4Component 1 2 3 4______________________________________Wt. % TMAH 1.60 1.00 1.00 0.50Wt. % MEA 12.5 37.9 37.9 80.0Wt. % H.sub.2 O 85.9 61.1 61.1 19.50Total % 100.00 100.00 100.00 100.00Development I I spray IModemJ/cm.sup.2 70 50 50 100Result good good poor LR; spray poor developRatio 1:7.8 1:37.9 1:37.9 1:160______________________________________
TABLE IV______________________________________1,2-MPA, Examples 5- 8 5 6 7 8______________________________________Wt. % TMAH 1.25 1.25 1.00 1.05Wt. % 1,2-MPA 15.0 15.0 18.0 21.0Wt. % X-100 0.01Wt. % H.sub.2 O 83.75 83.75 81.00 77.94Total % 100.00 100.00 100.00 100.00Development I spray 2 I spray 2Modemj/cm.sup.2 60 70 50 70Result res. poor good res. spray and poor sprayRatio 1:12 1:12 1:18 1:20______________________________________
TABLE V______________________________________1,3 MPA, Examples 9- 13 9 10 11 12 13______________________________________Wt % TMAH 1.20 1.20 1.20 1.20 0.96Wt % 1,3MPA 14.4 14.4 14.40 14.40 14.40Wt % X-100 -- -- .01 .01 .01Wt %H.sub.2 O 84.40 84.40 84.39 84.39 84.63Total % 100 00 100.00 100.00 100.00 100.00Develop- spray spray spray spray sprayment Mode 2 2 2 2 1mJ/cm.sup.2 60 60 80 70 190Result res. good res. good goodRatio 1:12 1:12 1:12 1:12 1:15______________________________________
TABLE VI______________________________________1,3 MPA, Examples 14- 18 14 15 16 17 18______________________________________Wt % TMAH 1.00 1.10 1.10 0.95 0.70Wt % 1,3MPA 15.0 16.5 16.5 19.0 26.53Wt % X-100 .005 .01 .05 -- --Wt % H.sub.2 O 83.995 82.39 82.35 80.05 72.77Total % 100.000 100.00 100.00 100.00 100.00Develop- spray spray spray I Iment Mode 1 1 1mJ/cm.sup.2 110 60 70 50 50Result good good side- good rough wall slopeRatio 1:15 1:15 1:15 1:20 1:37.9______________________________________
TABLE VII______________________________________Comparative Examples 19- 23Component 19 20 21 22 23______________________________________Wt % TMAH 3.0 1.65 1.05 0.84 0.90Wt % EDA 9.0 4.95 12.6 17.4 34.02Wt % H.sub.2 O 88.0 93.40 86.35 81.76 65.08Total % 100.0 100.00 100.00 100.00 100.00Development I I I I IModemJ/cm.sup.2 10-100 50 50 50 60Result strip res. res. res. heavy res.; LRRatio 1:3 1:3 1:12 1:20 1:37.8______________________________________
TABLE VIII______________________________________Comparative Examples 24- 28Component 24 25 26 27 28______________________________________Wt % TMAH 2.40 2.55 0.87 0.90 2.2Wt % EG 7.20 30.6 17.40 34.02 --Wt % H.sub.2 O 90.40 66.95 81.73 65.08 97.8Total % 100.00 100.00 100.00 100.00 100.0Development I I spray spray IMode 2 2mJ/cm.sup.2 60 80 70 50 50Result res. res. res. heavy res. res.Ratio 1:3 1:12 1:20 1:37.8 --______________________________________
TABLE IX______________________________________Comparative Examples 29- 34Component 29 30 31 32 33 34______________________________________Wt & 1.00 1.00 1.00 1.00 1.00 1.00TMAHWt % DEA 10.00 20.00 -- -- -- --Wt % TEA -- -- 10.00 20.00 -- --Wt % DEEA -- -- -- -- 10.00 20.00Wt % H.sub.2 O 89.00 79.00 89.00 79.00 89.00 79.00Total % 100.00 100.00 100.00 100.00 100.00 100.00Development I I I I I IModemJ/cm.sup.2 400 400 400 400 -- --Result latent latent latent latent strip strip image image image image only only only onlyRatio 1:10 1:20 1:10 1:20 1:10 1:20______________________________________
TABLE X______________________________________Component 35 36 37 38 39 40______________________________________TMAH 1.25 1.20 1.00 0.70 0.84 2.01,2-MPA 15 -- -- -- -- --1,3-MPA 0 14.40 15.0 26.53 -- --EDA 0 -- -- -- 16.8 --X-100 0 .01 .01 -- -- --H.sub.2 O 83.75 84.39 83.99 72.77 82.36 98.00Total % 100.00 100.00 100.00 100.00 100.00 100.00Development spray spray spray spray I sprayMode 2 1 2 3 2mJ/cm.sup.2 70 60 110 50 50 90Result res. slight good rough heavy heavy poor res. res. res. sprayRatio 1:12 1:12 1:15 1:37.9 1:20 --______________________________________
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Compositions and methods for developing quinone diazide positive-working photoresists. The compositions consist essentially of an aqueous solution of a tetraalkylammonium hydroxide primary alkali and an alkanolamine having the following structure: ##STR1## wherein n is zero or 1, and each R is independently selected from hydrogen, methyl, or ethyl. The methods involve use of this composition to develop the indicated photoresists. The addition of an alkanolamine of the indicated type prevents the formation of irregular deposits on the edges of unexposed portions of the photoresist lines when the photoresist is developed. Selection of these alkanolamines also increases the uniformity of line widths of photoresist lines developed according to the present invention, and increases the process latitude of the developer.
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FIELD OF THE INVENTION
The present application claims priority of Japanese Patent Application No. 2011-154049 filed on Jul. 12, 2011, the disclosure of which is expressly incorporated by reference herein in its entirety.
The invention relates to a fuse holder which is capable of plugging and pulling out a fuse while retaining the fuse mounted in an electric junction box or the like. In particular, the invention relates to a fuse holder used for temporarily blocking supply of dark current into electrical components mounted in a vehicle during exportation of the vehicle.
DESCRIPTION OF THE RELATED ART
During the exportation of a vehicle, dark current continuously flows into electrical components of the vehicle for a prolonged period. As a result, a battery runs out, and an engine does not work. In order to avoid this phenomenon, a fuse is temporarily eliminated from a circuit for supplying electric power from the battery to the electrical components when the vehicle for exportation is shipped. The battery is reassembled when the vehicle is delivered to, for example, a car dealer.
Moreover, in order to avoid missing of the fuse which is taken out from the vehicle during the exportation of the vehicle, as well as, to make the operations such as plugging and/or pulling out of the fuse easy, a component “fuse holder” is often used. For more detail, see JP H7-169382A. The fuse holder is configured to plug or pull out the fuse with respect to the frame of an electric junction box while retaining the fuse therein. The fuse holder can be moveably attached to the frame from one position in which the fuse can be electrically connected to the connecting terminal disposed in the frame another position in which the fuse is disconnected or decoupled from the connecting terminal.
The conventional fuse holder as described previously is attached or coupled to the frame after the fuse is mounted to the fuse holder. On the other hand, the fuse may not be temporarily eliminated or taken out from a frame of a vehicle for domestic demand. This is because the time of transport or delivery is relatively short, and battery consumption caused by the dark current is thus not severe. In this case, only the fuse is attached to the frame. In other words, the fuse holder is not attached to the frame. As such, the process for attaching the fuse to the frame cannot be commonalized between the vehicle for domestic demand and the vehicle for export, and thereby adversely affecting production efficiency.
Furthermore, the above problem may occur in products other than the vehicle.
SUMMARY OF THE INVENTION
In order to overcome the afore-mentioned drawbacks and problems, the invention provides a fuse holder which can be attached or coupled to a frame and a fuse after the fuse is attached or coupled to the frame, a method for connecting the fuse by using the fuse holder, and a fuse-connecting structure equipped with the fuse holder.
In one aspect, the invention provides a fuse holder attachable to a frame and retainable a fuse. The fuse holder has a pair of flexible arms extending in the same direction as the fuse holder is attached to the frame. The fuse holder is moveably attached or coupled to the frame while retaining the fuse therein such that it can be situated between a first position in which the fuse is electrically connected to a connecting terminal disposed in the frame, and a second position in which the fuse is disconnected or decoupled from the connecting terminal. The pair of flexible arms is configured to sandwich the fuse therebetween, as well as, to engage with the fuse. The pair of flexible arms can be formed such that it can be bent in a direction away from each other.
In another aspect, the invention provides a method for connecting fuse by using the above fuse holder. The method specifically includes the following steps: attaching or coupling the fuse, which is not retained in the fuse holder, to the frame, and subsequently inserting the fuse holder into the frame in the same direction as the fuse is attached or coupled to the frame, thereby attaching or coupling the fuse holder to both the frame and the fuse.
In the other aspect, the invention provides a fuse-connecting structure having the above fuse holder, the above fuse, the above frame, and the above connecting terminal. The fuse has a portion with which the pair of flexible arms engages.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention may be put into practice in various ways and a number of embodiments will be described by way of example to illustrate the invention with reference to the accompanying drawings, in which:
FIG. 1 is a perspective view of one embodiment of a fuse holder in accordance with the invention;
FIG. 2 is a cross-sectional view taken along line A-A of FIG. 1 ;
FIG. 3 is provided for illustrating an example to attach or couple a fuse to the fuse holder of FIG. 1 ;
FIG. 4 is a perspective view depicting a state in which the fuse holder of FIG. 3 is attached or coupled to a frame and the fuse;
FIG. 5 is a cross-sectional view taken along line C-C of FIG. 4 ;
FIG. 6 is a perspective view depicting a state in which the fuse is decoupled or disconnected from the frame by means of the fuse holder of FIG. 4 ;
FIG. 7 is a cross-sectional view taken along line D-D of FIG. 6 ;
FIG. 8 is provided for illustrating alternative example to attach or couple the fuse to the fuse holder of FIG. 1 ;
FIG. 9 is a perspective view depicting a state in which the fuse is attached or coupled to the fuse holder of FIG. 8 ;
FIG. 10 is a perspective view depicting the fuse holder as shown in FIG. 3 and a frame which is different from the frame as shown in FIG. 3 ; and
FIG. 11 is a perspective view depicting a state in which the fuse is decoupled from the frame by means of the fuse holder as shown in FIG. 10 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
One embodiment of a fuse holder 1 , one embodiment of a method for connecting a fuse by using the fuse holder 1 , and a fuse-connecting structure equipped with the fuse holder 1 will be thereafter described in detail with reference to FIGS. 1-9 .
The fuse holder as shown in FIGS. 1 and 2 corresponds to a part or component which is configured to couple or decouple a fuse with respect to a frame 3 of an electric junction box as shown in FIGS. 4-7 while retaining the fuse 2 therein.
The electric junction box is to be mounted to a vehicle, and is configured to supply or distribute electric power from a battery into a plurality of electrical components. The electric junction box has a frame 3 which is shown to include a portion or space 30 to which the fuse 2 and the fuse holder 1 are attached, and portions or spaces 38 , 39 to which any necessary component(s) or part(s) other than the fuse 2 and the fuse holder 1 is(are) attached. The frame 3 can be formed of synthetic resin.
Referring to FIG. 5 , the frame 3 is capable of receiving a bus bar 4 which is configured to electrically connect the electric components or parts together which are attached or coupled to the frame 3 . The bus bar 4 can be produced by pressing a metallic plate or metallic sheet, and have a connecting terminal 40 which is electrically connected to the fuse 2 . The connecting terminal 40 has a slot 41 for inserting a terminal 8 of the fuse 2 thereinto.
As mentioned previously, the electric junction box 1 is equipped with a fuse-connecting structure 10 which has the fuse holder 1 , the fuse 2 , the frame 3 and the connecting terminal 40 .
The fuse 2 is a part or component of a circuit for supplying electric power from a battery into a clock, a smart key, or other electrical components such as an antitheft device. Referring to FIG. 8 , the fuse 2 is shown to include a housing 20 formed of synthetic resin, a pair of terminals 8 extending from the housing 20 , and a fusible element received in the housing 20 . Moreover, the housing 20 has a rectangular-shaped body portion 21 , a flange portion 22 foiled in one end of the body portion 21 , and a recess 23 formed in both opposed sides of the body portion 21 . The pair of terminals 8 projects from or extends from the other end of the body portion 21 . The two recesses 23 are foil red for each side (i.e. side surface). Furthermore, the two recesses 23 are arranged in line with the pair of terminals 8 . In other words, the two recesses 23 are arranged in parallel with the pair of terminal 8 . A pair of flexible arms 5 of the fuse holder 1 engages with the recesses 23 . The recess 23 corresponds to “a portion with which the pair of flexible arms engages” as recited in the attached claims.
The fuse holder 1 can be formed of synthetic resin, and has a base portion 7 , a pair of flexible arms 5 extending from the outer edge or face of the base portion 7 in a direction indicated by an arrow “Y” (see FIG. 8 ), and a pair of locking arms 6 extending from the outer edge or face of the base portion 7 in a direction as indicated by the arrow “Y” and located lateral to the pair of the flexible arms 5 , as shown in FIGS. 1 and 2 . The pair of flexible arms 5 is configured to engage with the fuse 2 ; as well as, to sandwich the fuse 2 therebetween. The pair of locking arms 6 is made engageable with the frame 3 . In this regard, a direction as indicated by the arrow “Y” can be defined by a direction in which the fuse holder 1 is attached or coupled to the frame 3 . Furthermore, the direction as indicated by an arrow “X”, and the direction as indicated by an arrow “Y” bisect each other at right angles. The direction as indicated by an arrow “Z” is orthogonal to both the direction as indicated by the arrow “X” and the direction as indicated by the arrow “Y”.
The pair of flexible arms 5 is arranged apart from each other in the direction as indicated by the arrow “X”. Each flexible arm 5 is shown to include a pair of flexible portions 50 , a connecting portion 51 in which the pair of flexible portions 50 is connected to each other at each one end portion, and a pair of projections 52 extending from both end portions of the connecting portion 51 , which are disposed in a direction as indicated by “Z”, toward the opposite flexible arm 5 . The pair of flexible portions 50 is spaced apart from each other in a direction as indicated by the mow “Z” and extends from the outer edge or surface of the base portion 7 in a direction as indicated by the arrow “Y”. As shown in FIGS. 5 and 9 , four projections 52 are capable of engaging with four depressions 23 of the fuse 2 respectively, thereby retaining the fuse 2 therein. As such, the fuse 2 can be attached or mounted to the fuse holder 1 .
The pair of locking arms 6 is arranged apart from each other in a direction as indicated by the arrow “X”. Each locking arm 6 can be formed in the shape of a plate or sheet. There is provided a through-hole 60 in the center of the locking arm 6 . As a result, each locking arm is formed in the shape of a frame. Between each locking arm 6 and each flexible arm 5 , there is provided a gap or clearance. Due to the gap or clearance the pair of flexible arms 5 is capable of bend in a direction away from each other (i.e., a direction as indicated by the arrow “X”).
Referring to FIG. 3 , a method for attaching or coupling the fuse 2 to the fuse holder 1 can be described. The fuse 2 and the fuse holder 1 can be approximated in a direction as indicated by the arrow “Y” (i.e., B direction), and then the fuse 2 can be attached or coupled upwardly to the fuse holder 1 by jamming the fuse 2 between the pair of flexible arms 5 of the fuse holder 1 . Alternatively, as shown in FIG. 8 , the fuse 2 and the fuse holder 1 can be approximated in a direction as indicated by the arrow “Z” (i.e., E direction), and then the fuse 2 can be attached or coupled to the fuse holder 1 by laterally sliding the fuse 2 between the pair of flexible arms 5 of the fuse holder 1 . In other words, the invention proposes above two methods for attaching or coupling the Rise 2 to the fuse holder 1 .
In the former method as shown in FIG. 3 , the flexible portion 50 can be temporarily deformed elastically toward the locking arm 6 when the flange 22 of the fuse 2 passes between the pair of projections 52 . The flexible portion 50 is then recovered from the deformed state after the flange 22 of the fuse 2 passes between the pair of projections 52 , thereby allowing the projection 52 to engage with the depression 23 of the fuse 2 . On the other hand, in the latter method as shown in FIG. 8 , the flexible portion 50 is not elastically deformed.
With reference to FIGS. 3 to 7 , the portion or space 30 to which the fuse 2 and the fuse holder 1 are attached is comprised of a circumferential wall 31 configured to position the fuse holder 1 therein, a pair of inner walls 32 disposed inside the circumferential wall 31 and configured to sandwich the fuse 2 therebetween, a first lock 33 disposed on each of the opposed inner surfaces of the circumferential wall 31 , and a second lock 34 disposed on each of the opposed inner surfaces of the circumferential wall 31 .
The distance between one opened end portion of the circumferential wall 31 and the second lock 34 is less than the distance between the opened end portion of the circumferential wall 31 and the first lock 33 . The first lock 33 and the second lock 34 can be locked with the through-hole 60 formed in the locking arm 6 of the fuse holder 1 . Moreover, referring to FIGS. 4 and 5 , the locking arm 6 is locked with the first lock 33 , thereby maintaining the state that the terminal 8 of the fuse 2 retained in the fuse holder 1 is inserted into the slot 41 of the connecting terminal 40 . With reference to FIGS. 6 and 7 , the locking arm 6 is locked with the second lock 34 , thereby maintaining the state in which the terminal 8 of the fuse 2 retained in the fuse holder 1 is positioned outside the slot 41 of the connecting terminal 40 .
As mentioned previously, the fuse holder 1 can be attached or coupled to the frame 3 such that it can be moved between a first position in which the fuse 2 is electrically connected to the connecting terminal 40 disposed in the frame 3 and a second position in which the fuse 2 is disconnected or decoupled from the connecting terminal 40 while retaining the fuse 2 therein.
Referring to FIG. 3 , the fuse 2 is capable of being attached or coupled to the portion or space 30 even if it is not retained in the fuse holder 1 . In other words, the fuse 2 can be electrically connected to the connecting terminal 40 disposed in the frame 3 in an independent manner.
Next, there will be illustrated a method for connecting the fuse 2 by using the fuse holder 1 .
Firstly, with reference to FIG. 3 , the fuse 2 which is not retained in the fuse holder 1 is attached or coupled to the portion or space 30 of the frame 3 . Subsequently, the fuse holder 1 is inserted into the portion or space 30 of the frame 3 in the same direction as the fuse 2 is attached to the portion or space 30 (i.e. B direction) such that the fuse holder 1 is attached or coupled to the frame 3 and the fuse 2 is attached or coupled to the fuse holder 1 . After the completion of the afore-mentioned operation, the fuse holder 1 is arranged in the first position as shown in FIGS. 4 and 5 , and the fuse 2 is electrically connected to the connecting terminal 40 . Furthermore, as mentioned previously, in a case where the fuse 2 is intended to be attached to the fuse holder 1 , the flange 22 of the fuse 2 abuts against the projection 52 of the pair of flexible arms 5 immediately before the fuse holder 1 is arranged in the first position. At this point, the pair of flexible arms 5 is temporarily bent such that they are away from each other. Due to elastic restoring force of the flexible arm 5 , the pair of flexible arms 5 can be restored to its normal state (i.e., non-deformed state), thereby allowing the fuse 2 to be attached to the fuse holder 1 . In addition, the pair of flexible arms 5 will not bend after the fuse 2 is attached to the fuse holder 1 .
In order to prevent dark current from flowing into the electrical component of the vehicle, the fuse holder 1 can be lifted from the first portion as shown in FIGS. 4 and 5 to the second position as shown in FIGS. 6 and 7 . As a result, the fuse 2 is decoupled or disconnected from the connecting terminal 40 . On the other hand, in order to electrically connect the fuse 2 to the connecting terminal 40 once gain, the fuse holder 1 can be situated from the second position as shown in FIGS. 6 and 7 to the first position as shown in FIGS. 4 and 5 .
As such, the pair of flexible arms 5 is formed such that it can be bent in a direction away from each other. As a result, the fuse holder 1 can be attached or coupled to the assembly of the fuse 2 and the frame 3 after the fuse 2 is attached to the frame 3 . Accordingly, a product with or without the fuse holder 1 can be commonly produced by the afore-mentioned process or step of attaching or coupling the fuse 2 to the frame 3 . Alternatively, the fuse holder 1 may be attached or coupled to the frame 3 after the attachment of the fuse 2 to the fuse holder 1 .
For reference, a product equipped with the fuse holder 1 may be an electric junction box for a vehicle for export, and a product without the fuse holder 1 may be an electric junction box for a vehicle for domestic demand.
Due to the fuse-connecting structure 10 equipped with the fuse holder 1 the fuse 2 which is decoupled from the connecting terminal 40 can be protected from any loss or damage.
The inventive method for connecting the fuse by using the fuse holder 1 makes it easy to disconnect the fuse 2 from the connecting terminal 40 , as well as, to electrically connect the fuse 2 to the connecting terminal 40 .
The inventive fuse-connecting structure equipped with the fuse holder 1 can also employ a frame 103 as shown in FIGS. 10 and 11 in place of the frame 3 as mentioned above. In other words, a fuse-connecting structure 110 equipped with the fuse holder 1 has the fuse holder 1 , the fuse 2 , the frame 103 , and the connecting terminal received in the frame 103 , as shown in FIGS. 10 and 11 .
The frame 103 is formed of synthetic resin, and has a constitution which is substantially equal to the portion or space 30 to which the fuse 2 and the fuse holder 1 are attached.
As such, the frame can have at least one portion or space to which a component(s) or part(s) is attached. Moreover, the frame as stated above is not necessarily disposed in the electric junction box. In addition, the connecting terminal may be a part of the bus bar, or may be connected to the terminal of an electrical wire.
While the invention has been described with reference to exemplary embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims.
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The invention provides a fuse holder attachable to a frame and retainable a fuse, having a pair of flexible arms extending in the same direction as the fuse holder is attached to the frame and moveably attached or coupled to the frame while retaining the fuse therein.
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BACKGROUND
1. Field of the Disclosure
The disclosure relates generally to data communications, and in particular, to specifying a parser on a server, and transferring and reconstructing the parser to a client.
2. The Prior Art
Background
Upstream Proxy servers are known in the art and provide an interface between a web client and a server by making requests on the client's behalf and modifying the content that is received before it is presented back to the client. Upstream proxy servers enable browsers to make normal requests to the proxy, which then makes the request from the content server. One application in which proxy servers are useful is a real-time web collaboration environment, where multiple clients are viewing the same cached page that must be dynamically updated, such as a page presenting stock quotes.
As is known by those of ordinary skill in the art, upstream proxy servers are to be distinguished from a “transparent” HTTP proxy, which is recognized specifically as a proxy server by the browser, allowing requests to be submitted in a different fashion. The user of a transparent proxy never sees a difference in the page they receive, i.e., the links are not modified.
One issue with upstream proxy servers is that any links that appear on pages must link back to the proxy server, and not the actual source of the content. To accomplish this, typical proxy servers must perform parsing on the web content prior to presenting the content to the requesting users. Parsing typically involves downloading the requested content, parsing the content to find any embedded links, modifying the links to point back to the proxy server rather than the content source, perform any further content transformation necessary, and then forward the content to the requesting client.
A further challenge to parsing is the increasing use of Java script pages, which allow the generation of web pages dynamically within the receiving client's web browser. Such pages may generate their own links within the browser page which must be parsed and re-directed to the proxy server. Typically, such server-based parsing routines are hard-coded as procedures provided with a specific product, and are not easily extensible or modified.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
FIG. 1 is a diagram of a data communication system including a proxy server configured in accordance with this disclosure.
FIG. 2 is a flow diagram of parsing received content in accordance with the teachings of this disclosure.
FIG. 3 is a diagram of a data communication system including a proxy server coupled one or more clients configured to parser content locally in accordance with this disclosure.
FIG. 4 is a flow diagram of locally parsing received content by a client in accordance with the teachings of this disclosure.
FIG. 5 is a further flow diagram of locally parsing received content by a client in accordance with the teachings of this disclosure.
DETAILED DESCRIPTION
Persons of ordinary skill in the art will realize that the following description is illustrative only and not in any way limiting. Other modifications and improvements will readily suggest themselves to such skilled persons having the benefit of this disclosure. In the following description, like reference numerals refer to like elements throughout.
This disclosure may relate to data communications. Various disclosed aspects may be embodied in various computer and machine readable data structures. Furthermore, it is contemplated that data structures embodying the teachings of the disclosure may be transmitted across computer and machine readable media, and through communications systems by use of standard protocols such as those used to enable the Internet and other computer networking standards.
The disclosure may relate to machine readable media on which are stored various aspects of the disclosure. It is contemplated that any media suitable for retrieving instructions is within the scope of the present disclosure. By way of example, such media may take the form of magnetic, optical, or semiconductor media, and may be configured to be accessible by a machine as is known in the art.
Various aspects of the disclosure may be described through the use of flowcharts. Often, a single instance of an aspect of the present disclosure may be shown. As is appreciated by those of ordinary skill in the art, however, the protocols, processes, and procedures described herein may be repeated continuously or as often as necessary to satisfy the needs described herein. Accordingly, the representation of various aspects of the present disclosure through the use of flowcharts should not be used to limit the scope of the present disclosure.
FIG. 1 is a diagram of a proxy server system 100 configured in accordance with the teachings of this disclosure. The system 100 includes a content server for providing content to the Internet. The system 100 also includes a client that is coupled to the Internet through a proxy server. The proxy server may include memory 102 and a processor 104 as is known in the art for the storage, retrieval, and execution of embodiments of this disclosure. The proxy server contains a parser that is configured to parse content requested by the client in accordance with the teachings of this disclosure as will be described in more detail below.
In one aspect of this disclosure, the parser of this disclosure is contained in an XML file that contains the parser structure and behavior. The server may read this file and build the parser upon startup.
It is contemplated that the parser may adhere to a specific structure, which may then be used to determine structure of the parser at runtime. In one aspect, when instantiated, a tree-like structure representing the various configured parsers may be created. The structure reflects the hierarchical relationships between configured parsers, and is used to select the appropriate parser for a single request at parse-time. Additionally, the parser may contain script that may be executed during document reformatting to precisely control the reformatting process.
The parser of this disclosure introduces an element known as a metamatch. As the server initializes, it builds the metamatch element. The metamatch element contains one or more parsing objects, known as metamatch objects. Each metamatch object may contain one or more rule objects for parsing individual types of content, or sources of content. Thus, depending on the types of rules in a particular metamatch, metamatches may be optimized to parse a page from a particular source, or be more general and optimized to parse only a specific type of content. When constructed using a flexible language such as XML, many metamatch objects can be defined, and the metamatches may be related to each other in a hierarchal fashion as is known in the art. By so organizing the metamatches in a hierarchy, when a request comes in from a parser, the proxy server may walk through the metamatches to determine which rule applies to the content that needs to be parsed.
Additionally, as the metamatch element is built upon constituent metamatch objects, more specialized metamatch objects can reside alongside more general metamatches, with the more specialized objects inheriting some of the behavior from the more generalized objects.
The metamatch element may also contain an attribute that used to identify the most appropriate rule to parse content with as parsing requests are received.
In one aspect of this disclosure, the metamatch object comprises an object in Java. It has several attributes, such as the protocol, host, port, path, and contenttype, including comma separated lists of respective portions of the inbound request's meta data (the requested URL, the document type, etc). These may be used when linking a metamatch object with a metasearch object, allowing the parser to branch through the trees of rules.
Rule objects may also be defined in XML. The rule objects may contain an attribute that is a comma separated list of rule names which should be excluded from the tree that the rule exists in. This allows rules to override rules that were inherited from a parent metamatch object. Additionally, rules may override or deprecate other rules. Deprecated rules are effectively deleted from the metamatch that is created with the new Rule.
FIG. 2 is flow diagram of a parsing method in accordance with this disclosure. In performing the parsing, it will be assumed that the parser is built after the server initializes as mentioned above. The parser may be built at any time prior to the first parse request. After a request is made by the client, content arrives at the proxy server, initiating the parsing process.
Moving first to act 200 , a metamatch object is selected that best applies to the received content. This may be accomplished using the parsing expression as described above.
After the selected metamatch object is identified, the content may be parsed in act 202 . In one aspect, the content may be parsed in two steps.
The content may be first broken down into smaller pieces of text using one or more rule regular expressions. All expressions are combined into a large top-level expression, with one top-level expression being associated with a metamatch. In one aspect, the parsing process works by repeatedly applying the regular expression to the input, looking for the first best match in the input each time, then continuing from the end of the last match, until the end of the input is reached. The text is divided into fragments, with some fragments being text that matched a specified Rule, other fragments being the text in between matched fragments. In a further aspect, the text is only parsed once, after which the appropriate Rule scripts may act on it.
These smaller text objects may then be parsed according to the expressions in the rule objects contained in the selected metamatch object. The result of this process is a tree structure containing the parser rules and their associated text object. The process may then move to act 206 , where the proxy server iterates through the tree, executing the rules and reformatting the document. As each rule is executed, an associated rule script may be called and executed to reformat the content.
In a further aspect, various Rule scripts are provided which can execute at several different points in the parsing/reformatting process. For example, there are onBeforeParse, onAfterParse, onBeforeRender, and onAfterRender scripts available at the metamatch level. At the Rule level, there are onMatch and onRender scripts. It is contemplated that most reformatting may be done at the Rule-level onRender script, where, for example, a link is reformatted to point to the proxy server. For some HTML tag types, like a Base Href, an onMatch script is necessary to dynamically affect the parsing behavior as the document is being parsed.
Finally, the parsed objects may be written out into an output document. The output document may then be flattened out into a string and sent out to the client.
Thus far parsing on the server side has been described. It is contemplated that parsing on the client side may advantageous as well. Such an embodiment will now be disclosed.
FIG. 3 is a diagram of a proxy server system 300 configured in accordance with the teachings of this disclosure. The system 300 includes a content server for providing content to the Internet. The system 300 also includes at least one client 305 1 through 305 n coupled to the Internet through a proxy server 303 . The proxy server 303 may include memory 302 and a processor 304 as is known in the art for the storage, retrieval, and execution of embodiments of this disclosure. The proxy server contains a parser that is configured to parse content requested by the client in accordance with the teachings of this disclosure. The clients 305 1 through 305 n may comprise a personal computer as is known on the art suitable for operating a web browser, and also includes a parser 306 as will be described below.
In one aspect of a disclosed parser system, the parser code as disclosed above is also transferred to clients of the proxy server, allowing content to be parsed on the client in the same manner as was described above for parsing on the server. In this embodiment, the parsing code is constructed using a combination of Java and JavaScript, where Java provides the framework and JavaScript controls the reformatting behavior. It is contemplated that other languages may also be employed, such as VBScript or C#. The choice of language may depend on the particular environment where the code is to be executed.
FIG. 4 is a flowchart of a method of parsing in accordance with the teachings of this disclosure. The processes of FIG. 4 begins in act 400 where the parser as disclosed above is downloaded by a client from a server. It is contemplated that the parser may be downloaded as a collection of Java classes and a serialized Java object. The downloading may occur during the web session setup. It is contemplated that the same code as is used to construct the server parser may be downloaded to the client.
The process may then move to act 402 , where the parser is reconstructed locally in the client. During this reconstruction, all necessary state and instance information from the server parser may be installed in the client. The reformatting behavior may be sent to the client's browser in a web page as JavaScript.
Once the parser is reconstructed, the client is then able to locally parse received content in act 404 . Once the Java and JavaScript representing the parser is delivered to the client, links may be made from the Java parser to the JavaScript representing the reformatting behaviors as described above. When received content is parsed locally in the client, a call may be made into the Java parser, which then can execute and parser the content. The parsed document object may then be reformatted by calling into the various JavaScript reformatting functions.
FIG. 5 is a further flow diagram of parsing in accordance with the teachings of this disclosure. FIG. 5 shows the interaction between components in a client as parsing occurs. The sequence starts in act 500 , where a parsing request is received. The process then moves to act 502 , where parsing moves to the Java portion of the client-side parser. As the document is reformatted, a call may be placed into JavaScript for each rule script as needed in act 504 . The process in FIG. 5 may be repeated as often as necessary to parse the received content.
FIG. 5 thus discloses a method of communicating between Java code and JavaScript functions emulating the behavior of the server version of the parser on the client.
As will be appreciated by those skilled in the art, a key feature of the disclosed parser can “hook-in” to client-side writing of a document. Such content is frequently generated in the client, meaning that prior art server-side parsing and processing may not be sufficient. It is contemplated that any language may be employed as long as the disclosed parser can “hook-in” to the process of writing a document into the client.
Thus, using the teachings of this disclosure, content may be parsed in the same way as it would have been on the server. This local parsing aspect provides many advantages. For example, the teachings of this disclosure provides for consistent parsing behavior throughout a client/proxy server system as data is parsed on either the client or the server in the same manner. Thus, users of the proxy server can be assured of predictable parsing behavior.
Furthermore, the teachings of this disclosure reduce the maintenance of the parsing code. Since the same code can be utilized on both the server and client, maintaining a separate client codebase can be substantially reduced or eliminated. This can greatly reduce maintenance and troubleshooting.
Additionally, the teaching of this disclosure provide for a single source for parser extensions and modifications. The document parser of this disclosure may be quickly modified or customized to address unique content issues. As the same code may be used to provide both the server and client parsers, changes only need to be made in a single location, greatly reducing the likelihood of errors or inconsistencies.
While the aspects disclosed herein deal with HTTP content, the disclosed parser may also be usable in a more general sense to parse any arbitrary content. This may be useful where it is desirable to offload parsing responsibilities from a server to distribute the processing load.
While embodiments and applications of this disclosure have been shown and described, it would be apparent to those skilled in the art that many more modifications and improvements than mentioned above are possible without departing from the inventive concepts herein. The disclosure, therefore, is not to be restricted except in the spirit of the appended claims.
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The present disclosure presents a system for parsing based upon content type, and provides a content-rich set of parsing rules that can be optimized for a wide variety of applications. The present system also recognizes different types of content in addition to text, such as behaviors, and associates rules to parse a wide variety of content. The parser may be downloaded to a number of clients by the server, and content may be parsed locally by the clients in a manner similar to the server.
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This application is a continuation of application Ser. No. 382,565, filed May 27, 1982, now abandoned.
CROSS-REFERENCE TO RELATED CASE
The clutch plate of the present invention is somewhat similar to the clutch plate which is disclosed in commonly owned copending application Ser. No. 376,623 filed May 10, 1982 by Gerhard Rotter and now U.S. Pat. No. 4,478,326.
BACKGROUND OF THE INVENTION
The present invention relates to torque transmitting devices in general, and more particularly to improvements in means for damping vibrations which tend to develop when one of two or more rotary assemblies of a torque transmitting device turns relative to the other assembly or assemblies. Typical examples of such torque transmitting devices are clutch plates which are used in friction clutches of automotive vehicles to transmit torque from a driving member to a driven member, e.g., from the crankshaft of an internal combustion engine to the input shaft of a change-speed transmission.
It is known to assemble a friction clutch plate of several (at least three) assemblies one of which is the input assembly and can comprise a disc-shaped carrier of friction linings, another of which is the output assembly and can comprise a rotary hub and a flange on the hub, and a third of which can comprise at least one disc-shaped or plate-like friction generating component. One or more coil springs or analogous energy storing means are interposed between the input and output assemblies to yieldably oppose the limited amount of angular movement between such assemblies, and the third assembly is installed in the path of transmission of power between the input and output assemblies to offer a resistance to relative angular movement at least during part of rotation of the input assembly with reference to the output assembly and/or vice versa. A second component of the third assembly stores energy and urges the aforementioned friction generating component against one of the input and output assemblies. The energy storing component reacts against the other of the input and output assemblies.
A clutch plate of the just outlined character is disclosed, for example, in German Offenlegungsschrift No. 1,600,194. In the clutch plate of this German publication, the carrier of friction linings is non-rotatably secured to a disc-shaped cover, and one side of the cover is adjacent to a friction generating component which is disposed between two friction pads. The other side of the cover is adjacent to the energy storing component which is stressed in the axial direction and constitutes a dished spring serving to insure the generation of necessary friction which opposes the angular movement between the carrier of friction linings and the hub. The radially outermost portion of the energy storing component reacts against the cover, and its innermost portion bears against an adjustable nut which meshes with the hub. The latter extends through the cover and has an enlarged portion or boss at that side of the cover which faces away from the energy storing component. The friction generating component is confined between the boss and the respective side of the cover, i.e., one of the aforementioned friction pads bears against the radially outwardly extending boss and the other friction pad bears against the cover. The friction generating component has edge faces which engage the energy storing means between the input and output assemblies of the clutch plate.
A drawback of the just discussed conventional clutch plate is that it is expensive, mainly because it comprises a relatively large number of complex parts such as an externally threaded hub with a boss, an internally threaded nut, and others. Furthermore, the assembling of the just discussed clutch plate takes up a substantial amount of time. Moreover, the vibrationdamping unit takes up a considerable amount of space, as considered in the axial direction of the clutch plate. Such space is not available in all friction clutches so that the clutch plate of the German publication can be used only in certain types of clutches. Still further, the weight and hence the inertia of the conventional clutch plate is substantial which is highly undesirable, e.g., as regards the synchronizing devices for change-speed transmissions in automotive vehicles.
OBJECTS AND SUMMARY OF THE INVENTION
An object of the invention is to provide a novel and improved torque transmitting device, such as a clutch plate, which is simpler, less expensive and more compact than in heretofore known clutch plates.
Another object of the invention is to provide a lightweight clutch plate whose dimensions, as considered in the axial direction, are a fraction of the dimensions of heretofore known equivalent or similar clutch plates.
A further object of the invention is to provide a torque transmitting device, particularly a clutch plate for use in the friction clutch of an automotive vehicle, wherein the number of component parts is less than in heretofore known clutch plates.
An additional object of the invention is to provide the clutch plate with novel and improved torsional vibration damping means which is not only simple and compact but also sufficiently versatile to find application in many conventional clutch plates.
Another object of the invention is to provide a torque transmitting device with novel and improved torsional vibration damping means which occupies little room, which occupies room that is normally available in a clutch plate, and which ensures the generation of optimal frictional resistance to relative angular movement between the various assemblies of the clutch plate.
A further object of the invention is to provide a clutch plate which embodies the improved torsional vibration damping means but is nevertheless designed in such a way that its inertia is lower than that of heretofore known clutch plates.
Still another object of the invention is to provide a machine, apparatus or the like which embodies the improved clutch plate.
Another object of the invention is to provide a clutch plate which can be used in existing friction clutches or the like as a superior substitute for heretofore known clutch plates.
The invention is embodied in a torque transmitting device, particularly in a clutch plate for use in the friction clutch of an automotive vehicle. The torque transmitting device comprises a rotary output assembly (e.g., a hub having a coaxial radially outwardly extending annular flange) and a rotary input assembly which is coaxial with and serves to transmit torque to the output assembly. The input and output assemblies are rotatable relative to each other through a predetermined angle, and one of these assemblies includes a substantially disc-shaped portion (such as the aforementioned flange of the hub forming part of the output assembly). The torque transmitting device further comprises a set of coil springs or another suitable energy storing means interposed between and arranged to yieldably oppose rotation of the input and output assemblies relative to one another, and a third assembly which constitutes torsional vibration damping means installed in the path of transmission of torque between the input and output assemblies and including a friction generating first component at one side and an axially stressed resilient second component at the other side of the disc-shaped portion. The second component reacts against the other of the input and output assemblies and bears directly against the first component. At least one of the two components extends through the disc-shaped portion of the one assembly, and the two components cooperate to frictionally oppose relative rotation of the input and output assemblies at least through a portion of the aforementioned angle.
The input assembly can comprise two additional disc-shaped portions one of which preferably constitutes an annular carrier of friction linings (if the improved device is a clutch plate) and the other of which can constitute an annular cheek which is rigid with and spaced apart from the carrier so that the disc-shaped portion of the one assembly can find room between the two additional disc-shaped portions.
The second component can constitute an annular dished spring having an outer portion (as considered in the radial direction of the output assembly) which bears directly against the first component and an inner portion which reacts against one of the additional disc-shaped portions, e.g., against the carrier of the input assembly.
The improved torque transmitting device can further comprise second torsional vibration damping means which is interposed between the input and output assemblies and includes an axially stressed resilient element and a friction pad which is adjacent to and is biased by the resilient element. The resilient element reacts against one of the input and output assemblies (e.g., against the carrier of the input assembly) and the friction pad bears against the other of the input and output assemblies (e.g., against the flange of the hub forming part of the output assembly). The second component preferably surrounds the resilient element and/or the friction pad of the second damping means.
The disc-shaped portion of the one assembly can be provided with apertures through which portions (such as axially disposed arms) of the one component extend. For example, the arms can be provided on the first component to be engaged by the radially outermost portion of the second component. The arrangement is preferably such that the portions or arms of the one component extend through the apertures of the disc-shaped portion of the one assembly with limited freedom of angular movement between such disc-shaped portion and the one component.
The first component of the third assembly can be disposed between the flange of the hub forming part of the output assembly and the annular carrier or cheek of the input assembly. The second component of the third assembly is then disposed between the flange of the hub and the annular cheek or carrier of the input assembly.
A friction pad can be interposed between the second component and the other assembly. For example, and if the second component is disposed between the carrier of friction linings and the flange, the friction pad is installed between such carrier and the radially innermost portion of the second component. Another friction pad can be interposed between the first component and the flange of the hub. If desired, the first component can be flanked by two friction pads one of which bears against the flange and the other of which bears against the carrier or cheek of the input assembly, depending upon whether the first component is installed between the flange and the carrier or between the flange and the cheek.
The novel features which are considered as characteristic of the invention are set forth in particular in the appended claims. The improved torque transmitting device itself, however, both as to its construction and its mode of operation, together with additional features and advantages thereof, will be best understood upon perusal of the following detailed description of certain specific embodiments with reference to the accompanying drawing.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a fragmentary elevational view of a torque transmitting device constituting a clutch plate which embodies one form of the invention and wherein the friction generating component of the first or outer torsional vibration damping unit extends through the flange on the hub;
FIG. 2 is a substantially axial sectional view of the clutch plate as seen in the direction of arrows from the line II--II of FIG. 1; and
FIG. 3 is a fragmentary axial sectional view of a modified clutch plate wherein the hub is integral with the flange and the arms are provided on the resilient component of the outer torsional vibration damping unit.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The torque transmitting device which is shown in FIGS. 1 and 2 constitutes a clutch plate and comprises an output assembly including a hub 1 and a disc-shaped portion or flange 3 which is coaxial with and is non-rotatably secured to the hub. The latter can transmit torque to a driven member 2, such as the input shaft of the change-speed transmission in an automotive vehicle. The hub 1 is provided with internal splines for the axially parallel peripheral teeth or ribs of the shaft 2.
The flange 3 is formed with an annulus of windows 4, 5, 6, 7, 8 and 9 for energy storing means in the form of coil springs 19, 20, 21, 22, 23 and 24, respectively.
The hub 1 is surrounded by and is rotatable within limits relative to a disc-shaped annular portion or carrier 10 for two friction linings 11 which are disposed at the opposite sides thereof and flank its radially outermost portion. The carrier 10 forms part of an input assembly which serves to transmit torque to the flange 3 via coil springs 19 to 24 and which further includes a second disc-shaped portion or cheek 12. The latter is also rotatable relative to the hub 1 and is rigidly connected with the carrier 10 by a set of rivets 12a, e.g., by three rivets which alternate with pairs of energy storing coil springs. The rivets 12a not only rigidly couple the carrier 10 to the cheek 12 but also constitute distancing elements which maintain the disc-shaped portions 10 and 12 at a fixed distance from one another, as considered in the axial direction of the hub 1. The marginal portion of the flange 3 is formed with three angularly spaced recesses or notches 3a each of which receives, with substantial play (as considered in the circumferential direction of the hub 1), the intermediate portion of the respective rivet 12a.
The left-hand friction lining 11 of FIG. 2 can be moved into contact with the flywheel on the crankshaft of the internal combustion engine in an automotive vehicle, and the right-hand friction lining 11 can be engaged and urged in a direction to the left, as viewed in FIG. 2, by a pressure plate forming part of a friction clutch which can transmit torque from the crankshaft to the input shaft 2 of the transmission.
The carrier 10 is formed with six windows 13 to 18 each of which registers with a similar window of the cheek 12. FIG. 2 merely shows one (13') of the six windows in the cheek 12. Each window (13-18) of the carrier 10 and the corresponding window of the cheek 12 registers with one of the windows 4 to 9 in the flange 3. By way of example, and as shown in the upper part of FIG. 2, the window 13 of the carrier 10 registers with the window 4 of the flange 3 as well as with the window 13' of the cheek 12. These three windows receive portions of the energy storing coil spring 19. The windows 14, 5 and the corresponding window of the cheek 12 receive portions of the coil spring 20; the windows 15, 6 and the corresponding window of the cheek 12 receive portions of the coil spring 21; the windows 16, 7 and the corresponding window of the cheek 12 receive portions of the coil spring 22; the windows 17, 8 and the corresponding window of the cheek 12 receive portions of the coil spring 23; and the windows 18, 9 and the corresponding window of the cheek 12 receive portions of the coil spring 24.
The function of the coil springs 19 to 24 is as follows: The arrow 25 denotes in FIG. 1 the direction in which the input assembly (including the carrier 10 and the cheek 12) rotates when one of the linings 11 transmits torque from the engine to the carrier 10. The coil springs 19 to 24 then transmit torque to the output assembly including the hub 1 and the flange 3 so that the shaft 2 is driven in the same direction. The arrow 26 denotes the direction in which the shaft 2 can drive the input assembly 10, 12 when the vehicle is coasting. When the flange 3 begins to rotate relative to the input assembly 10, 12 in the direction of arrow 25, the coil spring 23 becomes effective ahead of the other coil springs because the edge faces 27 and 28 respectively bounding portions of the windows 8 and 17 are in register with one another. The dimensions of the windows 8, 17 (and of the corresponding window in the cheek 12), as considered in the circumferential direction of the flange 3, are identical; therefore, the coil spring 23 performs the additional function of automatically returning the flange 3 to a predetermined starting or zero angular position with reference to the input assembly 10, 12 as soon as the transmission of torque between the two assemblies is terminated or interrupted.
When the flange 3 completes a certain angular movement relative to the carrier 10 and cheek 12 (see the angle alpha 1 in FIG. 1), the spring 20 begins to store energy in addition to the spring 23. This is due to the fact that the edge face 29 in the window 5 of the flange 3 reaches and engages the adjacent end convolution of the spring 23 because the flange 3 continues to turn in the direction of arrow 25. As the flange 3 continues to turn in the direction of arrow 25, the remaining four coil springs (namely, the springs 19, 21, 22 and 24) begin to store energy one after the other in a predetermined sequence which is a function of the dimensions of the respective windows. It is clear, however, that two or more coil springs can become effective simultaneously. For example, the spring 23 can begin to store energy simultaneously with the spring 22, 24, 21, 20 or 19, and so forth.
The situation is analogous when the flange 3 begins to turn in the direction of arrow 26. It is not necessary that the angles through which the flange 3 must turn in the direction of arrow 26, in order to cause selected coil springs to store energy, be identical with those when the flange 3 turns in the direction of arrow 25. The rivets 12a and the radially extending edge faces 30, 31 bounding the corresponding notches 3a of the flange 3 determine the maximum extent of relative angular movement between the flange and the input assembly 10, 12 in the direction of arrow 25 or 26.
When the carrier 10 and the member 12 turn through an angle alpha 2 (note FIG. 1), the rivets 12a reach the radially extending edge faces 30 of the flange 3 (it is assumed that the parts 10 and 12 turn in the direction of arrow 25). If the parts 10 and 12 turn in the direction of arrow 26, the rivets 12a engage the edge faces 31 when the input assembly 10, 12 completes an angular movement through the same angle (alpha 2 ), it being assumed that the rivets 12a are normally disposed centrally of the respective notches 3a.
The outer torsional vibration damping unit which serves to generate friction in order to damp vibrations in the circumferential direction of the flange 3 comprises an annular disc-shaped friction generating component 32 which surrounds the hub 1 and is disposed between the right-hand side of the flange 3 (as viewed in FIG. 2) and the cheek 12 of the input assembly. The radially inner portion of the component 32 is flanked by two ring-shaped friction pads 33 and 34; the pad 33 is disposed between the flange 3 and the component 32, and the pad 34 is installed between the component 32 and the cheek 12. The outer damping unit further comprises a second annular component 38 which is a dished spring and is installed between the carrier 10 and the flange 3 in such a way that the radially innermost portion of the spring 38 reacts against the inner side of the carrier 10 while the radially outermost portion of this spring bears against axially extending portions or fingers 37 of the component 32. The fingers 37 extend through apertures in the flange 3; such apertures can constitute inward extensions of the respective windows (4 to 9) in the flange 3.
FIG. 1 shows that the arms 37 of the component 32 extend through the radially innermost portions (apertures) of the corresponding windows 4 to 9 in the flange 3. The width of the apertures for the arms 37 of the component 32 is selected in such a way that the flange 3 can turn with reference to the arms 37 through an angle alpha 3 in one direction (arrow 25) and through an angle alpha 4 in the opposite direction (arrow 26).
The radially outermost portion of the component or spring 38 can be provided with radially outwardly extending arms which alternate with the arms 37 of the component 32. The purpose of the component 38 is to bias the component 32 against the friction pad 34, i.e., toward the inner side of the cheek 12 of the input assembly.
The inner torsional vibration damping unit of the clutch plate comprises a resilient element here shown as an annular undulate spring 36, and a ring-shaped friction pad 35. The spring 36 bears against the inner side of the carrier 10 radially inwardly of the component 38 and biases the friction pad 35 against the adjacent side of the flange 3 in immediate or close proximity of the peripheral surface of the hub 1. It will be noted that the axially stressed spring 36 urges the cheek 12 of the input assembly 10, 12 toward the respective side of the flange 3, i.e., against the friction pad 34 which, in turn, urges the component 32 against the friction pad 33 so that the latter bears against the flange 3.
It will be noted that the friction pad 34 is biased (a) by the component 38 (by way of the component 32) to bear against the inner side of the cheek 12, and (b) by the resilient element 36 (via carrier 10, rivets 12a and cheek 12) to bear against the corresponding side of the component 32. The friction pads 33 and 35 are stressed solely by the resilient element 36. The component 38 and the friction pad 34 are designed in such a way that the frictional moment which is generated thereby exceeds the frictional moment which is generated by the friction pad 33 and resilient element 36.
When the flange 3 is rotated in the direction of the arrow 25 or in the direction of arrow 26, the friction pads 33 and 35 generate friction ahead of the friction pad 34. Such so-called idling friction is effective while the flange 3 turns through the aforementioned angle alpha 3 or alpha 4 . This is due to the fact that, in view of the aforementioned greater frictional moment during such stage of angular movement of the flange 3 relative to the carrier 10 and the cheek 12 or vice versa, the component 32 does not change its angular position relative to the carrier 10 and cheek 12.
When the flange 3 completes its angular movement through the angle alpha 3 or alpha 4 , the edge faces 39 or 40 in the windows 4 to 9 of the flange 3 engage the edge faces 41 or 42 of the arms 37 on the component 32 of the outer damping unit so that the component 32 begins to share the angular movement of the flange. This entails that the component 32 turns relative to the carrier 10 and the cheek 12 until the rivets 12a reach the edge faces 30 or 31 in the corresponding notches 3a of the flange 3. During such stage of angular movement of the flange 3 relative to the assembly 10, 12, a relatively high (i.e., pronounced) frictional moment is generated between the component 32 or the friction pad 34 on the one hand and the cheek 12 on the other hand. Additional friction develops between the component 38 and the carrier 10. The friction pad 35 is effective during each and every stage of relative angular movement between the flange 3 and the input assembly 10, 12. On the other hand, the friction pad 33 ceases to generate friction when the component 32 begins to turn with the flange 3, i.e., the friction pad 33 is effective only as long as the component 32 is free to turn relative to the flange 3 and/or vice versa.
In order to ensure that the component 32 of the outer damping unit assumes a predetermined angular position relative to the flange 3 when the damping unit including the components 32 and 38 is inactive, the component 32 is formed with one or more bifurcated projections, e.g., with two projections, which extend radially outwardly. The spacing between the two prongs 43, 44 of each of these projections (as well as the angular spacing of the two projections, as considered in the circumferential direction of the hub 1) is selected in such a way that the radially extending edge faces 45, 46 of the prongs 43, 44 bounding the cutouts between the prongs of the respective projections register with the edge faces 47 and 48 respectively bounding portions of the windows 13 and 16 to engage the corresponding end convolutions of the coil springs 19 and 22. This ensures that, when the component 32 assumes its starting or neutral position, the edge faces 45 and 46 of its prongs 43, 44 respectively register with the edge faces 47 and 48 in the windows 13 and 16.
FIG. 3 illustrates a portion of a modified clutch plate which is provided with a different outer damping unit. Furthermore, the hub 1' is integral with the flange 3'. The friction generating component 132 of the outer damping unit does not have any axially extending arms and is flanked by the friction pads 33, 34 the same as in the embodiment of FIGS. 1 and 2. The resilient component 49 of the outer damping unit has axially extending portions or arms 50 which extend through apertures in the flange 3' to bear directly against the component 132. The rightmost portions of the arms 50 (as viewed in FIG. 3) are preferably non-rotatably secured (e.g., soldered) to the component 132 so that the components 132, 49 can rotate as a unit. The radially innermost portion of the component 49 (which constitutes a dished spring) reacts against the inner side of the carrier 10. The latter is rigidly connected with the cheek 12, e.g., in a manner as described in connection with and as shown in FIGS. 1 and 2. As shown in FIG. 3 by broken lines, a further friction pad 51 can be inserted between the component 49 and the carrier 10. The same holds true for the embodiment of FIGS. 1 and 2, i.e., a further friction pad can be inserted between the component 38 and the carrier 10.
The construction of the inner damping unit (including an undulate resilient element 36 and a friction pad 35) is or can be the same as that of the inner damping unit in the embodiment of FIGS. 1 and 2.
An important advantage of the improved torque transmitting device is that its outer damping unit consists of a small number of very simple, inexpensive and compact components. This renders it possible to install these components in existing clutch plates and to thus greatly enhance the torsional vibration damping characteristics of such clutch plates. The components of the outer damping unit contribute little (if anything) to the dimensions of the improved device, as considered in the axial direction of the input and output assemblies. As can be seen in FIG. 2, the dimensions of the outer damping unit (as considered in the radial direction of the input and output assemblies) can be readily selected in such a way that the components of this damping unit need not extend radially outwardly beyond the coil springs 19 to 24. In fact, and as can also be seen in the drawing, the radial dimensions of the components 32 and 38 or 49 and 132 can be selected in such a way that these components are disposed entirely within the confines of the annulus of coil springs 19 to 24. This is desirable and advantageous because such components 32 and 38 or 49 and 132 add little, if anything, to the bulk and inertia of the torque transmitting device.
The inner damping unit can be designed to oppose rotation of the input and output assemblies relative to each other during that stage or those stages of relative rotation when the outer damping unit is ineffective, i.e., while the apertures of the flange 3 or 3' are free to rotate relative to the arms 37 or 50. In the illustrated embodiments, the inner damping unit opposes rotation of the flange 3 or 3' relative to the input assembly and/or vice versa during each and every stage of rotation of the input and output assemblies relative to one another. The feature that the components 32, 38 or 132, 49 of the outer damping unit are in direct engagement with one another also contributes to compactness of the torque transmitting device, as considered in the axial direction of the input and output assemblies, as well as to a reduction of the overall weight of such device.
The provision of friction pad 34 between the component 32 or 132 of the outer damping unit and the adjacent disc-shaped portion (12) of the input assembly renders it possible to regulate the damping action of the outer damping unit with a high degree of predictability i.e., so that the damping action is best suited for the particular application of the torque transmitting device. The same holds true for the friction pad 51 between the second component (49) of the outer damping unit and the adjacent discshaped portion (10) of the input assembly, as well as for the friction pad 33 between the component 32 or 132 and the flange 3 or 3', i.e., these friction pads also contribute to predictability of the damping action.
It has been found that the improved damping units eliminate rattling and/or other noise when the torque transmitting device is in use. This is due to the fact that the axially stressed parts 38, 36 or 49, 36 prevent any uncontrolled movements of various parts in the axial direction of the device. Furthermore, the selected damping action remains unchanged for practically unlimited periods of time.
Without further analysis, the foregoing will so fully reveal the gist of the present invention that others can, by applying current knowledge, readily adapt it for various applications without omitting features that, from the standpoint of prior art, fairly constitute essential characteristics of the generic and specific aspects of my contribution to the art and, therefore, such adaptations should and are intended to be comprehended within the meaning and range of equivalence of the appended claims.
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A clutch plate whose output assembly is constituted by a rotary hub and a radial flange, and whose input assembly has an annular carrier of friction linings and an annular cheek rigid with and spaced apart from the carrier so that the flange finds room between the cheek and the carrier. The flange can rotate relative to the carrier and cheek against the opposition of coil springs in registering windows of the flange, carrier and cheek. A first torsional vibration damping unit opposes at least a certain part of angular movement between the flange and the input assembly and has friction generating disc disposed at one side as well as an annular dished spring disposed at the other side of the flange and bearing directly against the friction generating disc. The flange has apertures receiving with play axially disposed arms of the dished spring and/or friction generating disc. Friction pads are inserted between the dished spring and the carrier or cheek as well as at both sides of the friction generating disc. A second torsional vibration damping unit is installed between the flange and the carrier or cheek and is effective during each stage of angular movement of the flange relative to the input assembly or vice versa.
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RELATED APPLICATIONS
The present application claims the benefit of provisional patent application “Voice Actuation with Context Learning for Intelligent Machine Control”, Ser. No. 60/186,469, filed Mar. 2, 2000.
BACKGROUND OF THE INVENTION
1. Field of Invention
The present invention relates generally to the field of machine control. More specifically, the present invention is related to a system and method for voice actuation, with contextual learning, for intelligent machine control.
2. Discussion of Prior Art
Much prior art work has been devoted to developing graphical user interface (GUI) tools for machine control. FIG. 1 illustrates a prior art scenario wherein users utilize a computer 102 , with display capabilities, to monitor a programmable device 104 . Computer 102 communicates with the device 104 via a communication link 106 . In most prior art systems, a GUI is displayed on computer 102 via which users control the functionality of programmable device 104 . Users are able to manipulate the GUI by entering commands (via a keyboard) or by clicking on an appropriate area of the GUI (using a mouse).
One of the problems associated with such a setup is that in most industrial programmable devices, a process has to be repeated more than once and it becomes tiring on the part of the operator to repeat a sequence of commands. In addition to being tiring, in the case of testing, some tests require the operator to handle or manipulate the sample in some fashion during the test. For example, some types of peel test require the operator to make slices in the sample during testing. Therefore, it would be beneficial to have an easy-to-use interactive voice actuated control system with an enhanced GUI interface for intelligent machine control.
The following references describe prior art in the filed of voice activated control of devices, but none provide for voice activated control of a testing machine using a statistical prediction algorithm. Furthermore, none of the prior art provide for reliable machine operation via a system receiving voice inputs and providing intelligent help for operation of the machine. Additionally, none of the prior art described below provides for a filter for validating commands before executing them in a machine. The prior art described below is similar to the system described in FIG. 1 .
U.S. Pat. No. 5,748,843 discloses an apparatus wherein an operator controls specific operations of apparel manufacture equipment through verbal commands recognized by the equipment as distinct from other sounds in the environment and of the equipment. The speech recognition computer also preferably maintains the capability to recognize words or commands.
U.S. Pat. No. 4,462,080 discusses an apparatus for controlling a computer-controlled system, such as a computer numerically controlled (CNC) machine tool, in accordance with voice commands spoken by a human operator.
U.S. Pat. No. 4,896,357 describes an industrial playback robot, which comprises speech discriminating means for discriminating the kind of teaching datum from a speech input, and the teaching datum is stored into a memory means as a teaching datum. Additionally, U.S. Pat. No. 3,946,157 provides for an improved speech recognition device for controlling a machine.
It should however be noted that none of the prior art references mentioned above provide for encompassing voice and context in a testing machine. Furthermore, none of the references mentioned above provide for a statistical algorithm that predicts most likely actions of users. Whatever the precise merits, features and advantages of the above cited references, none of them achieve or fulfills the purposes of the present invention.
SUMMARY OF THE INVENTION
The present invention provides for a voice actuated control system with contextual learning for a testing device (such as an industrial tensile testing machine). An adaptive command predictor adds robustness to the voice command interpreter by evaluating each candidate command in the context of the operator's usage pattern. The command predictor is also integrated with a GUI interface panel such that an intelligent user assist function is naturally created. The command predictor is based on a statistical Markov model that adapts to the machine operator's usage patterns. This context-learning algorithm is most effective when machine operation is nonrandom. In this way, next command recommendations based on probability distributions are most meaningful. This technology is useful in the industrial setting to reduce operator fatigue, allow freedom of movement, assist the physically challenged, and improve productivity.
Furthermore, the present invention provides for intelligent help based on adaptive context learning of operator commands. The embedded discrete Markov model of the users' commands provides for this intelligent system that essentially determines the user's degree of expertise when using the machine and helps to direct proper operations.
In an extended embodiment, the system of the present invention is used in smart automobiles to learn driver's operating patterns and adjust the vehicle handling and performance based on this self-learned information.
Furthermore, such a system can be used in industrial environments for voice actuation with adaptive context learning to reduce the probability of false actuation.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates a prior art scenario wherein users utilize a computer with display capabilities to monitor a programmable device.
FIG. 2 illustrates a materials testing system wherein crosshead of the mechanical load frame is moved up and down in order to stretch or compress the specimen under test.
FIG. 3 is a block diagram of the system architecture of the present invention.
FIG. 4 illustrates the method for training the speech recognition system until a satisfactory level of command recognition is achieved.
FIGS. 5 a and 5 b collectively illustrate how transition between different states affects the probability of transition of the path between the states.
FIG. 6 shows a portion of the tester's state diagram.
FIG. 7 illustrates the behavior of the implemented system during a test.
FIG. 8 is an example of a data report output from the tensile test system after successfully performing a tensile test on a wire specimen.
FIG. 9 illustrates the present invention's method for voice actuation and context learning for intelligent machine control.
FIG. 10 gives a further breakdown of the validation step described in the method of FIG. 9 .
FIG. 11 illustrates the various embodiments the system described in FIG. 3 can be used with.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
While this invention is illustrated and described in a preferred embodiment, the invention may be produced in many different configurations, forms and materials. There is depicted in the drawings, and will herein be described in detail, a preferred embodiment of the invention, with the understanding that the present disclosure is to be considered as an exemplification of the principles of the invention and the associated functional specifications for its construction and is not intended to limit the invention to the embodiment illustrated. Those skilled in the art will envision many other possible variations within the scope of the present invention.
The present invention provides a system and method for intelligent help based on adaptive contextual learning of operator commands via an embedded statistical Markov model. In the example to follow, an industrial tensile testing machine is used to illustrate various embodiments of the system. But, one skilled in the art can implement the system of the present invention in other equivalent testing machines without departing from the scope of the present invention. Described below is such a tensile testing machine and its various functional components.
FIG. 2 illustrates a materials testing system 200 wherein crosshead 202 of the mechanical load frame 203 is moved up and down in order to stretch or compress the specimen 204 under test. Specimen 204 is held by means of clamps 206 . Load cell 208 provides force data and an integral quadrature encoder (not shown) provides position information. In tensile mode, the specimen is stretched to the breaking point under computer control while real time data is acquired. The present invention provides for a voice actuated control system with context learning for such a testing device. Given below is a description of the system architecture.
System Architecture
FIG. 3 is a block diagram of the system architecture 300 of the present invention. An operator uses voice input device 302 (such as a wireless headset) to issue voice commands 304 to the system. Manual input such as with a keyboard or mouse is also within the scope of the present invention. It should be noted that prior to tester operation, an individual user trains the speech recognition system (as described below), via user vocabulary training 306 and voice command interpreter 308 , until satisfactory command recognition is achieved.
FIG. 4 illustrates method 400 for training the speech recognition system until a satisfactory level of command recognition is achieved. The procedure begins with an authentication procedure (step 402 ) wherein a user is authenticated via a username and password. Upon validation, users define one or more keywords representative of one or more voice-enabled commands (step 404 ). Next, the first of the keywords is marked for processing (step 406 ), and voice inputs for the marked keyword are received via the voice input device (step 408 ). Furthermore, the received voice input is stored in a storage device that is operatively connected to the system. Next, the system checks (step 410 ) to see if a satisfactory level of speech recognition has been achieved based on the voice inputs for the marked keyword. If a satisfactory level has not been achieved (step 412 ), then the system requests more voice inputs for the marked keyword. On the other hand, if a satisfactory level has been reached ( 414 ), the system marks the next keyword for processing (step 420 ) and repeats steps 408 through 416 until all necessary voice inputs for all keywords have been obtained (step 418 ).
As stated above, the command vocabulary consists of one or more multiword commands. During tester operation, the voice command interpreter sends recognized commands to the command processor. Going back to the system diagram in FIG. 3 , command processor 310 does not accept the commands until the user command predictor 312 validates them. In this way, the chance of unintended machine actions due to improper speech recognition is reduced. This can be especially important in an industrial environment where significant background noise may exist.
User command predictor 312 is responsible for learning the context 311 in which a given command is being issued, both from the voice system and from the keyboard and mouse 315 . This is accomplished using a discrete-time Markov chain to estimate the statistical likelihood of each candidate next command. In the event that a very unlikely command is presented to command processor 310 , the voice reply system asks the user to repeat the command. Once accepted, valid commands are used to update the Markov chain probabilities, resulting in on-line contextual learning 311 .
The output of user command predictor 312 is also fed directly 316 to GUI interface panel 314 to provide intelligent help. The Markov command predictor is used quite naturally to recommend the next most probable action thereby providing a dynamic assist to the machine operator.
Voice Command Processing
Voice processing software used in conjunction with the present invention handles the low level voice processing tasks, including user vocabulary training and spoken command recognition or rejection. An example of software that can be used in conjunction with this invention is the Dragon Dictate Software® from Dragon Systems, Inc®.
Upon first time login on the tester system, a new user trains the speech recognition system by repeating keywords that are then associated with each of the one or more voice-enabled commands. The keywords are user defined, and can, therefore, be of any language or dialect. The tester system maintains a separate vocabulary file for each registered user. It should be noted that although the system is able to maintain a separate vocabulary file for each registered user, it also allows each user to have several of his own vocabulary files that he can choose from. This allows for training of the system under different noise background conditions that may exist in an industrial environment as other machines are being used or surrounding operations are being conducted.
Typical training requires repeating a keyword between three and eight times. The training algorithm signals the operator when a reliable level of voice recognition has been achieved for each keyword. Once trained, recognized speech commands are communicated to the command processor as candidate actions to be taken.
Command Prediction
A typical application of industrial material testers is repeated by testing of a particular batch or sample set of like product. The operator repeats the same or a similar sequence of operations for each sample. User command predictor 312 ( FIG. 3 ) is designed to automatically learn and recognize these operator usage patterns. Moreover, the learning is continuous, so that the system actually adapts to any pattern variations.
A discrete-time Markov chain is used to develop a statistical model of the operator's usage pattern. Operation of the tester is partitioned into discrete states. Commands from the keyboard, button clicks from the mouse, and voice commands can all initiate a state transition. Associated with each state transition path is a probability value that indicates the likelihood of its activation. With each valid command, a state transition occurs, and the probabilities associated with each transition are then updated. As the operator continues to use the tester, state transition probabilities evolve. They indicate which is the next most likely command that will be received, given the present state of the machine. This information can then be used for command prediction. The user is prompted to repeat commands below a preset minimum likelihood threshold. Only verified low-likelihood commands are accepted as valid and processed.
FIG. 5 a and 5 b collectively illustrate how transition between different states affect the probability of transition of the path between the states. If two states exist: State A 502 and state B 504 , there is also a probability value 506 , p AB (t)=x, associated with the path between the two states, indicating the likelihood of transition. In the event the user provides a valid command 508 , and the command causes a transition from State A 502 to State B 504 , this probability value is updated 506 (p AB (t)=y) indicating that the likelihood of transition has increased. Thus, the transition probabilities are adaptively modified and therefore are helpful later in predicting erroneous command inputs on the part of the user.
FIG. 6 shows a portion of the tester's state diagram 600 . State 1 602 is active when the tester is initializing the crosshead to its zero position location. In this case, many of the button commands do not change the state. But, it should be noted that stop transition 604 will move the system to other states 606 . Furthermore, it is seen that when the positioning of the crosshead has been completed 607 , the system moves to state 2 608 .
Table 1 shows a typical set of state transition probabilities associated with 13 system commands (column 1) when the system is in the state: Initializing Crosshead (column 2), and when it is in the state: Test Finished (column 3).
TABLE 1
State transition probabilities for two states:
Initializing crosshead and test finished.
State: Initializing Crosshead
State: Test Finished
Command
Probability (%)
Probability (%)
Start
0.98
10.64
Pause
0.98
0.82
Tare
0.98
0.82
Peak
0.98
0.82
Stop
88.24
0.82
Save
0.98
33.61
Gage
0.98
0.82
Mark
0.98
0.82
Up
0.98
11.48
Down
0.98
9.84
Home
0.98
10.68
Zero
0.98
9.02
Initial
0.98
9.84
It is seen from the table that when the crosshead is initializing, the most likely command is to stop it, since the probability of transition associated with this command is 88.24%. On the other hand, when a test is finished, the most likely command is to save the data, since this command has the highest probability (33.61%) of causing a transition in this state.
FIG. 7 illustrates a GUI 700 showing the behavior of the implemented system during a test. There are two panels shown. The leftmost panel is the GUI interface panel 702 . The rightmost panel 704 is used to indicate the present Markov state of the test system, and the probabilities associated with each next command. This panel consists of a list of commands 706 and a list of probabilities 708 associated with each of the commands in list 706 . Each command can be activated either by a mouse click on the GUI panel, the keyboard, or by voice commands. In a further embodiment, the command with highest probability of transition is displayed with a visual modification to indicate that it is the next likely command. For example, it should be noted that ‘Mark’ button 710 is italicized on the GUI panel because it is the next most likely command, with a probability of 30.50%. This command is used to place reference marks in the data set during a test. Therefore, the command predictor assists the operator by suggesting the next most likely command.
FIG. 8 is an example of a data report output from the tensile testing system after successfully performing a tensile test on a wire specimen. It should be noted that the marks in the data labeled ‘1’, 2’, and ‘3’ were placed in the data via voice command activating the ‘Mark’ button 710 ( FIG. 7 ) during the test. Furthermore, in the course of using speech recognition to place demarcations in the data set shown in FIG. 8 , there is some delay between the time the voice command is recognized and the time at which the data mark would appear. The present system automatically tunes itself to compensate for that delay and properly locate the data mark such that it is at the correct point in the data set (as if instantaneous recognition has been achieved).
FIG. 9 illustrates method 900 associated with voice actuation and context learning for intelligent machine control. The method begins by receiving one or more voice inputs (step 902 ). Next, one or more keywords are identified from the received one or more voice inputs (step 904 ). Then, the identified keywords are matched with corresponding one or more commands (step 906 ). Lastly, the matched one or more commands are validated via a statistical model (step 908 ), and executed in the tester device (step 910 ).
FIG. 10 gives a further breakdown of the method 1000 associated with the validation step (step 908 FIG. 9 ). In this statistical model of validation, the operation of a testing device is partitioned into one or more discrete states (step 1002 ). Next, a current state is identified from said one or more discrete states (step 1004 ). Then, at least one command is identified from received voice inputs that cause a transition from the current state to another discrete state (step 1006 ). Next, a probability is identified for such a transition (step 1008 ). A check is then performed to see if the identified probability is greater than a certain threshold ‘t’ (step 1010 ). In the event that the probability is greater that the threshold ‘t’ (step 1021 ), the transition probability is updated (step 1020 ) for this transition step, and the identified command is validated (step 1022 ). On the other hand, if the threshold test is not met (step 1012 ), another check is performed to see if at least two voice inputs for the identified command have been received (step 1014 ), and if so 1015 , steps 1020 and 1022 are repeated. In the instance only one voice input has been received for the identified command 1016 , the system requests for at least one more voice input (step 1018 ) and steps 902 to 910 ( FIG. 9 ) are repeated.
FIG. 11 illustrates the various embodiments the system described in FIG. 3 can be used with. For example, both local users 1102 and remote users 1104 are able to access and implement the system. Furthermore, intelligent vehicles 1106 can be devised to learn a driver's operating pattern and can further be used to adjust the vehicle handling and performance based on the self-learned information. Physically challenged people 1108 can benefit from the system of the present invention because of the easy-to-use voice activated interface. Lastly, technicians with little or no experience 1110 or users utilizing the system as a training tool 1112 benefit from the intelligent help system. Therefore, when transition updates are deactivated (but context help is on), the present system can be utilized as a training tool. It could also be used as a skill evaluation tool by keeping track of the number of incorrect commands that are detected.
Furthermore, the context learning part of the system is not only used for intelligent help, but in combination with the voice response is useful in noisy industrial environments to reduce the chance of accepting misinterpreted commands. In this way, the machine operation with voice actuation becomes more reliable. Essentially, the context learning works as an additional filter before the machine accepts commands.
This added reliability described above makes the system of the present invention useful for voice actuation in noisy environments. One such application for a system with voice actuation in combination with context learning is the cockpit of aircraft. In particular, fighter pilots need accurate speech recognition under noisy conditions.
In yet another embodiment, the intelligent assist function via context sensitive command interpretation is activated but the learning part is turned off. This is useful when non-expert users are on the system and it is not desirable to allow that user to influence modification of the Markov transition probabilities. For example, an expert user would activate the context learning system and develop the transition probabilities that would be correct for a skilled user. Then the transition probability updating can be inhibited. Now less skilled users would be able to use the intelligent help, let the system recommend the next most likely command, etc., but they could not corrupt the established transition probabilities. This would be most useful for training unskilled operators or in a very noisy environment where transition updates would not be desirable.
Therefore, the system and method of the present invention provide for a voice actuated control system with context learning for testing machines such as the tensile testing machine. Furthermore, it features an adaptive command predictor that adds robustness to the voice command interpreter by evaluating each candidate command in the context of the operator's usage pattern. The command predictor is also integrated with a GUI interface panel such that an intelligent user assist function is naturally created. The command predictor is based on a statistical Markov model that adapts to the machine operator's usage patterns. Next, command recommendations are based on probability distributions that are developed online during machine operation. This technology is useful in the industrial setting to reduce operator fatigue, allow freedom of movement, assist the physically challenged, and improve productivity.
Conclusion
A system and method has been shown in the above embodiments for the effective implementation of a voice actuation with contextual learning for intelligent machine control. While various preferred embodiments have 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, as defined in the appended claims. For example, the present invention should not be limited by software/program, computing environment, or specific computing hardware. In addition, the contextual learning function, in one mode, can be selectively disabled while continuing voice actuated control to provide a voice only interface to operate the specific parts of the tensile testing machine.
The above enhancements for icons and its described functional elements are implemented in various computing environments. For example, the present invention may be implemented on a conventional IBM PC or equivalent, multi-nodal system (e.g. LAN) or networking system (e.g. Internet, WWW, wireless web). All programming, GUIs, display panels, screenshots, and data related thereto are stored in computer memory, static or dynamic, and may be retrieved by the user in any of: conventional computer storage, display (i.e. CRT) and/or hardcopy (i.e. printed) formats. The programming of the present invention may be implemented by one of skill in the art of DSP and intelligent control programming.
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An interactive voice actuated control system for a testing machine such as a tensile testing machine is described. Voice commands are passed through a user-command predictor and integrated with a graphical user interface control panel to allow hands-free operation. The user-command predictor learns operator command patterns on-line and predicts the most likely next action. It assists less experienced operators by recommending the next command, and it adds robustness to the voice command interpreter by verbally asking the operator to repeat unlikely commanded actions. The voice actuated control system applies to industrial machines whose normal operation is characterized by a nonrandom series of commands.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a predistortion compensation apparatus, performing distortion compensation processing in advance on a transmission signal before amplification.
2. Description of the Related Art
In recent years, high-efficient digital transmission has widely been adopted in radio communication. When multilevel phase modulation is adopted in the radio communication, it is an important technique to suppress nonlinear distortion by linearizing the amplification characteristic of a power amplifier on the transmission side, so as to reduce adjacent channel leak power.
Also, when it is intended to improve power efficiency using an amplifier having a degraded linearity, a technique for compensating nonlinear distortion caused by the degraded linearity is essentially required.
FIG. 1 shows an exemplary block diagram of transmission equipment in the conventional radio equipment. A transmission signal generator 1 outputs a digital serial data sequence. A serial-to-parallel (S/P) converter 2 then converts the digital data sequence into two series, in-phase component signals (I-signals) and quadrature component signals (Q-signals), by alternately distributing the digital data sequence on a bit-by-bit basis.
A digital-to-analog (D/A) converter 3 converts the I-signal and the Q-signal into an analog baseband signal, respectively, so as to input into a quadrature modulator 4 . This quadrature modulator 4 multiplies the input I-signal and Q-signal (a baseband transmission signal) by a reference carrier wave 8 , and a carrier wave phase-shifted by 90° from the reference carrier wave 8 , and adds the multiplied results, thus performing orthogonal transformation, and outputs the above signal.
A frequency converter 5 mixes the quadrature modulation signal with a local oscillation signal, and converts the mixed signal into a radio frequency. A transmission power amplifier 6 performs power amplification of the radio frequency signal being output from frequency converter 5 , and radiates to the air from an antenna 7 .
Here, in the mobile communication using W-CDMA, etc., transmission equipment power is substantially large, as much as 10 mW to several tens of mW, and the input/output characteristic (having a distortion function f(p)) of transmission power amplifier 6 shows non-linearity, as shown by the dotted line in FIG. 2 . This nonlinear characteristic produces a non-linear distortion. As shown by the solid line (b) in FIG. 3 , the frequency spectrum in the vicinity of a transmission frequency f 0 comes to have a raised sidelobe, shifted from the characteristic shown by the broken line (a) in FIG. 3 . This produces a leak to adjacent channels, resulting in adjacent channel interference. Namely, due to the nonlinear distortion shown in FIG. 2 , the leak power of the transmission wave to the adjacent frequency channels becomes large, as shown in FIG. 3 .
An ACPR (adjacent channel power ratio) represents the magnitude of leak power, being defined as a ratio of leak power to adjacent channels, which corresponds to a spectrum area in the adjacent channels sandwiched between the lines B and B′ in FIG. 3 , to the power in the channel of interest, which corresponds to a spectrum area between the lines A and A′. Such the leak power affects other channels as noise, and degrades the communication quality of the channel of interest. For this reason, a strict regulation has been established.
The leak power is substantially small in a linear region of, for example, a power amplifier (refer to a linear region I in FIG. 2 ), and is substantially large in a nonlinear region II. Accordingly, in order to obtain a high-output transmission power amplifier, the linear region I has to be widened. However, this requires an amplifier having a larger capacity than is actually needed, which causes a disadvantageous problem in both cost and size of the apparatus. To cope with this problem, it has been applied to add a distortion compensation function to radio equipment so as to compensate for the transmission power distortion.
FIG. 4 shows a block diagram of transmission equipment having a digital nonlinear distortion compensation function. A digital data group (transmission signals) transmitted from transmission signal generator 1 is converted in S/P converter 2 into two series, I-signals and Q-signals. The two signal series are then input to a distortion compensator 9 , which is configured of a DSP (digital signal processor) as a preferable example.
As shown in the lower part of FIG. 4 in enlargement, distortion compensator 9 includes: a distortion compensation coefficient storage 90 for storing a distortion compensation coefficient h(pi) corresponding to the power level pi (where, i=0−1023) of a transmission signal x(t); a predistortion portion 91 for performing a distortion compensation process (predistortion) onto the transmission signal, using the distortion compensation coefficient h(pi) corresponding to the transmission signal power level; and further, a distortion compensation coefficient calculator 92 for updating a distortion compensation coefficient in distortion compensation coefficient storage 90 , by comparing the transmission signal x(t) with a demodulation signal (a feedback signal) y(t) demodulated in a quadrature detector 12 , which will be described later, and calculating the distortion compensation coefficient h(pi) so that the difference between the above compared values becomes zero.
The signal on which the predistortion process is performed in distortion compensator 9 is input into D/A converter 3 . D/A converter 3 converts the input I-signal and Q-signal into analog baseband signals, and inputs the converted signals into quadrature modulator 4 . Quadrature modulator 4 performs quadrature modulation by multiplying the input I-signal and Q-signal by a reference carrier wave 8 and a carrier wave being phase-shifted by 90° from reference carrier wave 8 , respectively. Quadrature modulator 4 performs quadrature modulation by adding the multiplication result, and outputs the modulated signal.
A frequency converter 5 performs frequency conversion by mixing the quadrature modulation signal with a local oscillation signal. A transmission power amplifier 6 performs power amplification of the radio frequency signal being output from frequency converter 5 , and radiates to the air from antenna 7 .
A portion of the transmission signal is input to a frequency converter 11 via a directional coupler 10 , and input into a quadrature detector 12 after being frequency converted by the above frequency converter 11 . Quadrature detector 12 performs quadrature detection by multiplying the input signal by a reference carrier wave, and by a signal being phase-shifted by 90° from the reference carrier wave, respectively. Thus, the baseband I-signal and Q-signal on the transmission side are reproduced, and then input into an analog-to-digital (A/D) converter 13 .
A/D converter 13 converts the input I-signal and Q-signal into digital signals, and inputs into distortion compensator 9 . Through the adaptive signal processing, using an LMS (least-mean-square) algorithm, in distortion compensation coefficient calculator 92 of distortion compensator 9 , the pre-compensated transmission signal is compared with the feedback signal being demodulated in quadrature detector 12 . Then, distortion compensator 9 calculates the distortion compensation coefficient h(p1) so that the difference of the above comparison values becomes zero, and updates the above-obtained coefficient having been stored in distortion compensation coefficient storage 90 . Through the repetition of the calculations above, nonlinear distortion in transmission power amplifier 6 is restrained, and adjacent channel leak power is reduced.
As a configuration of the embodiment of distortion compensator 9 shown in FIG. 4 , a configuration example in case of performing distortion compensation using the adaptive LMS has been disclosed, as shown in FIG. 5 , for example, in the PCT Internal Publication No. WO 03/103163.
In FIG. 5 , a multiplier 15 a corresponds to predistortion section 91 shown in FIG. 4 , in which a transmission signal x(t) is multiplied by a distortion compensation coefficient h n-1 (p). Also, a distortion device 15 b having a distortion function f(p) corresponds to transmission power amplifier 6 shown in FIG. 4 .
Also, a portion including frequency converter 11 in which the output signal from transmission power amplifier 15 b is feedbacked, orthogonal detector 12 and A/D converter 13 shown in FIG. 4 is shown as a feedback system 15 c in FIG. 5
Further, in FIG. 5 , distortion compensation coefficient storage 90 shown in FIG. 4 is constituted of a look-up table (LUT) 15 e . Distortion compensation coefficient calculator 92 shown in FIG. 4 for generating an update value for the distortion compensation coefficient stored in look-up table 15 e is constituted of a distortion compensation coefficient calculator 16 shown in FIG. 5 .
In the distortion compensation apparatus having such the configuration shown in FIG. 5 , look-up table 15 e stores a distortion compensation coefficient for canceling the distortion of transmission power amplifier 6 , a distortion device 15 b , in a two-dimensional address position corresponding to each discrete power value of the transmission signal x(t).
When the transmission signal x(t) is input, an address generator 15 d calculates the power p(=x 2 (t)) of the transmission signal x(t), and generates an address in the direction of one dimension, for example, an address in the X-axis direction which uniquely corresponds to the calculated power p(=x 2 (t)) of the transmission signal x(t). At the same time, address generator 15 d obtains a difference ΔP from the power P 1 (=x 2 (t−1)) of a transmission signal x(t−1) at the preceding time point (t−1) having been stored in address generator 15 d . Address generator 15 d then generates an address in the direction of another dimension, for example, in the Y-axis direction, which uniquely corresponds to the difference ΔP.
Accordingly, address generator 15 d outputs the storage location of look-up table 15 e being specified by both the address P in the X-axis direction and the address ΔP in the Y-axis direction, as specified information of a readout address (AR).
Thus, the distortion compensation coefficient h n-1 (p) stored in the above readout address is read out from look-up table 15 e , which is used for the distortion compensation processing in multiplier 15 a.
Meanwhile, an update value for updating a distortion compensation coefficient stored in look-up table 15 e is calculated in a distortion compensation coefficient calculator 16 . More specifically, distortion compensation coefficient calculator 16 includes a conjugate complex signal output portion 15 f , which outputs a conjugate complex signal y*(t), and multipliers 15 h - 15 j . A subtractor 15 g outputs a difference e(t) between the transmission signal x(t) and the feedback demodulation signal y(t). Multiplier 15 i multiplies the distortion compensation coefficient h n-1 (p) by y*(t), and obtains an output u*(t) (=h n-1 (p)y*(t)). Multiplier 15 h multiplies the difference e(t) being output from subtractor 15 g by u*(t). Multiplier 15 j multiplies a step-size parameter μ by the output of multiplier 15 h.
Subsequently, an adder 15 k adds the distortion compensation coefficient h n-1 (p) and the output of multiplier 15 j , i.e. μe(t)u*(t), so as to obtain an update value of look-up table 15 e . This update value is stored in the write address (AW) as an address corresponding to the power p(=x 2 (t)) of the transmission signal, being specified by the address in the X-axis direction and the address in the Y-axis direction generated by address generator 15 d.
Additionally, the readout address (AR) and the write address (AW) explained above is the same address. However, because a calculation time, etc. is required before obtaining the update value, the readout address being delayed in a delay portion 15 m is used as write address.
Each delay portion 15 m , 15 n , 15 p adds a delay time D to the transmission signal. Here, the delay time D denotes time duration from the time the transmission signal x(t) is input to the time the feedback demodulation signal y(t) is input to subtractor 15 g . This delay time D to be set in each delay portion 15 m , 15 n , 15 p is determined so as to satisfy D=D 0 +D 1 , where D 0 is the delay time in transmission power amplifier 15 b , and D 1 is the delay time in feedback system 15 c.
Using the above configuration, the following calculations are performed.
h n ( p )= h n-1 ( p )+μ e ( t ) u *( t )
e ( t )= x ( t )− y ( t )
y ( t )= h n-1 ( p ) x ( t ) f ( p )
u *( t )= x ( t ) f ( p )=h n-1 ( p ) y *( t )
p=|x ( t )| 2
Here, x, y, f, h, u and e are complex numbers, and * denotes a conjugate complex number.
Through the above calculation processing, the distortion compensation coefficient h(p) is updated so as to minimize the differential signal e(t) between the transmission signal x(t) and the feedback demodulation signal y(t). Finally, the value converges to an optimal distortion compensation coefficient, and the distortion of transmission power amplifier 6 is compensated.
Now, FIG. 6 is a schematic diagram of the data in the real part side in distortion compensation coefficient storage 90 (refer to FIG. 4 ), or look-up table 15 e shown in the example of FIG. 5 , in which the above distortion compensation coefficient h(pi) is stored. A magnitude P is set to one axis direction out of the two dimensions, while a magnitude ΔP is set to the other axis direction. In the axis direction perpendicular to these axes, a distortion compensation coefficient value h(p) is expressed.
In FIG. 6 , each peak which appears in places (as an example, a portion surrounded by a circle 100 ) is a portion in which a distortion compensation coefficient value h(p) becomes (or is becoming) an abnormal data (that is, h(p) having a large amplitude). The phenomenon of the above generation of the peaks is caused by the calculated update value of the distortion compensation coefficient becoming an abnormal value, when a large differential signal e(t) is produced by a largely varied feedback signal due to a large phase jitter, variation of the amplification characteristic, etc. in the analog portion including power amplifier 6 .
If the predistortion processing is performed on the transmission signal, and the table update processing is performed, using such an abnormal value having the above-mentioned characteristic, the abnormal value in the table further produces an updated distortion compensation coefficient of an abnormal value. Finally, the distortion compensation coefficient diverges, bringing about an abnormal amplifier output as a result of the execution of the distortion compensation processing.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to avoid divergence of the distortion compensation coefficient by detecting in early stages an abnormal value of the distortion compensation coefficient stored in a distortion compensation coefficient storage, and replacing with a mean value of the neighboring data before the abnormal value diverges.
As a first aspect of a distortion compensation apparatus according to the present invention to achieve the above object, a distortion compensation apparatus includes: a storage storing a distortion compensation coefficient in a specified write address, and outputting a distortion compensation coefficient stored in a specified readout address; a predistortion portion performing distortion compensation processing onto a transmission signal, using the distortion compensation coefficient being output from the storage; and a distortion compensator calculating a distortion compensation coefficient based on the transmission signal before the distortion compensation processing and the transmission signal after being amplified by an amplifier. The distortion compensator further reads out the distortion compensation coefficients stored in the storage, extracts a distortion compensation coefficient satisfying a predetermined condition, and performs correction processing for reducing the amplitude of the extracted distortion compensation coefficient. As the predetermined condition, existence of sufficiently large amplitude as compared to another distortion compensation coefficient being stored adjacently may be applied. The correction processing may be performed by making the distortion compensation coefficient approach the value of the other distortion compensation coefficient, using the other distortion compensation coefficient being stored adjacently. There may be provided alternate executions of a period for calculating the distortion compensation coefficient in the distortion compensator and for performing the distortion compensation processing onto the predistortion portion using the distortion compensation coefficient being read out from the storage, and a phase correction period for correcting a phase rotation of the transmission signal after being amplified by the amplifier. The above correction processing may be performed in the above phase correction period.
As a second aspect of the distortion compensation apparatus according to the present invention to achieve the aforementioned object, a distortion compensation includes: a storage storing a distortion compensation coefficient in a specified write address, and outputting a distortion compensation coefficient stored in a specified readout address; a predistortion portion performing distortion compensation processing onto a transmission signal, using the distortion compensation coefficient being output from the storage; a distortion compensator calculating a distortion compensation coefficient based on the transmission signal before the distortion compensation processing and the transmission signal after being amplified by an amplifier; and an address generator specifying a two-dimensional address of the storage, according to the transmission signal level before the distortion compensation processing. By grouping into each group having a predetermined number of distortion compensation coefficients stored in each series in the address direction of a second dimension out of the two-dimensional storage addresses, being located within a predetermined range in the address direction of a first dimension out of the two-dimensional storage addresses, the distortion compensator performs processing of replacing an abnormal value of the distortion compensation coefficients in the group by a mean value of other distortion compensation coefficients in the group of interest, successively for each group in the series.
As a third aspect of the distortion compensation apparatus according to the present invention to achieve the aforementioned object, a distortion compensation includes: a storage storing a distortion compensation coefficient in a specified write address, and outputting a distortion compensation coefficient stored in a specified readout address; a predistortion portion performing distortion compensation processing onto a transmission signal, using the distortion compensation coefficient being output from the storage; a distortion compensator calculating a distortion compensation coefficient based on the transmission signal before the distortion compensation processing and the transmission signal after being amplified by an amplifier; and an address generator specifying a two-dimensional address of the storage, according to the transmission signal level before the distortion compensation processing. For each series in the address direction of a second dimension out of the two-dimensional storage addresses, being located within a predetermined range in the address direction of a first dimension out of the two-dimensional storage addresses, the distortion compensator performs reading out the distortion compensation coefficients stored in the series of interest, and successively replacing, by a mean value, a distortion compensation coefficient exceeding an abnormal value decision criterion among the distortion compensation coefficients being read out. The mean value may be obtained from distortion compensation coefficients excluding a maximum value and an initial value among the distortion compensation coefficients being read out. Further scopes and features of the present invention will become more apparent by the following description of the embodiments with the accompanied drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a block diagram illustrating one example of transmission equipment in the conventional radio equipment.
FIG. 2 shows a diagram illustrating input/output characteristics (having distortion function f(p)) of a transmission power amplifier.
FIG. 3 shows a diagram illustrating a nonlinear distortion produced by the nonlinear characteristic.
FIG. 4 shows a block diagram of transmission equipment having a digital nonlinear distortion compensation function using a DSP (digital signal processor).
FIG. 5 shows a diagram illustrating a configuration of an embodiment of distortion compensator 9 shown in FIG. 4 .
FIG. 6 shows a schematic diagram of the data in the real part side in distortion compensation coefficient storage 90 (refer to FIG. 4 ), or look-up table 15 e shown in the example of FIG. 5 , in which the above distortion compensation coefficient h(pi) is stored.
FIG. 7 shows a block diagram of an embodiment of the transmission equipment, configured of a distortion compensation apparatus having a digital nonlinear distortion compensation function according to the present invention
FIG. 8 shows a process flowchart illustrating a first method for detecting and correcting an abnormal peak portion.
FIG. 9 shows a diagram illustrating step S 1 in the flowchart shown in FIG. 8 .
FIG. 10 shows a process flowchart illustrating a second method for detecting and correcting an abnormal peak portion.
FIG. 11A shows a diagram illustrating states of the Pn series shown in FIG. 10 , before the abnormal value detection.
FIG. 11B shows a diagram illustrating states of the Pn series shown in FIG. 10 , after the processing against the detected abnormal value.
FIG. 12A shows an explanation diagram of variation of phase φ in a feedback signal to a reference signal.
FIG. 12B shows an explanation diagram of alternate occurrence of each phase correction period Δt and each distortion compensation coefficient update period ΔT by means of an intermittent controller.
DETAILED DESCRIPTION OF THE INVENTION
The preferred embodiment of the present invention is described hereinafter referring to the charts and drawings. However, it is noted that the scope of the present invention is not limited to the embodiments described below.
FIG. 7 is a block diagram of an embodiment of the transmission equipment, configured of a distortion compensation apparatus having a digital nonlinear distortion compensation function according to the present invention.
Here, like reference numerals refer to the portions having the like functions shown in FIGS. 4 and 5 .
In FIG. 7 , distortion compensator 9 includes a control block 30 , and control block 30 includes a CPU 32 and a nonvolatile memory 33 , which are connected to a bus 31 . Further, a distortion compensation coefficient generator 16 works similarly to the circuit shown in FIG. 5 . In the exemplary embodiment shown in FIG. 7 , an update switch 21 is provided between distortion compensation coefficient generator 16 and a distortion compensation coefficient look-up table 15 e storing distortion compensation coefficients.
As will be described later, this update switch 21 leads the distortion compensation coefficient generated in distortion compensation coefficient generator 16 to distortion compensation coefficient look-up table 15 e during a timing period controlled by CPU 32 . With this, the content of an address location specified by a write address AW is updated.
At the time of initial startup of distortion compensator 9 , CPU 32 reads out an initial table value of the distortion compensation coefficient stored in nonvolatile memory 33 , so as to store into look-up table 15 e as an internal value. Here, the initial table value of the distortion compensation coefficient is, for example, a data having a predetermined value.
When the operation is started, as described earlier, a readout address AR corresponding to an input transmission signal is generated in address generator 15 d , and the distortion compensation coefficient in the corresponding address is read out from look-up table 15 e . The distortion compensation coefficient being read out is multiplied by the transmission signal in multiplier 15 a.
Meanwhile, from a difference between a feedback signal y(t) and the transmission signal x(t), a distortion compensation coefficient for update is generated in distortion compensation coefficient generator 16 . The generated distortion compensation coefficient for update is written into a write address AW of distortion compensation coefficient look-up table 15 e corresponding to the readout address AR, through update switch 21 . Thus, the distortion compensation coefficients are updated successively for each input transmission signal.
Here, the distortion compensation coefficients stored in distortion compensation coefficient look-up table 15 e are as illustrated in FIG. 6 . Accordingly, in the application of the present invention, CPU 32 in control block 30 detects abnormal peak values shown in FIG. 6 (as an example, the portion surrounded by circle 100 in FIG. 6 ), and corrects these abnormal values.
As an exemplary embodiment, a method for detecting and correcting abnormal peak portion of the distortion compensation coefficients is described below.
FIG. 8 is a process flowchart illustrating a first method for detecting and correcting the abnormal peak portion. This process flow is performed under the control of CPU 32 .
First, consecutive M (natural number more than 1) pieces of distortion compensation coefficients on a Pn series, as an example, h 1 , h 2 and h 3 in three (3) consecutive address locations are obtained, as one group of the distortion compensation coefficients. From an end portion of the Pn series, the above process is successively performed for each group (step S 1 ). FIG. 9 is a diagram illustrating this state, in which the n-th group Gn including the distortion compensation coefficients h 1 , h 2 and h 3 , in 3 consecutive address locations of the Pn series is shown, together with a group Gn+1 adjacent thereto.
Here, each h 1 -h 3 may be a real part of the complex number h, or an imaginary part of h, or a square root of the sum of squares (amplitude) of the real part and the imaginary part of h, or the like. Here, the real part is applied in this example.
Referring back to FIG. 8 , as to the n-th group Gn, the following calculation is performed (step S 2 ).
e 1=( h 1 +h 2 +h 3)/ h 1
e 2=( h 1 +h 2 +h 3)/ h 2
e 3=( h 1 +h 2 +h 3)/ h 3
Here, h 1 ≈h 2 ≈h 3 is satisfied when an abnormal value does not exist. As a result of integer calculation (calculation by rounding up or rounding down below the decimal point), each value ‘en’ (n=1, 2, 3) has 2 or 3. In contrast, when any abnormal value is existent, for example, when h 1 >>h 2 and h 1 >>h 3 , then e 1 =1, e 2 >>1 and e 3 >>1. Thus, it is understood h 1 is an abnormal value. For example, in case of a reference value being set to 5, when ‘en’ has the reference value 5 or more, the ‘en’ is detected as abnormal value.
Therefore, in FIG. 8 , it is decided whether e 1 =1, e 2 >>1 (no less than 5) and e 3 >>1 (no less than 5) (step S 3 ), if the above conditions are met, h 1 is determined as an abnormal value. Then, this h 1 is replaced by a mean value of the distortion compensation coefficients h 2 and h 3 , that is, (h 2 +h 3 )/2 (step S 4 ). The above process is also applied for detecting abnormal values in regard to e 2 and e 3 .
Here, not only by using a mean value, divergence can also be suppressed if the abnormal value is replaced by a value near the adjacent value.
On completion of the process of detecting the abnormal value and replacing by the mean value in regard to the n-th group Gn, the process from the above steps S 1 to S 4 is executed as to the next (n+1)th group, Gn+1 (step S 6 , following N in step S 5 ).
Next, on completion of the process of detecting the abnormal value and replacing by the mean value in regard to the series Pn (Y in step S 5 ), the process proceeds for the next series (step S 8 ). Preferably, the above process of detecting the abnormal value and replacing by the mean value are continued until the process completes for a predetermined range of series. On completion, the whole process is completed (step S 7 ).
Here, in the above process of detecting the abnormal value and replacing by the mean value, the reason for limiting to a predetermined range, instead of processing through the entire range of the stored distortion compensation coefficients, is as follows:
In general, abnormal value of the distortion compensation coefficients tends to occur in such locations that a transmission signal level is large, or small, as compared to the average power. Therefore, from the viewpoint of efficiency, it is preferable to perform supervision and correction in concentration against abnormal values in a range portion either having a large transmission signal level or a small transmission signal level.
Needless to say, it is desirable to detect abnormality of h as to the range other than the above-mentioned predetermined range of the stored distortion compensation coefficients, at a rate of once for N-times (N is a plural number), in addition to periodically executing the process shown in FIG. 8 . In this case, the predetermined range shown in FIG. 7 is modified to the range other than the predetermined range once for the N-times.
Further, the processing method shown in FIG. 8 , i.e. a method of successively processing by grouping the Pn series into each group having a predetermined number of consecutive distortion compensation coefficients h 1 , h 2 , h 3 is devised in consideration of the processing capacity of CPU 32 .
The present invention is not limited to the method in the above embodiment example. Namely, as a second embodiment, it is also possible to employ a method according to the processing flowchart shown in FIG. 10 .
Namely, FIG. 10 is a process flowchart illustrating the second method for detecting and correcting an abnormal peak portion. The feature of the second method is that the entire distortion compensation coefficient data in the Pn series are processed simultaneously.
In FIG. 10 , first, the entire distortion compensation coefficient data in the Pn series are acquired (step S 11 ). Next, from the acquired data, a mean value is obtained after both a maximum value and a value having no trace of being updated (i.e. an initial value) are ignored (omitted) (step S 12 ). Here, since the initial value is a predetermined value, when the value matches the predetermined value, the value is regarded as initial value, and accordingly, the data can be ignored.
FIGS. 11A , 11 B are diagrams illustrating the above situations. FIG. 11A shows a situation before the abnormal value detection processing, while FIG. 11B shows a situation after the abnormal value processing. In these figures, the entire data locations in the Pn series are expressed in the horizontal (transverse) axis direction, and the magnitude of the distortion compensation coefficients are expressed in the vertical axis direction.
In FIG. 11A , ‘Pk’ is a maximum value of the entire distortion compensation coefficients in the Pn series. Also, ‘Av’ is a mean value being obtained after the maximum value and the initial value(s) are ignored.
Referring back to FIG. 10 , subsequently, as for each data h(p) excluding the initial value(s), an absolute value |ERR|, where ERR indicates the difference of each data value from the mean value Av, is obtained (step S 13 ). Then it is decided whether or not the |ERR| exceeds a range Δh (for example, 1,000) which is an abnormal value decision criterion (step S 14 ).
If the |ERR| exceeds the criterion range Δh for deciding the abnormal value (Y in step S 14 ), the data of interest is decided to be an abnormal value, and accordingly, the data of interest is replaced by the mean value Av (step S 15 ).
On completion of the above process, the processing proceeds to the next series (step S 16 ), and is repeated until the processing is completed for an arbitrary number of rows (step S 17 ).
Here, the arbitrary number of rows is meant for the range of rows covering the object range, in which a region having a high occurrence frequency of the abnormal values is swept in the P direction.
Through the above process, it becomes possible to eliminate abnormal data in look-up table 15 e , as shown in FIG. 11B .
Lastly, preferable execution timing of the processing shown in FIGS. 8 and 10 according to the present invention will be described below.
In regard to FIG. 5 , it has been described before that the delay time D in delay portions 15 m , 15 n , 15 p is determined so as to satisfy D=D 0 +D 1 . However, even when the delay time D is properly set, there may be cases that stable and satisfactory distortion compensation operation cannot be achieved, and as a result, wasteful outband radiation power is produced.
Such a case is produced by the occurrence of a clock jitter caused by a thermal noise, which is produced in the analog system including the D/A converter and the A/D converter, and other external disturbance. The clock jitter produces an abrupt variation in the phase of the feedback signal y(t), affecting the convergence of the distortion compensation coefficients.
The clock jitter produces an unstable period and repeated variations. Among others, a large phase variation is produced by a phase variation of a local signal used for the frequency converter. Caused by this, a phase φ of the feedback signal varies against the reference signal, as exemplarily shown in FIG. 12A .
When such a phase variation caused by the clock jitter is not considered, an unstable vibration occurs in the distortion compensation coefficients in the range of the phase variation. Since these distortion compensation coefficients are multiplied to the transmission signal, this causes generation of unwanted waves.
To cope with this problem, the applicant of the present invention has proposed an invention in the prior patent application (PCT Internal Publication No. WO 03/103163), which enables stable and satisfactory distortion compensation operation even a phase difference between a reference signal and a feedback signal varies caused by a jitter, etc.
In FIG. 12A , it is assumed that a phase difference occurs between a reference signal (transmission signal) and a feedback signal caused by a clock jitter, as shown by a symbol A. In this case, if it is intended to correct this phase difference by detecting the phase difference between the reference signal and the feedback signal, the phase correction cannot follow a rapid phase variation caused by the jitter.
As a result, even if the phase correction is performed and look-up table 15 e of the distortion compensation coefficients is updated, the distortion compensation coefficient does not converge stably, affected by the phase difference φ PP . Therefore, it is difficult to obtain satisfactory distortion compensation operation. To cope with this problem, in the prior patent application described above, an intermittent controller is provided, by which a phase correction period Δt and a distortion compensation coefficient update period ΔT are generated.
The phase difference φ between the reference signal and the feedback signal is corrected in the phase correction period Δt. Also, the distortion compensation coefficient is updated in the distortion compensation coefficient update period ΔT. The above operation is repeated thereafter.
Accordingly, when applying the present invention also, as disclosed in the above prior patent application, a timing signal specifying the phase correction period Δt and the distortion compensation coefficient update period ΔT is generated by CPU 32 . Further, by means of a distortion compensation coefficient generator 16 , in this phase correction period Δt, the phase correction is performed. Also, the abnormal value detection of the distortion compensation coefficient and the replacement processing using the mean value in accordance with the present invention are performed as well.
Meanwhile, in the distortion compensation coefficient update period ΔT, by writing into look-up table 15 e , distortion compensation coefficient generator 16 updates the distortion compensation coefficient value being generated based on the difference between the reference signal and the feedback signal, while an update switch 21 is switched on.
As such, by repeating update and correction of the look-up table values continuously in a substantially short time, it becomes possible to effectively obtain an effect of eliminating abnormal values.
To summarize, according to the present invention, an abnormal value of the distortion compensation coefficient stored in a distortion compensation coefficient storage can be detected accurately, and the value can be restored to a mean value. Thus, it becomes possible to prevent divergence of the distortion compensation coefficient stored in the distortion compensation coefficient storage.
The foregoing description of the embodiments is not intended to limit the invention to the particular details of the examples illustrated. Any suitable modification and equivalents may be resorted to the scope of the invention. All features and advantages of the invention which fall within the scope of the invention are covered by the appended claims.
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Provided is a distortion compensation apparatus to prevent divergence of distortion compensation coefficients caused by an abnormal distortion compensation coefficient value. The distortion compensation apparatus includes a storage for storing a distortion compensation coefficient in a specified write address, and outputting a distortion compensation coefficient stored in a specified readout address; a predistortion portion for performing distortion compensation processing onto a transmission signal, using the distortion compensation coefficient being output from the storage; and a distortion compensator for calculating a distortion compensation coefficient based on the transmission signal before the distortion compensation processing and the transmission signal after being amplified by an amplifier. The distortion compensator further reads out the distortion compensation coefficients stored in the storage, extracts a distortion compensation coefficient satisfying a predetermined condition, and performs correction processing to reduce the amplitude of the extracted distortion compensation coefficient.
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This is a division of application Ser. No. 013,837 , filed Feb. 5, 1993.
BACKGROUND OF THE INVENTION
This invention relates to novel phenolic compounds. In one embodiment, the invention relates to phenolic curing agents for epoxy resins.
Polyphenolic compounds are useful as curing agents for epoxy resins. When used as a component of an epoxy resin-based electrical lamination formulation, it is desirable for both the epoxy resin and the curing agent to have a low melt viscosity, as formulations which can be applied to glass fibers in the melt, rather than in solution, are favored.
It is therefore an object of the invention to provide novel phenolic compounds. It is an object of one aspect of the invention to provide polyphenols which have a low melt viscosity.
SUMMARY OF THE INVENTION
According to the invention, a phenolic compound is provided which can be described by the formula ##STR2## in which Ar is a C 6-20 aromatic moiety, L is a cyclohexanenorbornane linking moiety, L' is a divalent cycloaliphatic moiety, and each of m and n is a number within the range of 0 to about 10. Such polyphenols include the product of the addition reaction of one or more phenols with a cyclohexenenorbornene such as 5-(3-cyclohexen-1-yl)bicyclo[2.2.1]hept-2-ene, and optionally dicyclopentadiene, in the presence of an addition catalyst such as boron trifluoride etherate. The resulting polyphenols are useful as curing agents for epoxy resins and as precursors of thermosetting resins such as epoxy resins and cyanate ester resins.
DETAILED DESCRIPTION OF THE INVENTION
The invention polyphenols can be prepared by the addition reaction of a phenol with a cyclohexenenorbornene compound such as 5-(3-cyclohexen-1yl)bicyclo[2.2.1]hept-2-ene. Suitable phenols include mono and polynuclear phenols having at least one unsubstituted position ortho- or para- to a phenolic hydroxyl group, such as phenol, cresol, 3,4- and 3,5-dimethylphenol, resorcinol, biphenol, 1-naphthol and bisphenol A or F. Phenol is preferred.
Suitable cyclohexenenorbornene compounds include ##STR3## referred to herein as "monoadduct," "diadduct" and "triadduct," respectively, and isomers thereof.
The cyclohexenenorbornene is an adduct of 4-vinylcyclohexene and cyclopentadiene which can be prepared by contacting 4-vinylcyclohexene and dicyclopentadiene, preferably in the presence of a polymerization inhibitor such as t-butyl catechol, at a temperature of at least about 180° C., preferably about 220° to 260° C., for a time within the range of about 2 hours to about 8 hours. Under these conditions, the dicyclopentadiene is cracked to cyclopentadiene, and the vinylcyclohexene and cyclopentadiene undergo an addition reaction to produce a mixture of mono-, di- and poly-adducts along with cyclopentadiene oligomers (e.g., trimer, tetramer, pentamer, etc.). The reaction product mixture containing predominately 5-(3-cyclohexen-l-yl)-2-norbornene (monoadduct) is allowed to cool to about 50°-70° C. and is stirred under reduced pressure to strip off unreacted vinylcyclohexene. The reaction product is then purified by fractional vacuum distillation to remove by-products including, optionally, di- and poly-adducts and cyclopentadiene oligomers, and the purified product is passed through an adsorbent bed for removal of t-butyl catechol. Preparation of a vinylcyclohexene/cyclopentadiene adduct is illustrated in Example 1 herein.
The invention polyphenols can optionally include a residue L' of a cyclic diene such as, for example, dicyclopentadiene, cyclopentadiene, norbornadiene dimer, norbornadiene, methylcyclopentadiene dimer, limonene, 1,3- and 1,5-cyclooctadiene, α- and y-terpinene, 5-vinylnorbornene, 5-(3-propenyl)-2-norbornene, and cyclopentadiene oligomers. The preparation of such a phenol is illustrated in Example 4 herein.
The phenol/adduct reaction is generally carried out by contacting, under addition reaction conditions, the vinylcyclohexene/cyclopentadiene adduct and optional cyclic diene with a molar excess, preferably about 10 to about 30 moles, of the selected phenol per mole of the adduct. The reaction is most efficiently carried out in the presence of a Lewis acid addition catalyst such as BF 3 , coordination complexes thereof such as boron trifluoride etherate, AlCl 3 , FeCl 3 , SnCl 4 , ZnCl 2 , silica and silica-alumina complexes and at an elevated temperature within the range of about 70° to about 200° C., preferably about 100° to about 180° C. The reaction is continued until the desired degree of reaction has been completed, usually for a time within the range of about 30 minutes to about 10 hours, generally about 1 hour to about 3 hours. Preparation of such polyphenols is illustrated in Examples 2, 4, 5 and 6 herein.
The invention phenolic compound can be combined with an epoxy resin by, for example, melt-blending, preferably in the presence of a curing catalyst such as an imidazole. Subsequent cure of the epoxy resin is effected by heating the epoxy/phenol mixture at a temperature above about 150° C., preferably within the range of about 200° to about 300° C., for at least about 0.25 hour. Cure of epoxy resins with invention phenols is illustrated in Examples 7, 8 and 9 herein.
The invention polyphenols are useful as curing agents for epoxy resins, as precursors for thermosettable resins such as epoxy resins and cyanate ester resins, and as stabilizing additives for thermoplastics. The invention epoxy resin compositions are useful in molding powder, coating and electrical encapsulation and laminating applications.
EXAMPLE 1
Preparation of 5-(3-cyclohexen-1-yl)bicyclo[2.2.1]hept-2-ene.
Dicyclopentadiene and 4-vinylcyclohexene in equimolar mixture were heated in an autoclave at 240° C. for 4-4.5 hours. The reaction product was diluted with cyclohexane and passed through a packed bed of alumina to remove the t-butylcatechol inhibitor introduced with the reactants. The resulting product mixture was distilled in a wiped film evaporator at 3 mm Hg pressure at 90° C. to produce a light fraction containing unreacted vinylcyclohexene and dicyclopentadiene and the mono-adducts of 4-vinylcyclohexene and cyclopentadiene. A 150 g sample of this distillate was vacuum distilled using a 10-tray Oldershaw column to give four fractions. The fourth fraction, 65 g, was shown by gas chromatographic analysis to consist of 0.15% dicyclopentadiene, 88.3% endo-5-(3-cyclohexen-1-yl)-2-norbornene, 6.1% exo-5-(3-cyclohexen-1-yl)-2-norbornene and two additional components present in the amount of 1.9% and 2.4% which are believed to be isomeric adducts of the formula ##STR4## several additional components totalling about 0.4%, 0.4% tricyclopentadiene and about 0.4% unidentified components. Analysis of the fraction by nuclear magnetic resonance indicated about 87 mole percent of the endo adduct, about 9 mole percent of the exo adduct and about 5% of the isomeric adducts.
EXAMPLE 2
Preparation of Polyphenol Based on 5-(3-cyclohexen-1-yl)bicyclo [2.2.1]hept-2-ene. To a reactor equipped with a stirrer, condensor and addition funnel were added 188.2 g (2.0 mole) of phenol and 1.0 g BF 3 .Et 2 O catalyst. The reaction mixture was heated to 70° C., and 17.4 g (0.1 mole) of 5-(3-cyclohexen-1-yl)bicyclo[2.2.1]hept-2-ene was added over a 20-minute period. The temperature was raised to 150° C. over a 11/2-hour period and held for 21/2 hours. Unreacted phenol was distilled. The recovered product had a melting range of 70°-80° C., a phenolic hydroxyl content of 0.495 eq/100 g and a melt viscosity of 240 cps (115° C.). The product polyphenol can be represented structurally as ##STR5##
EXAMPLE 3
Preparation of Polyphenol Based on Dicyclopentadiene (Comparison). To a reactor equipped with a stirrer, condensor and addition funnel were added 188.2 g (2.0 mole) of phenol and 1.Og of BF 3 .Et 2 O catalyst. The reaction mixture was heated to 70° C., and 13.2 g (0.1 mole) of dicyclopentadiene was added over a 20-minute period and held for 21/2 hours. Unreacted phenol was distilled. The recovered product had a melting range of 115°-120° C., a phenolic hydroxyl content of 0.62 eq/100 g, and a melt viscosity of 635 cps (115° C.). The product can be represented structurally as ##STR6##
EXAMPLE 4
Preparation of Polyphenol Based on 5-(3-cyclohexen-1-yl)bicyclo[2.2..1]hept-2-ene/dicyclopentadiene. To a reactor equipped with a stirrer, condensor and addition funnel were added 295.7 (3.14 mole) of phenol and 2.0 g of BF 3 . Et 2 ) catalyst. The reaction mixture was heated to 70° C., and 13.67 g (0.07856 mole) of 5-(3-cyclohexen-1-yl)bicyclo[2.2.1]hept-2-ene and 10.29 (0.07856 mole) of dicyclopentadiene were added over a 20-minute period. The temperature was raised to 150° C. over a 11/2-hour period and held for 21/2 hours. Unreacted phenol was distilled. The recovered product had a melting range of 70°-78° C. The product polyphenol includes repeating structural units ##STR7##
EXAMPLE 5
Preparation of Polyphenol Based on Vinylcyclohexene/Cyclopentadiene Diadduct. To a reactor equipped with a stirrer, condensor and addition funnel were added 376 g (4.0 mole) of phenol and 2.0 g of BF 3 .Et 2 ) catalyst. The reaction mixture was heated to 70° C., and 48 g (0.2 mole) of diadduct was added over a 20-minute period. The temperature was raised to 150° C. over a 11/2-hour period and held for about 21/2 hours. Unreacted phenol was distilled. The recovered product had a melting range of 85°-95° C. The product polyphenol can be represented structurally as ##STR8##
EXAMPLE 6
Preparation of Polyphenol from Mixed Dienes. To a reactor equipped with a stirrer, condensor and addition funnel were added 376 g (4.0 mole) of phenol and 2.0 g of BF 3 .Et 2 O catalyst. The reaction mixture was heated to 70° C., and 48 g of a diene mixture obtained from the Dieis-Alder reaction of cyclopentadiene and vinylcyclohexene were added over a 20-minute period. The temperature was raised to 150° C. over a 11/2-hour period and held for 21/2 hours. Unreacted phenol was distilled. The recovered product had a melting range of 87°-100° C. The product polyphenol includes repeating structural units ##STR9##
EXAMPLE 7
Cure of Epoxy Resin. 27.5 g of a 67/33 (wt) blend of the diglycidyl ether of bisphenol A and tetrabromo-BPA, 4.8 g of the polyphenol prepared in Example 2 and O.03 g 2-imidazole were melt-blended at 150° C. The mixture was then heated at 250° C. for 20 minutes. The resulting cured epoxy resin had a Tg of 91° C.
EXAMPLE 8
Cure of Epoxy Resin. 27.5 g of a 67/33 (wt) blend of the diglycidyl ether of bisphenol A and tetrabromo-BPA, 4.7 g of the polyphenol prepared in Example 5 and 0.03 g 2-imidazole were melt-blended at 150° C. The mixture was then heated at 250° C. for 20 minutes. The resulting cured epoxy resin had a Tg of 91° C.
EXAMPLE 9
Cure of Epoxy Resin. 2 g of the tetraglycidyl ether of the tetraphenol of ethane, 2 g of the polyphenol prepared in Example 5 and 0.03 g of 2-imidazole were melt-blended at 150° C. The mixture was then heated at 250° C. for 20 minutes. The resulting cured epoxy resin had a Tg of 185° C.
EXAMPLE 10
Cure of Epoxy Resin (Comparison). 4.08 g of a 67/33 (wt) blend of the diglycidyl ether of bisphenol A and tetrabromo-BPA, 1.61 g of the polyphenol prepared in Example 3, and 0.03 g of 2-imidazole were melt-blended at 150° C. The mixture was then heated at 250° C. for 20 minutes. The resulting cured epoxy resin had a Tg of 118° C.
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A phenolic compound is provided which can be described by the formula ##STR1## in which Ar is a C 6-20 aromatic moiety, L is a cyclohexanenorbornane linking moiety, L' is a divalent cycloaliphatic moiety, and each of m and n is a number within the range of 0 to about 10. Such phenols include the product of the addition reaction of phenol with a cyclohexenenorbornene compound such as 5-(3-cyclohexen-1-yl)bicyclo[2.2.1 ]hept-2-ene.
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[0001] The present invention relates to novel heterocyclic compounds of the general formula (I), their tautomeric forms, their stereoisomers, their pharmaceutically acceptable salts, pharmaceutical compositions containing them, methods for their preparation, use of these compounds in medicine and the intermediates involved in their preparation.
[0000]
[0002] The compounds of the general formula (I) lower blood glucose, lower or modulate triglyceride levels and/or cholesterol levels and/or low-density lipoproteins (LDL) and raises the high-density lipoproteins (HDL) plasma levels and hence are useful in combating different medical conditions, where such lowering (and raising) is beneficial. Thus, it could be used in the treatment and/or prophylaxis of obesity, hyperlipidaemia, hypercholesteremia, hypertension, atherosclerotic disease events, vascular restenosis, diabetes and many other related conditions.
[0003] The compounds of general formula (I) are useful to prevent or reduce the risk of developing atherosclerosis, which leads to diseases and conditions such as arteriosclerotic cardiovascular diseases, stroke, coronary heart diseases, cerebrovascular diseases, peripheral vessel diseases and related disorders. These compounds of general formula (I) are useful for the treatment and/or prophylaxis of metabolic disorders loosely defined as Syndrome X. The characteristic features of Syndrome X include initial insulin resistance followed by hyperinsulinemia, dyslipidemia and impaired glucose tolerance. The glucose intolerance can lead to non-insulin dependent diabetes mellitus (NIDDM, Type 2 diabetes), which is characterized by hyperglycemia, which if not controlled may lead to diabetic complications or metabolic disorders caused by insulin resistance. Diabetes is no longer considered to be associated only with glucose metabolism, but it affects anatomical and physiological parameters, the intensity of which vary depending upon stages/duration and severity of the diabetic state. The compounds of this invention are also useful in prevention, halting or slowing progression or reducing the risk of the above mentioned disorders along with the resulting secondary diseases such as cardiovascular diseases, like arteriosclerosis, atherosclerosis; diabetic retinopathy, diabetic neuropathy and renal disease including diabetic nephropathy, glomerulonephritis, glomerular sclerosis, nephrotic syndrome, hypertensive nephrosclerosis and end stage renal diseases, like microalbuminuria and albuminuria, which may be result of hyperglycemia or hyperinsulinemia.
BACKGROUND OF THE INVENTION
[0004] Hyperlipidaemia has been recognized as the major risk factor in causing cardiovascular diseases due to atherosclerosis. Atherosclerosis and other such peripheral vascular diseases affect the quality of life of a large population in the world. The therapy aims to lower the elevated plasma LDL cholesterol, low-density lipoprotein and plasma triglycerides in order to prevent or reduce the risk of occurrence of cardiovascular diseases. The detailed etiology of atherosclerosis and coronary artery diseases is discussed by Ross and Glomset [New Engl. J. Med., 295, 369-377 (1976)]. Plasma cholesterol is generally found esterified with various serum lipoproteins and numerous studies have suggested an inverse relationship between serum HDL-cholesterol level and risk for occurrence of cardiovascular disease. Many studies have suggested an increased risk of coronary artery diseases (CAD) due to elevated LDL and VLDL-cholesterol levels [Stampfer et al., N. Engl. J. Med., 325, 373-381 (1991)]. The other studies illustrate protective effects of HDL against progression of atherosclerosis. Thus, HDL has become a crucial factor in treating diseases with increased levels of cholesterol [Miller el. al., Br. Med. J. 282, 1741-1744 (1981); Picardo et al., Arteriosclerosis, 6, 434-441 (1986); Macikinnon et al., J. Biol. Chem. 261, 2548-2552 (1986)].
[0005] Diabetes is associated with a number of complications and also affect a large population. This disease is usually associated with other diseases such as obesity, hyperlipidemia, hypertension and angina. It is well established that improper treatment can aggravate impaired glucose tolerance and insulin resistance, thereby leading to frank diabetes. Further, patients with insulin resistance and type 2 diabetes often have raised triglycerides and low HDL-cholesterol concentrations and therefore, have greater risk of cardiovascular diseases. The present therapy for these diseases includes sulfonylureas and biguanides along with insulin. This type of drug therapy may lead to mild to severe hypoglycemia, which may lead to coma or in some cases may lead to death, as a result of unsatisfactory glycaemic control by these drugs. Recent addition of drugs in the treatment of diabetes are the thiazolidinediones, drugs having insulin-sensitizing action Thiazolidinediones like troglitazone, rosiglitazone and pioglitazone are prescribed alone or in combination with other anti-diabetic agents.
[0006] These are useful in treating diabetes, lipid metabolism but are suspected to have tumor-inducing potential and cause hepatic dysfunction, which may lead to liver failure. Further, serious undesirable side-effects have occurred in animal and/or human studies which include cardiac hypertrophy, hema dilution and liver toxicity in a few glitazones progressing to advanced human trials. The drawback is considered to be idiosyncratic. Presently, there is a need for a safe and an effective drug, to treat insulin resistance, diabetes and hyperlipidemia [ Exp. Clin. Endocrinol. Diabetes: 109(4), S548-9 (2001)]
[0007] Obesity is another major health problem being associated with increased morbidity and mortality. It is a metabolic disorder, in which excess of fat is accumulated in the body. Although, its etiology is unclear, the general feature includes excess of calorie intake than it is consumed. Various therapies such as dieting, exercise, appetite suppression, inhibition of fat absorption etc. have been used to combat obesity. However, more efficient therapies to treat this abnormality is essential as obesity is closely related to several diseases such as coronary heart disease, stroke, diabetes, gout, osteoarthritis, hyperlipidaemia and reduced fertility. It also leads to social and psychological problems [ Nature Reviews: Drug Discovery: 1(4), 276-86 (2002)].
[0008] Peroxisome Proliferator Activated Receptor (PPAR) is a member of the steroid/retinoid/thyroid hormone receptor family. PPAR∝, PPARγ and PPARδ have been identified as subtypes of PPARs. Extensive reviews regarding PPAR, their role in different diseased conditions are widely published [ Endocrine Reviews, 20(5), 649-699 (1999); J. Medicinal Chemistry, 43(4), 58-550 (2000); Cell, 55, 932-943 (1999); Nature, 405, 421-424 (2000); Trends in Pharmacological Sci., 469-473 (2000)]. PPARγ activation has been found to play a central role in initiating and regulating adipocyte differentiation [Endocrinology 135, 798-800, (1994)] and energy homeostasis, [ Cell, 83, 803-812 (1995); Cell, 99, 239-242 (1999)]. PPARγ agonists would stimulate the terminal differentiation of adipocyte precursors and cause morphological and molecular changes characteristic of a more differentiated, less malignant state. During adipocyte differentiation, several highly specialized proteins are induced, which are being involved in lipid storage and metabolism. It is accepted that PPARPγ activation leads to expression of CAP gene [ Cell Biology, 95, 14751-14756, (1993)], however, the exact link from PPARγ activation to changes in glucose metabolism and decrease in insulin resistance in muscle has not been clear. PPARα is involved in stimulating β-oxidation of fatty acids [Trends Endocrine. Metabolism, 4, 291-296 (1993)] resulting in plasma circulating free fatty acid reduction [ Current Biol., 5, 618-621 (1995)]. Recently, role of PPAR-Y activation in the terminal differentiation of adipocyte precursors has been implicated in the treatment of cancer. [ Cell, 79, 1147-1156 (1994); Cell, 377-389 (1996); Molecular Cell, 465-470 (1998); Carcinogenesis, 1949-1953 (1998); Proc. Natl. Acad. Sci., 94, 237-241 (1997); Cancer Research, 58, 3344-3352 (1998)]. Since PPARγ is expressed in certain cells consistently, PPARγ agonists would lead to nontoxic chemotherapy. There is growing evidence that PPAR agonists may also influence the cardiovascular system through PPAR receptors as well as directly by modulating vessel wall function [ Med. Res. Rev., 20 (5), 350-366 (2000)].
[0009] PPAR α agonists have been found useful in the treatment of obesity (WO 97/36579). Dual PPAR α and γ agonists have been suggested to be useful for Syndrome X (WO 97/25042). PPAR γ agonists and HAG-CoA reductase inhibitors have exhibited synergism and indicated the usefulness of the combination in the treatment of atherosclerosis and xanthoma (EP 0753 298).
[0010] Most recently PPAR delta was reported to modulate lipid metabolism in which PPAR delta serves as a widespread regulator of fat burning. In vitro activation of PPAR delta in adipocytes and skeletal muscle cells promotes fatty acid oxidation and utilization. It has also been reported that PPAR delta deficient mice challenged with high-fat diet show reduced energy uncoupling and are prone to obesity (Wang Y X et. al., Cell (2003), 113(2), 159-170). The transcriptional repression of atherogenic inflammation by ligand-activated PPAR delta was also reported, which further indicates the importance of PPAR delta in combating cardiovascular diseases (Lee, C H et al., Science 302, 453-457, 2003).
[0011] Leptin is a protein when bound to leptin receptors is involved in sending satiety signal to the hypothalamus. Leptin resistance would therefore lead to excess food in-take, reduced energy expenditure, obesity, impaired glucose tolerance and diabetes [ Science, 269, 543-46 (1995)]. It has been reported that insulin sensitizers lower plasma leptin concentration [ Proc. Natl. Acad. Sci. 93, 5793-5796 (1996): WO 98/02159)].
[0012] Several compounds have been reported which are dual agonists of PPAR α and γ like alkoxy phenyl propanoic acid derivatives, aryloxy propanoic acid derivatives, benzyl glycine derivatives etc have been reported and are in various developmental stages.
[0013] US 20030166697 (Nippon Shinayaku) discloses compounds of the following general formula:
[0000] R 1 -Het-D-E
[0000] wherein
[0000]
[0014] R 1 represents (un)substituted aryl, aromatic heterocyclic or cycloalkyl groups; ‘Het’ is an optionally substituted divalent aromatic heterocyclic group; W is —CH— or N; m=1-10; n=0-9; p=0-2; Y=O or S; R 3 is H or alkyl; Z=carboxy, alkoxy carbonyl etc.
[0015] WO 2000004011 discloses compounds having the following general formula for the treatment of dyslipidemia, atherosclerosis and diabetes;
[0000]
[0000] where X, Y=CH 2 , O, S, NRa (Ra=H, alkyl aryl, etc.); R=H, alkyl, cycloalkyl, etc.; R 1 =H, alkyl, hydroxyalkyl, —(CH 2 ) t —COORc where t=0-6 & Rc represents H or alkyl group, etc.; R 2 & R 3 =H, alkyl cycloalkyl, (C 6 -C 10 )aryl, (C 6 -C 10 )aryl(C 1 -C 7 )alkyl, 3-10 membered optionally substituted heterocyclic group etc.; or R 2 & R 3 optionally form a chain —(CH2) r1 (r=2-5), etc.; R 4 -R 7 =H, alkyl, (un)substituted aryl, etc.
[0016] However, the therapeutic potential of these compounds to treat diseases has not yet been proved and so there remains the need to develop newer medicines which are better or of comparable efficacy with the present treatment regimes, have lesser side effects and require a lower dosage regime
[0017] Surprisingly, we have found that the novel compounds of formula (I) are useful as hypocholesterolemic, hypolipidaemic, hypolipoproteinemic, anti-obesity and antihyperglycemic agents which may have additional body weight lowering effect and beneficial effect in the treatment and/or prophylaxis of diseases caused by hyperlipidaemia, diseases classified under Syndrome X and atherosclerosis, and methods for their preparation. Also surprisingly, the compounds of formula (I) have been found to be useful as hypocholesterolemic, hypolipidaemic, hypolipoproteinemic, anti-obesity and antihyperglycemic agents with reduced side effects. Also, the compounds showed preferable affinity towards PPAR subtypes.
PREFERRED EMBODIMENTS OF THE INVENTION
[0018] In an embodiment of the present invention is provided novel substituted heterocyclic compounds represented by the general formula (I), their tautomeric forms, their stereoisomers, their pharmaceutically acceptable salts, and pharmaceutical compositions containing them or their mixtures thereof.
[0019] In another embodiment of the present invention is provided a process for the preparation of novel substituted heterocyclic compounds represented by the general formula (I), their tautomeric forms, their stereoisomers, their pharmaceutically acceptable salts.
[0020] In a further embodiment of the present invention is provided pharmaceutical compositions containing compounds of the general formula (I), their tautomeric forms, their stereoisomers, their pharmaceutically acceptable salts, or their mixtures in combination with suitable carriers, solvents, diluents and other media normally employed in preparing such compositions.
DESCRIPTION OF THE INVENTION
[0021] Accordingly, the present invention provides novel compounds of the general formula (I),
[0000]
[0000] their tautomeric forms, their stereoisomers, their pharmaceutically acceptable salts, wherein
‘A’ represents an optionally substituted single or fused group selected from aryl, heteroaryl, heterocyclyl groups; or
[0000]
[0000] wherein ‘Ar’, ‘Ar 1 ’ and Ar 2 ′ may be the same or different and independently represents an optionally substituted single or fused aryl, heteroaryl or a heterocyclic group;
‘X’ represents oxygen, sulfur or nitrogen;
‘Y’ represents COOR 1 , CONR 1 R 2 ;
Z represents a bond or —CH 2 —;
‘m’ is an integer from 1-3;
R, R 1 & R 2 may be same or different and independently represents hydrogen, optionally substituted groups selected from linear or branched alkyl or aryl groups.
[0022] When any one of ‘A’, ‘Ar 1 ’ or ‘Ar 2 ’ is substituted, the substituents may be selected from hydroxy, oxo, halo, thio, nitro, amino, cyano, formyl, or optionally substituted groups selected from amidino, hydrazino, alkyl, haloalkyl, perhaloalkyl, alkoxy, haloalkoxy, perhaloalkoxy, alkenyl, alkynyl, cycloalkyl, cycloalkenyl, bicycloalkyl, bicycloalkenyl, alkoxy, alkenoxy, cycloalkoxy, aryl, aryloxy, aralkyl, aralkoxy, heterocyclyl, heteroaryl, heterocyclylalkyl, heteroaralkyl, heteroaryloxy, heteroaralkoxy, heterocyclyloxy, heterocyclylalkoxy, heterocyclylalkoxyacyl, acyl, acyloxy, acylamino, monosubstituted or disubstituted amino, arylamino, aralkylamino, carboxylic acid and its derivatives such as esters and amides, carbonylamino, hydroxyalkyl, aminoalkyl, alkoxyalkyl, aryloxyalkyl, aralkoxyalkyl, alkylthio, thioalkyl, arylthio, alkylsulfonylamino, alkylsulfonyloxy, alkoxycarbonylamino, aryloxycarbonylamino, aralkyloxycarbonylamino, aminocarbonylamino, alkylaminocarbonylamino, alkoxyamino, hydroxylamino, sulfenyl derivatives, sulfonyl derivatives, sulfonic acid and its derivatives; preferably the substituents may be selected from hydroxy, halo, oxo, or optionally substituted groups selected from alkyl, monosubstituted or disubstituted amino, alkoxy, acyl, aryl, aryloxy, aralkyl, aralkoxy, heterocyclyl, heteroaryl, heterocyclylalkyl, heteroaralkoxy, heterocyclyloxy, alkylthio, arylthio, alkylsulfonylamino, alkylsulfonyloxy, carboxylic acid and its derivatives such as esters and amides,
[0023] The substituents on ‘A’, ‘Ar 1 ’ or ‘Ar 2 ’ may further be optionally substituted by any of the groups as mentioned above;
[0024] When the groups representing ‘Ar’ are substituted, the substituents may be selected from halogen, optionally substituted groups selected from linear or branched alkyl, alkoxy, thioalkyl, haloalkyl, haloalkoxy, acyl, arylaminoalkyl, aminoalkyl groups.
[0025] In a preferred embodiment the groups, radicals described above may be selected from:
the “alkyl” group used either alone or in combination with other radicals, denotes a linear or branched radical containing one to eight carbons, selected from methyl, ethyl, n-propyl, iso-propyl, n-butyl, sec-butyl, tert-butyl, amyl, t-amyl, n-pentyl, 17-hexyl, iso-hexyl, heptyl, octyl and the like; the “alkenyl” group used either alone or in combination with other radicals, is selected from a radical containing from two to twelve carbons, more preferably groups selected from vinyl, allyl, 2-butenyl, 3-butenyl, 2-pentenyl; 3-pentenyl, 4-pentenyl, 2-hexenyl, 3-hexenyl, 4-hexenyl, 5-hexenyl, 2-heptenyl, 3-heptenyl, 4-heptenyl, 5-heptenyl, 6-heptenyl and the like; the “alkenyl” group includes dienes and trienes of straight and branched chains; the “alkynyl” group used either alone or in combination with other radicals, is selected from a linear or branched radical containing two to twelve carbon atoms, more preferably thynyl, 1-propynyl, 2-propynyl, 1-butynyl, 2-butynyl, 3-butynyl, 1-pentynyl, 2-pentynyl, 3-pentynyl, 4-pentynyl, 1-hexynyl, 3-hexynyl, 4-hexynyl, 5-hexynyl, and the like. The term “alkynyl” includes di- and tri-ynes; the “cycloalkyl” group used either alone or in combination with other radicals, is selected from a radical containing three to seven carbons, more preferably cyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl, cycloheptyl and the like; the “cycloalkenyl” group used either alone or in combination with other radicals, are preferably selected from cyclopropenyl, 1-cyclobutenyl, 2-cyclobutenyl, 1-cyclopentenyl, 2-cyclopentenyl, 3-cyclopentenyl, 1-cyclohexenyl, 2-cyclohexenyl, 3-cyclohexenyl, 1-cycloheptenyl, cycloheptadienyl, cycloheptatrienyl, and the like; the “alkoxy” group used either alone or in combination with other radicals, is selected from groups containing an alkyl radical, as defined above, attached directly to an oxygen atom, more preferably groups selected from methoxy, ethoxy, n-propoxy, iso-propoxy, n-butoxy, t-butoxy, iso-butoxy, pentyloxy, hexyloxy, and the like; the “alkenoxy” group used either alone or in combination with other radicals, is selected from groups containing an alkenyl radical, as defined above, attached to an oxygen atom, more preferably selected from vinyloxy, allyloxy, butenoxy, pentenoxy, hexenoxy, and the like; the “cycloalkoxy” group used either alone or in combination with other radicals, is selected from groups containing a cycloalkyl radical as defined above, attached directly to an oxygen atom, more preferably selected from cyclopropyloxy, cyclobutyloxy, cyclopentyloxy, cyclohexyloxy, cycloheptyloxy and the like. the “halo” or “halogen” group used either alone or in combination with other radicals, such as “haloalkyl”, “perhaloalkyl” etc. is selected from fluoro, chloro, bromo or iodo group; the “haloalkyl” group is selected from an alkyl radical, as defined above, suitably substituted with one or more halogens; such as perhaloalkyl, more preferably, perfluoro(C 1 -C 6 )alkyl such as fluoromethyl, difluoromethyl, trifluoromethyl, fluoroethyl, difluoroethyl, trifluoroethyl, mono or polyhalo substituted methyl, ethyl, propyl, butyl, pentyl or hexyl groups; the “haloalkoxy” group is selected from suitable haloalkyl, as defined above, directly attached to an oxygen atom, more preferably groups selected from fluoromethoxy, chloromethoxy, fluoroethoxy chloroethoxy and the like; the “perhaloalkoxy” group is selected from a suitable perhaloalkyl radical, as defined above, directly attached to an oxygen atom, more preferably groups selected from trifluoromethoxy, trifluoroethoxy, and the like; the “aryl” or “aromatic” group used either alone or in combination with other radicals, is selected from a suitable aromatic system containing one, two or three rings wherein such rings may be attached together in a pendant manner or may be fused, more preferably the groups are selected from phenyl, naphthyl, tetrahydronaphthyl, indane, biphenyl, and the like; the ‘aralkyl” group is selected from suitable aryl group as defined above attached to an alkyl group as defined above, more preferably selected from benzyl, phenethyl, naphthylmethyl, and the like; the “aryloxy” group is selected from a suitable aryl radical, as defined above, attached to a suitable alkoxy group, as defined above, more preferably the groups are selected from phenoxy, naphthyloxy and the like, which may be substituted; the “aralkoxy” group is selected from a suitable arylalkyl group, as defined above, attached to an oxygen atom, more preferably the groups are selected from benzyloxy, phenethyloxy, naphthylmethyloxy, phenylpropyloxy, and the like, which may be substituted; the “heterocyclyl” or “heterocyclic” group used either alone or in combination with other radicals, is selected from suitable saturated, partially saturated or unsaturated aromatic or non aromatic mono, bi or tricyclic radicals, containing one or more heteroatoms selected from nitrogen, sulfur and oxygen, more preferably selected from aziridinyl, azetidinyl, pyrrolidinyl, imidazolidinyl, piperidinyl, piperazinyl, 2-oxopiperidinyl, 4-oxopiperidinyl, 2-oxopiperazinyl, 3-oxopiperazinyl, morpholinyl, thiomorpholinyl, 2-oxomorpholinyl, azepinyl, diazepinyl, oxapinyl, thiazepinyl, oxazolidinyl, thiazolidinyl, dihydrothiophene, dihydropyran, dihydrofuran, dihydrothiazole, benzopyranyl, benzopyranonyl, benzodihydrofuranyl, benzodihydrothienyl, pyrazolopyrimidonyl, azaquinazolinoyl, thienopyrimidonyl, quinazolonyl, pyrimidonyl, benzoxazinyl, benzoxazinonyl, benzothiazinyl, benzothiazinonyl, thieno piperidinyl, and the like; the “heteroaryl” or “heteroaromatic” group used either alone or in combination with other radicals, is selected from suitable single or fused mono, bi or tricyclic aromatic heterocyclic radicals containing one or more hetero atoms selected from O, N or S, more preferably the groups are selected from pyridyl, thienyl, furyl, pyrrolyl, oxazolyl, thiazolyl, isothiazolyl, imidazolyl, isoxazolyl, oxadiazolyl, thiadiazolyl, triazolyl, tetrazolyl, benzofuranyl, benzothienyl, indolinyl, indolyl, azaindolyl, azaindolinyl, pyrazolopyrimidinyl, azaquinazolinyl, pyridofuranyl, pyridothienyl, thienopyrimidyl, quinolinyl, pyrimidinyl, pyrazolyl, quinazolinyl, pyridazinyl, triazinyl, benzimidazolyl, benzotriazolyl, phthalazynil, naphthylidinyl, purinyl, carbazolyl, phenothiazinyl, phenoxazinyl, benzoxazolyl, benzothiazolyl and the like; the “heterocyclylalkyl” group used either alone or in combination with other radicals, is selected from a suitable heterocyclyl group, as defined above, substituted with a suitable alkyl group as defined above, more preferably the groups are selected from pyrrolidinealkyl, piperidinealkyl, morpholinealkyl, thiomorpholinealkyl, oxazolinealkyl, and the like, which may be substituted; the “heteroaralkyl” group used either alone or in combination with other radicals, is selected from a suitable heteroaryl group, as defined above, attached to a straight or branched saturated carbon chain containing 1 to 6 carbons, more preferably the groups are selected from (2-furyl)methyl, (3-furyl)methyl, (2-thienyl)methyl, (3-thienyl)methyl, (2-pyridyl)methyl, 1-methyl-1-(2-pyrimidyl)ethyl and the like; the groups “heteroaryloxy”, “heteroaralkoxy”, “heterocycloxy”, “heterocylylalkoxy” are selected from suitable heteroaryl, heteroarylalkyl, heterocyclyl, heterocyclylalkyl groups respectively, as defined above, attached to an oxygen atom; the “acyl” group used either alone or in combination with other radicals, is selected from a radical containing one to eight carbons, more preferably selected from formyl, acetyl, propanoyl, butanoyl, iso-butanoyl, pentanoyl, hexanoyl, heptanoyl, benzoyl and the like, which may be substituted; the “acyloxy” group used either alone or in combination with other radicals, is selected from a suitable acyl group, as defined above, directly attached to an oxygen atom, more preferably such groups are selected from acetyloxy, propionyloxy, butanoyloxy, iso-butanoyloxy, benzoyloxy and the like; the “acylamino” group used either alone or in combination with other radicals, is selected from a suitable acyl group as defined earlier, attached to an amino radical, more preferably such groups are selected from CH 3 CONH, C 2 H 5 CONH, C 3 H 7 CONH, C 4 H 9 CONH, C 6 H 5 CONH and the like, which may be substituted; the “mono-substituted amino” group used either alone or in combination with other radicals, represents an amino group substituted with one group selected from (C 1 -C 6 )alkyl, substituted alkyl, aryl, substituted aryl or arylalkyl groups as defined earlier, more preferably such groups are selected from methylamine, ethylamine, n-propylamine, n-butylamine, n-pentylamine and the like; the “disubstituted amino” group used either alone or in combination with other radicals, represents an amino group, substituted with two radicals that may be same or different selected from (C 1 -C 6 )alkyl, substituted alkyl aryl, substituted aryl, or arylalkyl groups, as defined above, more preferably the groups are selected from dimethylamino, methylethylamino, diethylamino, phenylmethyl amino and the like; the “arylamino” used either alone or in combination with other radicals, represents an aryl group, as defined above, linked through amino having a free valence bond from the nitrogen atom, more preferably the groups are selected from phenylamino, naphthylamino, N-methyl anilino and the like; the “aralkylamino” used either alone or in combination with other radicals, represents an arylalkyl group as defined above linked through an amino group having a free valence bond from the nitrogen atom, more preferably selected from benzylamino, phenethylamino, 3-phenylpropylamino, 1-napthylmethylamino, 2-(1-napthyl)ethylamino and the like; the “oxo” or “carbonyl” group used either alone (—C═O—) or in combination with other radicals such as alkyl described above, for e.g. “alkylcarbonyl”, denotes a carbonyl radical (—C—O—) substituted with an alkyl radical described above such as acyl or alkanoyl; the “carboxylic acid” group, used alone or in combination with other radicals, denotes a —COOH group, and includes derivatives of carboxylic acid such as esters and amides; the “ester” group used alone or in combination with other radicals, denotes —COO— group, and includes carboxylic acid derivatives, more preferably the ester moieties are selected from alkoxycarbonyl, such as methoxycarbonyl, ethoxycarbonyl, and the like, which may optionally be substituted; aryloxycarbonyl group such as phenoxycarbonyl, naphthyloxycarbonyl, and the like, which may optionally be substituted; aralkoxycarbonyl group such as benzyloxycarbonyl, phenethyloxycarbonyl, napthylmethoxycarbonyl, and the like, which may optionally be substituted; heteroaryloxycarbonyl, heteroaralkoxycarbonyl, wherein the heteroaryl group, is as defined above, which may optionally be substituted; heterocyclyloxycarbonyl, where the heterocyclic group, as defined earlier, which may optionally be substituted; the “amide” group used alone or in combination with other radicals, represents an aminocarbonyl radical (H 2 N—C═O—), wherein the amino group is mono- or di-substituted or unsubstituted, more preferably the groups are selected from methylamide, dimethylamide, ethylamide, diethylamide, and the like; the “aminocarbonyl” group used either alone or in combination with other radicals, may be selected from ‘aminocarbonyl’, “aminocarbonylalkyl”, “n-alkylaminocarbonyl”, “N-arylaminocarbonyl”, “N,N-dialkylaminocarbonyl”, “N-alkyl-N-arylaminocarbonyl”, “N-alkyl-N-hydroxyaminocarbonyl”, and “N-alkyl-N-hydroxyaminocarbonylalkyl”, each of them being optionally substituted. The terms “N-alkylaminocabonyl” and “N,N-dialkylaminocarbonyl” denotes aminocarbonyl radicals, as defined above, which have been substituted with one alkyl radical and with two alkyl radicals, respectively. Preferred are “lower alkylaminocarbonyl” having lower alkyl radicals as described above attached to aminocarbonyl radical. The terms “N-arylaminocarbonyl” and “N-alkyl-N-arylaminocarbonyl” denote aminocarbonyl radicals substituted, respectively, with one aryl radical, or one alkyl, and one aryl radical. The term “aminocarbonylalkyl” includes alkyl radicals substituted with aminocarbonyl radicals; the “hydroxyalkyl” group used either alone or in combination with other radicals, is selected from an alkyl group, as defined above, substituted with one or more hydroxy radicals, more preferably the groups are selected from hydroxymethyl, hydroxyethyl, hydroxypropyl, hydroxybutyl, hydroxypentyl, hydroxyhexyl and the like; the “aminoalkyl” group used alone or in combination with other radicals, denotes an amino (—NH 2 ) moiety attached to an alkyl radical, as defined above, which may be substituted, such as mono- and di-substituted aminoalkyl. The term “alkylamino” used herein, alone or in combination with other radicals, denotes an alkyl radical, as defined above, attached to an amino group, which may be substituted, such as mono- and di-substituted alkylamino; the “alkoxyalkyl” group used alone or in combination with other radicals, denotes an alkoxy group, as defined above, attached to an alkyl group as defined above, more preferably the groups may be selected from methoxymethyl, ethoxymethyl, methoxyethyl, ethoxyethyl and the like; the “aryloxyalkyl” group used alone or in combination with other radicals, is selected from phenoxymethyl, napthyloxymethyl, and the like; the “aralkoxyalkyl” group used alone or in combination with other radicals, is selected from C 6 H 5 CH 2 OCH 2 , C 6 H 5 CH 2 OCH 2 CH 2 , and the like; the “alkylthio” group used either alone or in combination with other radicals, denotes a straight or branched or cyclic monovalent substituent comprising an allyl group as defined above, linked through a divalent sulfur atom having a free valence bond from the sulfur atom, more preferably the groups may be selected from methylthio, ethylthio, propylthio, butylthio, pentylthio and the like or cyclic alkylthio selected from cyclopropylthio, cyclobutylthio, cyclopentylthio, cyclohexylthio and the like, which may be optionally substituted; the “thioalkyl” group used either alone or in combination with other radicals, denotes an alkyl group, as defined above, attached to a group of formula —SR′, where R′ represents hydrogen, alkyl or aryl group, e.g. thiomethyl, methylthiomethyl, phenylthiomethyl and the like, which may be optionally substituted. the “arylthio” group used either alone or in combination with other radicals, is selected from an aryl group, as defined above, linked through a divalent sulfur atom, having a free valence bond from the sulfur atom, more preferably selected from phenylthio, naphthylthio and the like; the “alkoxycarbonylamino” group used alone or in combination with other radicals, is selected from a suitable alkoxycarbonyl group, as defined above, attached to an amino group, more preferably methoxycarbonylamino, ethoxycarbonylamino, and the like; the “aryloxycarbonylamino” group used alone or in combination with other radicals, is selected from an aryloxycarbonyl group, as defined above, attached to the an amino group, more preferably such groups are selected from C 6 H 5 OCONH, C 6 H 5 OCONCH 3 , C 6 H 5 OCONC 2 H 5 , C 6 H 4 (CH 3 O)CONH, C 6 H 4 (OCH 3 )OCONH, and the like; the “aralkoxycarbonylamino” group used alone or in combination with other radicals, is selected from an aralkoxycarbonyl group, as defined above, attached to an amino group, more preferably selected from C 6 H 5 CH 2 OCONH, C 6 H 5 CH 2 CH 2 CH 2 OCONH, C 6 H 5 CH 2 OCONHCH 3 , C 6 H 5 CH 2 OCONC 2 H 5 , C 6 H 4 (CH 3 )CH 2 OCONH, C 6 H 4 (OCH 3 )CH 2 OCONH, and the like; the “aminocarbonylamino”, “alkylaminocarbonylamino”, “dialkylaminocarbonylamino” groups used alone or in combination with other radicals, is a carbonylamino (—CONH 2 ) group, attached to amino(NH 2 ), alkylamino group or dialkylamino group respectively, where alkyl group is as defined above; the “amidino” group used either alone or in combination with other radicals, represents a —C(═N—NH 2 radical; the “alkylamidino” group represents an alkyl radical, as described above, attached to an amidino group; the “hydrazino” group used either alone or in combination with other radicals, represents a group of the formula —NHNH—, suitably substituted with other radicals, selected from those described above such as an alkyl hydrazino, where an alkyl group, as defined above is attached to a hydrazino group; the “alkoxyamino” group used either alone or in combination with other radicals, represents a suitable alkoxy group as defined above, attached to an amino group; the “hydroxyamino” group used either alone or in combination with other radicals, represents a —NHOH moiety, and may be optionally substituted with suitable groups selected from those described above; the “sulfenyl” group or “sulfenyl derivatives” used alone or in combination with other radicals, represents a bivalent group, —SO— or R x , where R x is an optionally substituted alkyl, aryl, heteroaryl, heterocyclyl, group selected from those described above; the “sulfonyl” group or “sulfones derivatives” used either alone or in combination with other radicals, with other terms such as alkylsulfonyl, represents a divalent radical —SO 2 —, or R x SO 2 —, where R x is as defined above. More preferably, the groups may be selected from “alkylsulfonyl” wherein suitable alkyl radicals, selected from those defined above, is attached to a sulfonyl radical, such as methylsulfonyl, ethylsulfonyl, propylsulfonyl and the like, “arylsulfonyl” wherein an aryl radical, as defined above, is attached to a sulfonyl radical, such as phenylsulfonyl and the like.
[0077] Suitable groups and substituents on the groups may be selected from those described anywhere in the specification.
[0078] Particularly useful compounds may be selected from
Methyl-2-methyl-5-{4-[2-(5-methyl-2-p-tolyl-oxazol-4-yl)-ethoxy]-benzyl}-[1,3]dioxane-2-carboxylate; Methyl-5-[6-(2-fluoro-benzyloxy)-naphthalen-2-ylmethyl]-2-methyl-[1,3]dioxane-2-carboxylate; Methyl-5-[6-(benzyloxy)-naphthalen-2-ylmethyl]-2-methyl-[1,3]dioxane-2-carboxylate; Methyl-2-methyl-5-cis-{4-[2-(5-methyl-2-phenyl-oxazol-4-yl)-ethoxy]-benzyl}-[1,3]dioxane-2-carboxylate; Methyl-2-methyl-5-{4-[2-(5-methyl-2-phenyl-oxazol-4-yl)-ethoxy]-benzyl}-[1,3]dioxane-2-carboxylate; Methyl-2-methyl-5-cis-[4-(5-methyl-2-phenyl-oxazol-4-ylmethoxy)-benzyl]-[1,3]dioxane-2-carboxylate; Methyl-2-methyl-5-cis-[4-(1-pyridin-2-yl-pyrrolidin-2-ylmethoxy)-benzyl]-[1,3]dioxane-2-carboxylate; Methyl-2-methyl-5-cis-{4-[2-(methyl-pyridin-2-yl-amino)-ethoxy]-benzyl}-[1,3]dioxane-2-carboxylate; Methyl-2-methyl-5-[4-(3-methyl-4-oxo-3,4-dihydro-quinazolin-2-ylmethoxy)-benzyl]-[1,3]dioxane-2-carboxylate; Methyl-2-methyl-5-cis-[4-(5-methyl-2-p-tolyl-oxazol-4-ylmethoxy)-benzyl]-[1,3]dioxane-2-carboxylate; Methyl-5-cis-[4-(2-carbazol-9-yl-ethoxy)-benzyl]-2-methyl-[1,3]dioxane-2-carboxylate; Methyl-5-cis-[4-(2-indol-1-yl-ethoxy)-benzyl]-2-methyl-[1,3]dioxane-2-carboxylate; Methyl-5-{4-[2-(2,3-dihydro-benzo[1,4]oxazin-4-yl)-ethoxy]-benzyl}-2-methyl-[1,3]dioxane-2-carboxylate; Methyl-2-methyl-5-cis-{4-[5-methyl-2-(5-methyl-thiophen-2-yl)-oxazol-4-ylmethoxy]-benzyl}-[1,3]dioxane-2-carboxylate; Methyl-2-methyl-5-cis-(4-{2-[5-methyl-2-(5-methyl-thiophen-2-yl)-oxazol-4-yl]-ethoxy}-benzyl)-[1,3]dioxane-2-carboxylate; Methyl-2-methyl-5-cis-{4-[3-(4-phenoxy-phenoxy)-propoxy]-benzyl}-[1,3]dioxane-2-carboxylate; Methyl-5-cis-{4-[2-(4-methanesulfonyloxy-phenyl)-ethoxy]-benzyl}-2-methyl-[1,3]dioxane-2-carboxylate; Methyl-5-cis-[4-(2-tert-Butyl-5-methyl-oxazol-4-ylmethoxy)-benzyl]-2-methyl-[1,3]dioxane-2-carboxylate; Methyl-2-methyl-5-cis-{4-[4-methyl-2-(4-trifluoromethyl-phenyl)-thiazol-5-ylmethoxy]-benzyl}-[1,3]dioxane-2-carboxylate; Methyl-2-methyl-5-cis-{4-[2-(4-phenoxy-phenoxy)-ethoxy]-benzyl}-[1,3]dioxane-2-carboxylate; Methyl-5-cis-[4-(2-fluoro-benzyloxy)-benzyl]-2-methyl-[1,3]dioxane-2-carboxylate; Methyl-2-methyl-5-[4-(2-phenoxazin-10-yl-ethoxy)-benzyl]-[1,3]dioxane-2-carboxylate; Methyl-2-methyl-5-cis-[4-(2-oxo-3-phenyl-oxazolidin-5-ylmethoxy)-benzyl]-[1,3]dioxane-2-carboxylate; Methyl-5-cis-{4-[2-(2,3-dihydro-benzo[1,4]thiazin-4-yl)-ethoxy]-benzyl}-2-methyl-[1,3]dioxane-2-carboxylate; Methyl-2-methyl-5-cis-[4-(2-phenothiazin-10-yl-ethoxy)-benzyl]-[1,3]dioxane-2-carboxylate; Methyl-5-cis-{4-[2-(4-hexyl-3-oxo-3,4-dihydro-2H-benzo[1,4]oxazin-2-yl)-ethoxy]-benzyl}-2-methyl-[1,3]dioxane-2-carboxylate, Methyl-2-methyl-5-cis-(4-{2-[2-methyl-5-(4-methylsulfanyl-phenyl)-pyrrol-1-yl]-ethoxy}-benzyl)-[1,3]dioxane-2-carboxylate; Methyl-5-cis-{4-[2-(2-tert-Butyl-5-methyl-oxazol-4-yl)-ethoxy]-benzyl}-2-methyl-[1,3]dioxane-2-carboxylate; (Z)-Methyl-2-methyl-5-cis-{4-[2-(phenyl-pyridin-2-yl-methyleneaminooxy)-ethoxy]-benzyl}-[1,3]dioxane-2-carboxylate; (E)-Methyl-2-methyl-5-cis-{4-[2-(phenyl-pyridin-2-yl-methyleneaminooxy)-ethoxy]-benzyl}-[1,3]dioxane-2-carboxylate; Methyl-2-methyl-5-{4-[2-(5-methyl-2-p-tolyl-oxazol-4-yl)-ethoxy]-benzyl}-[1,3]dioxane-2-carboxylate; Methyl-5-cis-[4-(5-tert-Butyl-2-p-tolyl-2H-pyrazol-3-ylmethoxy)-benzyl]-2-methyl-[1,3]dioxane-2-carboxylate; Methyl-2-methyl-5-trans-[4-(5-methyl-2-phenyl-oxazol-4-ylmethoxy)-benzyl]-[1,3]dioxane-2-carboxylate; Methyl-2-methyl-5-trans-[4-(1-pyridin-2-yl-pyrrolidin-2-ylmethoxy)-benzyl]-[1,3]dioxane-2-carboxylate; Methyl-2-methyl-5-trans-{4-[2-(methyl-pyridin-2-yl-amino)-ethoxy]-benzyl}-[1,3]dioxane-2-carboxylate; Methyl-2-methyl-5-trans-[4-(5-methyl-2-p-tolyl-oxazol-4-ylmethoxy)-benzyl]-[1,3]dioxane-2-carboxylate; Methyl-5-trans-[4-(2-carbazol-9-yl-ethoxy)-benzyl]-2-methyl-[1,3]dioxane-2-carboxylate; Methyl-5-trans-[4-(2-indol-1-yl-ethoxy)-benzyl]-2-methyl-[1,3]dioxane-2-carboxylate; Methyl-2-methyl-5-trans-{4-[S-methyl-2-(5-methyl-thiophen-2-yl)-oxazol-4-ylmethoxy]-benzyl}-[1,3]dioxane-2-carboxylate; Methyl-2-methyl-5-trans-(4-{2-[5-methyl-2-(5-methyl-thiophen-2-yl)-oxazol-4-yl]-ethoxy}-benzyl)-[1,3]dioxane-2-carboxylate; Methyl-2-methyl-5-trans-{4-[3-(4-phenoxy-phenoxy)-propoxy]-benzyl}-[1,3]dioxane-2-carboxylate; Methyl-5-trans-{4-[2-(4-methanesulfonyloxy-phenyl)-ethoxy]-benzyl}-2-methyl-[1,3]dioxane-2-carboxylate; Methyl-5-trans-[4-(2-tert-Butyl-5-methyl-oxazol-4-ylmethoxy)-benzyl]-2-methyl-[1,3]dioxane-2-carboxylate; methyl-2-methyl-5-trans-{4-[4-methyl-2-(4-trifluoromethyl-phenyl)-thiazol-5-ylmethoxy]-benzyl}-[1,3]dioxane-2-carboxylate; Methyl-2-methyl-5-trans-{4-[2-(4-phenoxy-phenoxy)-ethoxy]-benzyl}-[1,3]dioxane-2-carboxylate; Methyl-5-trans-[4-(2-fluoro-benzyloxy)-benzyl]-2-methyl-[1,3]dioxane-2-carboxylate; Methyl-2-methyl-5-trans-[4-(2-oxo-3-phenyl-oxazolidin-5-ylmethoxy)-benzyl]-[1,3]dioxane-2-carboxylate; Methyl-5-trans-{4-[2-(2,3-dihydro-benzo[1,4]thiazin-4-yl)-ethoxy]-benzyl}-2-methyl-[1,3]dioxane-2-carboxylate; Methyl-2-methyl-5-trans-[4-(2-phenothiazin-10-yl-ethoxy)-benzyl]-[1,3]dioxane-2-carboxylate; Methyl-5-trans-{4-[2-(4-hexyl-3-oxo-3,4-dihydro-2H-benzo[1,4]oxazin-2-yl)-ethoxy]benzyl}-2-methyl-[1,3]dioxane-2-carboxylate; Methyl-2-methyl-5-trans-(4-{2-[2-methyl-5-(4-methylsulfanyl-phenyl)-pyrrol-1-yl]-ethoxy}-benzyl)-[1,3]dioxane-2-carboxylate; Methyl-5-trans-{4-[2-(2-tert-Butyl-5-methyl-oxazol-4-yl)-ethoxy]-benzyl}-2-methyl-[1,3]dioxane-2-carboxylate; (Z)-Methyl-2-methyl-5-trans-{4-[2-(phenyl-pyridin-2-yl-methyleneaminooxy)-ethoxy]-benzyl}-[1,3]dioxane-2-carboxylate; (E)-Methyl-2-methyl-5-trans-{4-[2-(phenyl-pyridin-2-yl-methyleneaminooxy)-ethoxy]-benzyl}-[1,3]dioxane-2-carboxylate; Methyl-5-trans-[4-(5-tert-Butyl-2-p-tolyl-2H-pyrazol-3-ylmethoxy)-benzyl]-2-methyl-[1,3]dioxane-2-carboxylate; Methyl-2-methyl-5-cis-[4-(5-methyl-2-phenyl-oxazol-4-ylmethoxy)-phenyl]-[1,3]dioxane-2-carboxylate; Methyl-2-methyl-5-trans-[4-(5-methyl-2-phenyl-oxazol-4-ylmethoxy)-phenyl]-[1,3]dioxane-2-carboxylate; Methyl-2-methyl-5-cis-{4-[2-(5-methyl-2-phenyl-oxazol-4-yl)-ethoxy]-phenyl}-[1,3]dioxane-2-carboxylate; Methyl-2-methyl-5-cis-[4-(2-phenoxazin-10-yl-ethoxy)-phenyl]-[1,3]dioxane-2-carboxylate; Methyl-2-methyl-5-cis-[4-(3-methyl-4-oxo-3,4-dihydro-quinazolin-2-ylmethoxy)-phenyl]-[1,3]dioxane-2-carboxylate; Methyl-5-cis-[4-(2-indol-1-yl-ethoxy)-phenyl]-2-methyl-[1,3]dioxane-2-carboxylate; Methyl-5-cis-{4-[2-(5-ethyl-pyridin-2-yl)-ethoxy]-phenyl}-2-methyl-[1,3]dioxane-2-carboxylate; Methyl-2-methyl-5-cis-[4-(5-methyl-2-p-tolyl-oxazol-4-ylmethoxy)-phenyl]-[1,3]dioxane-2-carboxylate; Methyl-2-Methyl-5-cis-{4-[2-(5-methyl-2-p-tolyl-oxazol-4-yl)-ethoxy]-phenyl}-[1,3]dioxane-2-carboxylate; Methyl-5-cis-{4-[2-(4-methanesulfonyloxy-phenyl)-ethoxy]-phenyl}-2-methyl-[1,3]dioxane-2-carboxylate; Methyl-2-methyl-5-trans-[4-(5-methyl-2-p-tolyl-oxazol-4-ylmethoxy)-phenyl]-[1,3]dioxane-2-carboxylate; Methyl-2-methyl-5-trans-{4-[2-(5-methyl-2-phenyl-oxazol-4-yl)-ethoxy]-phenyl}-[1,3]dioxane-2-carboxylate; Methyl-2-methyl-5-trans-{4-[2-(5-methyl-2-p-tolyl-oxazol-4-yl)-ethoxy]-phenyl}-[1,3]dioxane-2-carboxylate; Methyl-2-methyl-5-trans-{4-[4-methyl-2-(4-trifluoromethyl-phenyl)-thiazol-5-ylmethoxy]-phenyl}-[1,3]dioxane-2-carboxylate; Methyl-2-methyl-5-cis-{4-[4-methyl-2-(4-trifluoromethyl-phenyl)-thiazol-5-ylmethoxy]-phenyl}-[1,3]dioxane-2-carboxylate; Methyl-2-methyl-5-cis-{4-(2-[2-methyl-5-(4-methylsulfanyl-phenyl)-pyrrol-1-yl]-ethoxy}-phenyl)-[1,3]dioxane-2-carboxylate; Methyl-5-cis-[4-(2-tert-Butyl-5-methyl-oxazol-4-ylmethoxy)-phenyl]-2-methyl-[1,3]dioxane-2-carboxylate; Methyl-5-trans-[4-(2-tert-Butyl-5-methyl-oxazol-4-ylmethoxy)-phenyl]-2-methyl-[1,3]dioxane-2-carboxylate; Methyl-2-methyl-5-cis-{4-[2-(4-phenoxy-phenoxy)-ethoxy]-phenyl}-[1,3]dioxane-2-carboxylate; Methyl-2-methyl-5-trans-{4-[2-(4-phenoxy-phenoxy)-ethoxy]-phenyl}-[1,3]dioxane-2-carboxylate; Methyl-5-cis-[4-(2-fluoro-benzyloxy)-phenyl]-2-methyl-[1,3]dioxane-2-carboxylate; Methyl-5-trans-[4-(2-fluoro-benzyloxy)-phenyl]-2-methyl-[1,3]dioxane-2-carboxylate; Methyl-5-cis-[4-(5-tert-Butyl-2-p-tolyl-2H-pyrazol-3-ylmethoxy)-phenyl]-2-methyl-[1,3]dioxane-2-carboxylate; Methyl-5-trans-[4-(5-tert-Butyl-2-p-tolyl-2H-pyrazol-3-ylmethoxy)-phenyl]-2-methyl-[1,3]dioxane-2-carboxylate; Methyl-2-methyl-5-trans-[4-(2-oxo-3-phenyl-oxazolidin-5-ylmethoxy)-phenyl]-[1,3]dioxane-2-carboxylate; Methyl-2-methyl-5-cis-[4-(2-oxo-3-phenyl-oxazolidin-5-ylmethoxy)-phenyl]-[1,3]dioxane-2-carboxylate; Methyl-5-trans-{4-[2-(4-Methanesulfonyloxy-phenyl)-ethoxy]-phenyl}-2-methyl-[1,3]dioxane-2-carboxylate; Methyl-{2-Methyl-5-trans-[4-(3-methyl-4-oxo-3,4-dihydro-quinazolin-2-ylmethoxy)-phenyl]-[1,3]dioxane-2 carboxylate; 2-methyl-5-{4-[2-(5-methyl-2-phenyl-oxazol-4-yl)-ethoxy]-benzyl}-[1,3]dioxane-2-carboxylic acid and its pharmaceutically acceptable salts; 2-Methyl-5-{4-[2-(5-methyl-2-p-tolyl-oxazol-4-yl)-ethoxy]-benzyl}-[1,3]dioxane-2-carboxylic acid and its pharmaceutically acceptable salts; 2-Methyl-5-cis-[4-(5-methyl-2-phenyl-oxazol-4-ylmethoxy)-benzyl]-[1,3]dioxane-2-carboxylic acid and its pharmaceutically acceptable salts; 2-Methyl-5-cis-[4-(1-pyridin-2-yl-pyrrolidin-2-ylmethoxy)-benzyl]-[1,3]dioxane-2-carboxylic acid and its pharmaceutically acceptable salts; 2-Methyl-5-cis-{4-[2-(methyl-pyridin-2-yl-amino)-ethoxy]-benzyl}-[1,3]dioxane-2-carboxylic acid and its pharmaceutically acceptable salts; 2-Methyl-5-[4-(3-methyl-4-oxo-3,4-dihydro-quinazolin-2-ylmethoxy)-benzyl]-[1,3]dioxane-2-carboxylic acid and its pharmaceutically acceptable salts; 2-Methyl-5-[4-(2-phenoxazin-10-yl-ethoxy)-benzyl]-[1,3]dioxane-2-carboxylic acid and its pharmaceutically acceptable salts; 2-Methyl-5-cis-[4-(5-methyl-2-p-tolyl-oxazol-4-ylmethoxy)-benzyl]-[1,3]dioxane-2-carboxylic acid and its pharmaceutically acceptable salts; 5-cis-[4-(2-Carbazol-9-yl-ethoxy)-benzyl]-2-methyl-[1,3]dioxane-2-carboxylic acid and its pharmaceutically acceptable salts; 5-cis-[4-(2-Indol-1-yl-ethoxy)-benzyl]-2-methyl-[1,3]dioxane-2-carboxylic acid and its pharmaceutically acceptable salts; 5-{4-[2-(2,3-Dihydro-benzo[1,4]oxazin-4-yl)-ethoxy]-benzyl}-2-methyl-[1,3]dioxane-2-carboxylic acid and its pharmaceutically acceptable salts; 2-Methyl-5-cis-{4-[5-methyl-2-(5-methyl-thiophen-2-yl)-oxazol-4-ylmethoxy]-benzyl}-[1,3]dioxane-2-carboxylic acid and its pharmaceutically acceptable salts; 5-cis-{4-[2-(2,3-Dihydro-benzo[1,4]thiazin-4-yl)-ethoxy]-benzyl}-2-methyl-[1,3]dioxane-2-carboxylic acid and its pharmaceutically acceptable salts; 2-Methyl-5-cis-[4-(2-phenothiazin-10-yl-ethoxy)-benzyl]-[1,3]dioxane-2-carboxylic acid and its pharmaceutically acceptable salts; 5-cis-{4-[2-(4-Hexyl-3-oxo-3,4-dihydro-2H-benzo[1,4]oxazin-2-yl)-ethoxy]-benzyl}-2-methyl-[1,3]dioxane-2-carboxylic acid and its pharmaceutically acceptable salts; 2-Methyl-5-cis-(4-{2-[5-methyl-2-(5-methyl-thiophen-2-yl)-oxazol-4-yl]-ethoxy}-benzyl)-[1,3]dioxane-2-carboxylic acid and its pharmaceutically acceptable salts; 2-Methyl-5-cis-{4-[2-(5-methyl-2-phenyl-oxazol-4-yl)-ethoxy]-benzyl}-[1,3]dioxane-2-carboxylic acid and its pharmaceutically acceptable salts; 2-Methyl-5-trans-{4-[2-(5-methyl-2-phenyl-oxazol-4-yl)-ethoxy]-benzyl}-[1,3]dioxane-2-carboxylic acid and its pharmaceutically acceptable salts; 2-Methyl-5-cis-{4-[3-(4-phenoxy-phenoxy)-propoxy]-benzyl}-[1,3]dioxane-2-carboxylic acid and its pharmaceutically acceptable salts; 5-cis-{4-[2-(4-Methanesulfonyloxy-phenyl)-ethoxy]-benzyl}-2-methyl-[1,3]dioxane-2-carboxylic acid and its pharmaceutically acceptable salts; 5-cis-[4-(2-tert-Butyl-5-methyl-oxazol-4-ylmethoxy)-benzyl]-2-methyl-[1,3]dioxane-2-carboxylic acid and its pharmaceutically acceptable salts; 2-Methyl-5-cis-{4-[4-methyl-2-(4-trifluoromethyl-phenyl)-thiazol-5-ylmethoxy]-benzyl}-[1,3]dioxane-2-carboxylic acid and its pharmaceutically acceptable salts; 2-Methyl-5-cis-{4-[2-(4-phenoxy-phenoxy)-ethoxy]-benzyl}-[1,3]dioxane-2-carboxylic acid and its pharmaceutically acceptable salts; 5-cis-[4-(2-Fluoro-benzyloxy)-benzyl]-2-methyl-[1,3]dioxane-2-carboxylic acid and its pharmaceutically acceptable salts; 2-Methyl-5-cis-(4-{2-[2-methyl-5-(4-methylsulfanyl-phenyl)-pyrrol-1-yl]-ethoxy}-benzyl)-[1,3]dioxane-2-carboxylic acid and its pharmaceutically acceptable salts; 5-cis-{4-[2-(2-tert-Butyl-5-methyl-oxazol-4-yl)-ethoxy]-benzyl}-2-methyl-[1,3]dioxane-2-carboxylic acid and its pharmaceutically acceptable salts; 5-cis-[6-(2-Fluoro-benzyloxy)-naphthalen-2-ylmethyl]-2-methyl-[1,3]dioxane-2-carboxylic acid and its pharmaceutically acceptable salts; 5-cis-[6-(Benzyloxy)-naphthalen-2-ylmethyl]-2-methyl-[1,3]dioxane-2-carboxylic acid and its pharmaceutically acceptable salts; (Z)-2-Methyl-5-cis-{4-[2-(phenyl-pyridin-2-yl-methyleneaminooxy)-ethoxy]-benzyl}-[1,3]dioxane-2-carboxylic acid and its pharmaceutically acceptable salts; (E)-2-Methyl-5-cis-{4-[2-(phenyl-pyridin-2-yl-methyleneaminooxy)-ethoxy]-benzyl}-[1,3]dioxane-2-carboxylic acid and its pharmaceutically acceptable salts; 5-cis-[4-(5-tert-Butyl-2-p-tolyl-2H-pyrazol-3-ylmethoxy)-benzyl]-2-methyl-[1,3]dioxane-2-carboxylic acid and its pharmaceutically acceptable salts; 2-Methyl-5-cis-{4-[2-(5-methyl-2-p-tolyl-oxazol-4-yl)-ethoxy]-benzyl}-[1,3]dioxane-2-carboxylic acid and its pharmaceutically acceptable salts; 2-Methyl-5-trans-[4-(5-methyl-2-phenyl-oxazol-4-ylmethoxy)-benzyl]-[1,3]dioxane-2-carboxylic acid and its pharmaceutically acceptable salts; 2-Methyl-5-trans-[4-(1-pyridin-2-yl-pyrrolidin-2-ylmethoxy)-benzyl]-[1,3]dioxane-2-carboxylic acid and its pharmaceutically acceptable salts; 2-Methyl-5-trans-{4-[2-(methyl-pyridin-2-yl-amino)-ethoxy]-benzyl}-[1,3]dioxane-2-carboxylic acid and its pharmaceutically acceptable salts; 2-Methyl-5-trans-[4-(5-methyl-2-p-tolyl-oxazol-4-ylmethoxy)-benzyl]-[1,3]dioxane-2-carboxylic acid and its pharmaceutically acceptable salts; 5-trans-[4-(2-Carbazol-9-yl-ethoxy)-benzyl]-2-methyl-[1,3]dioxane-2-carboxylic acid and its pharmaceutically acceptable salts; 5-trans-[4-(2-Indol-1-yl-ethoxy)-benzyl]-2-methyl-[1,3]dioxane-2-carboxylic acid and its pharmaceutically acceptable salts; 2-Methyl-5-trans-{4-[5-methyl-2-(5-methyl-thiophen-2-yl)-oxazol-4-ylmethoxy]-benzyl}-[1,3]dioxane-2-carboxylic acid and its pharmaceutically acceptable salts; 5-trans-{4-[2-(2,3-Dihydro-benzo[1,4]thiazin-4-yl)-ethoxy]-benzyl}-2-methyl-[1,3]dioxane-2-carboxylic acid and its pharmaceutically acceptable salts; 2-Methyl-5-trans-[4-(2-phenothiazin-10-yl-ethoxy)-benzyl]-[1,3]dioxane-2-carboxylic acid and its pharmaceutically acceptable salts; 5-trans-{4-[2-(4-Hexyl-3-oxo-3,4-dihydro-2H-benzo[1,4]oxazin-2-yl)-ethoxy]-benzyl}-2-methyl-[1,3]dioxane-2-carboxylic acid and its pharmaceutically acceptable salts; 2-Methyl-5-trans-(4-{2-[5-methyl-2-(5-methyl-thiophen-2-yl)-oxazol-4-yl]-ethoxy}-benzyl)-[1,3]dioxane-2-carboxylic acid and its pharmaceutically acceptable salts; 2-Methyl-5-trans-{4-[2-(5-methyl-2-phenyl-oxazol-4-yl)-ethoxy]-benzyl}-[1,3]dioxane-2-carboxylic acid and its pharmaceutically acceptable salts; 2-Methyl-5-trans-{4-[2-(5-methyl-2-phenyl-oxazol-4-yl)-ethoxy]-benzyl}-[1,3]dioxane-2-carboxylic acid and its pharmaceutically acceptable salts; 2-Methyl-5-trans-{4-[3-(4-phenoxy-phenoxy)-propoxy]-benzyl}-[1,3]dioxane-2-carboxylic acid and its pharmaceutically acceptable salts; 5-trans-{4-[2-(4-Methanesulfonyloxy-phenyl)-ethoxy]-benzyl}-2-methyl-[1,3]dioxane-2-carboxylic acid and its pharmaceutically acceptable salts; 5-trans-[4-(2-tert-Butyl-5-methyl-oxazol-4-ylmethoxy)-benzyl]-2-methyl-[1,3]dioxane-2-carboxylic acid and its pharmaceutically acceptable salts; 2-Methyl-5-trans-{4-[4-methyl-2-(4-trifluoromethyl-phenyl)-thiazol-5-ylmethoxy]-benzyl}-[1,3]dioxane-2-carboxylic acid and its pharmaceutically acceptable salts; 2-Methyl-5-trans-{4-[2-(4-phenoxy-phenoxy)-ethoxy]-benzyl}-[1,3]dioxane-2-carboxylic acid and its pharmaceutically acceptable salts; 5-trans-[4-(2-Fluoro-benzyloxy)-benzyl]-2-methyl-[1,3]dioxane-2-carboxylic acid and its pharmaceutically acceptable salts; 2-Methyl-5-trans-(4-{2-[2-methyl-5-(4-methylsulfanyl-phenyl)-pyrrol-1-yl]-ethoxy}-benzyl)-[1,3]dioxane-2-carboxylic acid and its pharmaceutically acceptable salts; 5-trans-{4-[2-(2-tert-Butyl-5-methyl-oxazol-4-yl)-ethoxy]-benzyl}-2-methyl-[1,3]dioxane-2-carboxylic acid and its pharmaceutically acceptable salts; 5-trans-[6-(2-Fluoro-benzyloxy)-naphthalen-2-ylmethyl]-2-methyl-[1,3]dioxane-2-carboxylic acid and its pharmaceutically acceptable salts; 5-trans-[6-(Benzyloxy)-naphthalen-2-ylmethyl]-2-methyl-[1,3]dioxane-2-carboxylic acid and its pharmaceutically acceptable salts; (Z)-2-Methyl-5-trans-{4-[2-(phenyl-pyridin-2-yl-methyleneaminooxy)-ethoxy]-benzyl}-[1,3]dioxane-2-carboxylic acid and its pharmaceutically acceptable salts; (E)-2-Methyl-5-trans-{4-[2-(phenyl-pyridin-2-yl-methyleneaminooxy)-ethoxy]-benzyl}-[1,3]dioxane-2-carboxylic acid and its pharmaceutically acceptable salts; 5-trans-[4-(5-tert-Butyl-2-p-tolyl-2H-pyrazol-3-ylmethoxy)-benzyl]-2-methyl-[1,3]dioxane-2-carboxylic acid and its pharmaceutically acceptable salts; 2-Methyl-5-trans-{4-[2-(5-methyl-2-p-tolyl-oxazol-4-yl)-ethoxy]-benzyl}-[1,3]dioxane-2-carboxylic acid and its pharmaceutically acceptable salts; 2-Methyl-5-cis-[4-(5-methyl-2-phenyl-oxazol-4-ylmethoxy)-phenyl]-[1,3]dioxane-2-carboxylic acid and its pharmaceutically acceptable salts; 2-Methyl-5-cis{4-[2-(5-methyl-2-phenyl-oxazol-4-yl)-ethoxy]-phenyl}-[1,3]dioxane-2-carboxylic acid and its pharmaceutically acceptable salts; 2-Methyl-5-cis-[4-(2-phenoxazin-10-yl-ethoxy)-phenyl]-[1,3]dioxane-2-carboxylic acid and its pharmaceutically acceptable salts; 2-Methyl-5-cis-[4-(3-methyl-4-oxo-3,4-dihydro-quinazolin-2-ylmethoxy)-phenyl]-[1,3]dioxane-2-Carboxylic acid and its pharmaceutically acceptable salts; 5-cis-[4-(2-Indol-1-yl-ethoxy)-phenyl]-2-methyl-[1,3]dioxane-2-carboxylic acid and its pharmaceutically acceptable salts; 5-cis-{4-[2-(5-Ethyl-pyridin-2-yl)-ethoxy]-phenyl}-2-methyl-[1,3]dioxane-2-carboxylic acid and its pharmaceutically acceptable salts; 2-Methyl-5-cis-[4-(5-methyl-2-p-tolyl-oxazol-4-ylmethoxy)-phenyl]-[1,3]dioxane-2-carboxylic acid and its pharmaceutically acceptable salts; 2-Methyl-5-cis-{4-[2-(5-methyl-2-p-tolyl-oxazol-4-yl)-ethoxy]-phenyl}-[1,3]dioxane-2-carboxylic acid and its pharmaceutically acceptable salts; 5-cis-{4-[2-(4-Methanesulfonyloxy-phenyl)-ethoxy]-phenyl}-2-methyl-[1,3]dioxane-2-carboxylic acid and its pharmaceutically acceptable salts; 2-Methyl-5-trans-[4-(5-methyl-2-phenyl-oxazol-4-ylmethoxy)-phenyl]-[1,3]dioxane-2-carboxylic acid and its pharmaceutically acceptable salts; 2-Methyl-5-trans-[4-(5-methyl-2-p-tolyl-oxazol-4-ylmethoxy)-phenyl]-[1,3]dioxane-2-carboxylic acid and its pharmaceutically acceptable salts; 2-Methyl-5-trans-{4-[2-(5-methyl-2-phenyl-oxazol-4-yl)-ethoxy]-phenyl}-[1,3]dioxane-2-carboxylic acid and its pharmaceutically acceptable salts; 2-Methyl-5-trans-{4-[2-(5-methyl-2-p-tolyl-oxazol-4-yl)-ethoxy]-phenyl}-[1,3]dioxane-2-carboxylic acid and its pharmaceutically acceptable salts; 2-Methyl-5-trans-{4-[4-methyl-2-(4-trifluoromethyl-phenyl)-thiazol-5-ylmethoxy]-phenyl}-[1,3]dioxane-2-carboxylic acid and its pharmaceutically acceptable salts; 2-Methyl-5-cis-{4-[4-methyl-2-(4-trifluoromethyl-phenyl)-thiazol-5-ylmethoxy]-phenyl}-[1,3]dioxane-2-carboxylic acid and its pharmaceutically acceptable salts; 2-Methyl-5-cis-(4-{2-[2-methyl-5-(4-methylsulfanyl-phenyl)-pyrrol-1-yl]-ethoxy}-phenyl)-[1,3]dioxane-2-carboxylic acid and its pharmaceutically acceptable salts; 5-cis-[4-(2-tert-Butyl-5-methyl-oxazol-4-ylmethoxy)-phenyl]-2-methyl-[1,3]dioxane-2-carboxylic acid and its pharmaceutically acceptable salts; 5-trans-[4-(2-tert-Butyl-5-methyl-oxazol-4-ylmethoxy)-phenyl]-2-methyl-[1,3]dioxane-2-carboxylic acid and its pharmaceutically acceptable salts; 2-Methyl-5-cis-{4-[2-(4-phenoxy-phenoxy)-ethoxy]-phenyl}-[1,3]dioxane-2-carboxylic acid and its pharmaceutically acceptable salts; 2-Methyl-5-trans-{4-[2-(4-phenoxy-phenoxy)-ethoxy]-phenyl}-[1,3]dioxane-2-carboxylic acid and its pharmaceutically acceptable salts; 5-cis-[4-(2-Fluoro-benzyloxy)-phenyl]-2-methyl-[1,3]dioxane-2-carboxylic acid and its pharmaceutically acceptable salts; 5-trans-[4-(2-Fluoro-benzyloxy)-phenyl]-2-m yl-[1,3]dioxane-2-carboxylic acid and its pharmaceutically acceptable salts; 5-cis-[4-(5-tert-Butyl-2-p-tolyl-2H-pyrazol-3-ylmethyl)-phenyl]-2-methyl-[1,3]dioxane-2-carboxylic acid and its pharmaceutically acceptable salts; 5-trans-[4-(5-tert-Butyl-2-p-tolyl-2H-pyrazol-3-ylmethoxy)-phenyl]-2-methyl-[1,3]dioxane-2-carboxylic acid and its pharmaceutically acceptable salts; 2-Methyl-5-trans-[4-(2-oxo-3-phenyl-oxazolidin-5-ylmethoxy)-phenyl]-[1,3]dioxane-2-carboxylic acid and its pharmaceutically acceptable salts; 2-Methyl-5-cis-[4-(2-oxo-3-phenyl-oxazolidin-5-ylmethoxy)-phenyl]-[1,3]dioxane-2-carboxylic acid and its pharmaceutically acceptable salts; 5-trans-{4-[2-(4-Methanesulfonyloxy-phenyl}-ethoxy]-phenyl-2-methyl-[1,3]dioxane-2-carboxylic acid and its pharmaceutically acceptable salts; 2-Methyl-5-trans-[4-(3-methyl-4-oxo-3,4-dihydro-quinazolin-2-ylmethoxy)-phenyl]-[1,3]dioxane-2-carboxylic acid and its pharmaceutically acceptable salts;
[0249] The novel compounds of this invention may be prepared using the reactions and techniques described in this section. The reactions are performed in solvents appropriate to the reagents and materials employed and are suitable for the transformations being effected. It is understood by those skilled in the art that the nature and order of the synthetic steps presented may be varied for the purpose of optimizing the formation of the compounds of the present invention.
[0000]
[0250] i. reduction of compound of formula (II) wherein all the symbols are as defined earlier to compound of formula (III) wherein all the symbols are as defined earlier.
[0251] ii. reacting compound of formula (III) wherein all the symbols are as defined earlier with suitable ketoester of the formula RC(O)Y wherein R is as defined earlier and Y is COOR 1 where R 1 is alkyl or aryl to yield compound of formula (Ia) wherein Y represents COOR 1 where R 1 is alkyl or aryl and all other symbols are as defined earlier.
[0252] iii. hydrolysis of compound of general formula (Ia) wherein Y is COOR 1 where R 1 is alkyl or aryl and all other symbols are as defined earlier to yield compound of general formula (I) wherein Y is COOH and all other symbols are as defined earlier.
[0253] iv. compound of formula (I) where Y represents COOH or (Ia) where Y represents COOR 1 where R 1 represents alkyl or aryl and all other symbols are as defined earlier may optionally be converted to further compound of formula (I) where Y represents CONR 1 R 2 where in all the symbols are as defined earlier by reacting with appropriate amine. The reactions can be carried out by suitable modifications of methods & techniques known to those skilled in the art. As an example of general techniques and methods which may be used, the techniques described in “Comprehensive Organic Transformations” R. C. Larock (2 nd Ed., 1999) (VCH Publishers Inc.) and “Advanced Organic Chemistry”, J. March (4 th Ed.), John Wiley & Sons may be used with appropriate modifications.
[0254] Method A: The diester of the formula (II) may be reduced to diol of formula (III). Suitable reducing agents may be hydrides such as LiAlH 4 , NaBH 4 , diborane, NaBH 4 /BF 3 OEt 2 , LiBH 4 , DIBAH, and the like. Reaction may be carried out in suitable solvents appropriate for the reducing agent used e.g. with LiAlH 4 , NaBH 3 , diborane, NaBH 4 /BF 3 OEt 2 aprotic solvents such as THF, ether and the likes or their combinations are preferred. With NaBH 4 , LiBH 4 etc. alcoholic solvents used alone or as mixtures may also be used. The reaction may be carried out at a temperature in the range 0° C. to reflux temperature of the solvent(s) used and the reaction time may range from 1 to 24 hours.
[0255] Method D: The diol of formula (I) may be converted to dioxane of formula (Ia) by reacting with appropriate ketoester (RC(O)COOR 1 ) in presence of a Lewis acid e.g. boron trifluoride etherate complex and the like. Reaction may be conducted in an appropriate solvent e.g., polar solvent such as acetonitrile or N,N-dimethyl formamide (DMF), ether solvent such as tetrahydrofuran (THF) or diethyl ether, diisopropyl ether, 1,2-dimethoxyethane, halogenated hydrocarbon solvents such as chloroform or dichloromethane, hydrocarbon solvent such as benzene, toluene, hexane, heptane or a mixtures of appropriate solvents selected from those described above. The reaction may be carried out at a temperature in the range −20° C. to reflux temperature of the solvent(s) used and the reaction time may range from 1 to 48 hours.
[0256] Method D: The compound of formula (Ia) may be hydrolysed to compound of formula (I) using suitable base e.g., NaOH, LiOH, KOH and the like. Reaction may be conducted in suitable solvents e.g., alcohols like methanol, ethanol, propanol, isopropanol, butanol and the like, THF, water or mixtures thereof. The reaction may be carried out at a temperature in the range 20° C. to reflux temperature of the solvent(s) used and the reaction time may range from 1 to 48 hours.
[0000]
[0257] i. reacting compounds of general formula (IV) where all symbols are as defined earlier and L represents a leaving group such as halogen, mesylate, tosylate, triflate & the like with compounds of general formula (V), where all symbols are as defined earlier and Y represent COOR 1 where R 1 represents alkyl or aryl to yield compound of general formula (Ia) where all symbols are as defined earlier and Y represent COOR 1 where R 1 represents alkyl or aryl.
[0258] ii. hydrolysis of compound of general formula (Ia) wherein Y is COOR 1 where R 1 represents alkyl or aryl and all other symbols are as defined earlier to yield compound of general formula (I) where in Y is COOH and all other symbols are as defined earlier.
[0259] Method C: The compound of formula (Ia) may be prepared by reacting compound of formula (IV) with compound of formula (V) under suitable conditions. The reaction may be carried out in presence of solvents such as acetone, tetrahydrofuran, dimethyl sulfoxide, dioxane, acetonitrile, dimethyl formamide, benzene, toluene, petroleum ether, heptane, hexane, 2-butanone, xylene, alcohols such as methanol, ethanol, propanol, butanol, iso-butanol tertbutanol, pentanol and the like or mixtures of appropriate solvents selected from those above. Bases such as alkali metal carbonates such as K 2 CO 3 , Na 2 CO 3 , CsCO 3 , and the like; or alkali metal hydroxides such as NaOH, KOH and the like, may be used in this reaction. Alkali metal hydrides such as NaH, KH can be used whenever solvent employed is not protic or contain carbonyl group. The reaction may be carried out at a temperature in the range 0° C. to reflux temperature of the solvent(s) used and the reaction time may range from 1 to 48 hours. The intermediate of general formula (V) may be prepared by one or more routes or combinations of reactions outlined in scheme III outlined below which comprises:
[0000]
[0260] i. reduction of compound of formula (VI) to compound of formula (VII) wherein all the symbols are as defined earlier and P represents a suitable protecting group for e.g. benzyl, methoxymethyl and the like.
[0261] ii. reacting compound of formula (V with suitable ketoester of the formula RC(O)Y wherein R is as defined earlier and Y represents COOR 1 where R 1 is alkyl or aryl to yield compound of formula (VIII) wherein P represents a suitable protecting group i.e benzyl, methoxymethyl and the like and Y represents COOR 1 where R 1 is alkyl or aryl and all other symbols are as defined earlier.
[0262] iii. reprotection of compound of formula (VIII) to yield compound of formula (V) wherein Y represents COOR 1 where R 1 represents alkyl or aryl and all other symbols are as defined earlier.
[0263] Method A: The compound of formula (VI) may be reduced to compound of formula (VII) by a suitable reducing agent as described in method A earlier.
[0264] Method B: The diol of formula (VI) may be converted to a compound of formula (VIII) by a procedure similar to that described in method B earlier.
[0265] method E: The compound of formula (VIII) may be deprotected to yield compound of formula (V). Suitable deprotecting methods known in the art for e.g. in T. W. Greene and P. G. M. Wuts “Protective groups in Organic Synthesis”, John Wiley L, Sons, Inc, 1999, 3 rd Ed., 201-245 along with references therein may be employed depending on the protecting group used.
[0266] The invention is explained in greater detail by the examples given below, which are provided by way of illustration only and therefore should not be construed to limit the scope of the invention.
[0267] It will be appreciated that one or more of the processes described in the general schemes above may be used to prepare the compounds of the present invention.
[0268] 1H spectral data given in the tables (vide infra) are recorded using a 300 MHz spectrometer (Bruker A VANCE-300) and reported in δ scale. Until and otherwise mentioned the solvent used for NMR is CDCl 3 using tetramethyl silane as the internal standard.
Example 1
Methyl-2-methyl-5-{4-[2-(5-methyl-2-p-tolyl-oxazol-4-yl)-ethoxy]-benzyl}-[1,3]dioxane-2-carboxylate
[0269] To a solution of 2-{4-[2-(5-Methyl-2-p-tolyl-oxazol-4-yl)-ethoxy]-benzyl}-propane-1,3-diol (1 g) in acetonitrile (10 mL) was added methyl pyruvate (0.94 mL) followed by 98% boron trifluoride diethyl ether complex (0.65 mL) and the reaction mixture was stirred at ambient temperature for extended hours (tlc). The reaction mixture was poured in to a solution of sodium bicarbonate and extracted with ethyl acetate. The combined organic extract was washed with water, brine solution, dried over sodium sulphate and evaporated under reduced pressure. The crude product was flash chromatographed over silicagel using a mixture of ethyl acetate and petroleum ether as eluent to obtain 910 mg of pure product.
[0270] 1 H NMR: 1.59 (3H, s), 2.26 (2H, s), 2.35 (3H, s), 2.38 (3H, s), 2.91-2.97 (3H, m), 3.45 (2H, t, J=10.9 Hz), 3.7-3.9 (5H, m), 4.2 (2H, t, J=6.7 Hz), 6.82 (2H, t) J=7.2 Hz), 6.97 (1H, d, J=8.46 Hz), 7.09 (1H, t, J=8.48 Hz), 7.23 (2H, d, J=8.07 Hz), 7.85 (2H, d, J=8.07 Hz).
[0271] Yield: 74%
Example 2
Methyl-2-methyl-5-cis-{4-[2-(5-methyl-2-phenyl-oxazol-4-yl)-ethoxy]-benzyl}-[1,3]dioxane-2-carboxylate
Step 1: Preparation of Methyl-5-(4-benzyloxy-benzyl)-2-methyl-[1,3]dioxane-2-carboxylate
[0272] 2-(4-Benzyloxy-benzyl)-propane-1,3-diol (37 g) was dissolved in 200 mL of acetonitrile, and 50.3 mL of methyl pyruvate was added. To the mixture, 39.2 mL of boron trifluoride diethyl ether complex (98%) was added with stirring at ambient temperature, and stirring was continued for 3-6 hours at ambient temperature. The reaction mixture was poured into an aqueous solution of sodium bicarbonate and extracted with ethyl acetate. The organic extract was washed with water, dried over sodium sulfate and evaporated under reduced pressure. The crude product was flash chromatographed over silica gel using a mixture of ethyl acetate and petroleum ether as eluent to obtain 18 g of pure product.
Step 2. Preparation of cis Methyl-5-(4-hydroxy-benzyl)-2-methyl-[1,3]dioxane-2-carboxylate
[0273] To a suspension of 10% palladium on charcoal (3.4 g) in methanol (100 mL) was added Methyl-5-(4-benzyloxy-benzyl)-2-methyl-[1,3]dioxane-2-carboxylate (18 g) prepared in step 1 above followed by ammonium formate (13 g) and the reaction mixture was heated to reflux for 2-5 hours. The reaction mixture was cooled to ambient temperature and the catalyst was filtered off. The filtrate was evaporated, the residue was taken in ethyl acetate and washed with water. The organic extract was dried over sodium sulfate and evaporated under reduced pressure to yield 13 g of product. This was re-crystallised from a mixture of ethyl acetate and petroleum ether to obtain 7 g of the desired product.
Step 3: Preparation of cis Methyl-2-methyl-5-{4-[2-(5-methyl-2-phenyl-oxazol-4-yl)-ethoxy]-benzyl}-[1,3]dioxane-2-carboxylate
[0274] A mixture of cis methyl-5-(4-hydroxy-benzyl)-2-methyl-[1,3]dioxane-2-carboxylate (prepared in step 2 above) (750 mg) 2-(5-methyl-2-phenyl-oxazol-4-yl)-ethyl methane sulfonate (790 mg) and potassium carbonate (780 mg) in anhydrous dimethyl formamide (10 mL) was stirred at 80° C. for extended periods in an inert atmosphere. The reaction mixture was cooled to ambient temperature, poured into ice cold water and extracted with ethyl acetate. The combined organic extract was washed with water, brine solution, dried over sodium sulphate and evaporated under reduced pressure. The crude product was flash chromatographed over silica gel using a mixture of ethyl acetate and petroleum ether as eluent to obtain 971 mg of pure product.
[0275] 1 H NMR: 1.49 (3H, s), 2.27 (3H, s), 2.32 (3H, s), 2.96 (2H, t, J=6.66 Hz), 3.45 (2H, t, J=10.4 Hz), 3.83-3.9 (5H, m), 4.21 (2H, t, J=6.72 Hz), 6.73-6.75 (3H, dd, J=6.57 & 2.01 Hz), 6.97 (3H, dd, J=3.55 & 6.57 Hz), 7.39-7.44 (2H, m), 7.97 (1H, dd, J=7.92 & 2.46 Hz).
[0276] Yield: 76%
[0277] The following compounds are prepared by procedure similar to those described in examples 1 or 2 with appropriate variations of reactants, reaction conditions and quantities of reagents.
Example 3
Methyl-2-methyl-5-{4-[2-(5-methyl-2-phenyl-oxazol-4-yl)-ethoxy]-benzyl}-[1,3]dioxane-2-carboxylate
[0278] 1 H NMR: 1.49 (3H, s), 2.26 (3H, s), 2.37 (3H, s), 2.91-2.99 (3H, q, J=13.74 & 6.69 Hz), 3.45 (2H, t, J=10.44 Hz), 3.73-3.93 (5H, m), 4.21 (2H, t, J=6.72 Hz), 6.82 (3H, t, J=7.23 Hz), 6.98 (1H, d, J=8.55 Hz), 7.10 (1H, d, J=8.43 Hz), 7.42 (3H, d, J=5.76 Hz), 7.98 (2H, t, J=2.37 Hz).
[0279] Yield: 21.4%
Example 4
Methyl-2-methyl-5-cis-[4-(5-methyl-2-phenyl-oxazol-4-ylmethoxy)-benzyl]-[1,3]dioxane-2-carboxylate
[0280] 1 H NMR: 1.5 (3H, s), 2.3 (3H, m), 2.4 (3H, s), 3.5 (1H, t, J=11.3 Hz), 3.7 (1H, m), 3.8 (3H, s), 3.9 (2H, m), 4.9 (2H, s), 6.9 (2H, t, J=7.9 Hz), 7.0 (2H, d, J=8.5 Hz), 7.4 (3H, m), 8.0 (2H, m).
[0281] Yield: 62.0%
Example 5
Methyl-2-methyl-5-cis-[4-(1-pyridin-2-yl-pyrrolidin-2-ylmethoxy)-benzyl]-[1,3]dioxane-2-carboxylate
[0282] 1 H NMR: 1.5 (3H, s), 2.1 (2H, m), 2.2 (2H, m), 2.26 (3H, m), 3.3 (2H, m), 3.5 (3H, m), 3.8 (3H, s), 3.9 (2H, m), 4.2 (1H, dd, J=9.1 & 3.1 Hz), 4.5 (1H, m), 6.4 (1H, d, J=8.5 Hz), 6.5 (1H, t, J=5.9 Hz), 6.9 (2H, d, J=8.5 Hz), 7.0 (2H, d, J=8.5 Hz), 7.4 (1H, m), 8.1 (1H, d, J=4.0 Hz).
[0283] Yield: 44%
Example 6
Methyl-2-methyl-5-cis-{4-[2-(methyl-pyridin-2-yl-amino)-ethoxy]-benzyl}-[1,3]dioxane-2-carboxylate
[0284] 1 H NMR: 1.5 (3H, s), 2.3 (3H, m), 3.1 (3H, s), 3.4 (2H, m), 3.7 (2H, m), 3.9 (3H, s), 3.9 (231, t, J=5.6 Hz), 4.1 (2H, t, J=5.5 Hz), 6.5 (2H, m), 6.8 (2H, d, J=3.4 Hz), 7.0 (2H, d, J=8.4 Hz), 7.4 (1H, m), 8.1 (1H, d, J=4.3 Hz).
[0285] Yield: 76%
Example 7
Methyl 2-methyl-5-[4-(3-methyl-4-oxo-3,4-dihydro-quinazolin-2-ylmethoxy)-benzyl]-[1,3]dioxane-2-carboxylate
[0286] 1 H NMR: 1.49 (3H, s), 2.28 (2H, s), 2.94-2.97 (1H, d, J=7.86 Hz), 3.46 (2H, t, J=12.39 Hz), 3.74 (3H, s), 3.82-3.94 (5H, s) 5.15 (2H, d, J=2.16 Hz), 6.95-7.05 (1H, d, J=8.46 Hz), 7.14-7.17 (1H, d, J=8.46 Hz), 7.51 (1H, t, J=6.75 Hz), 7.69-7.79 (2H, m), 8.30 (1H, t, J=7.92 Hz).
[0287] Yield: 56.8%
Example 8
Methyl-2-methyl-5-cis-[4-(5-methyl-2-p-tolyl-oxazol-4-ylmethoxy)-benzyl]-[1,3]dioxane-2-carboxylate
[0288] 1 H NMR: 1.5 (3H, s), 2.2 (3H, m), 2.39 (3H, s), 2.41 (3H, s), 3.4 (2H, t, J=10.9 Hz), 3.8 (3H, s), 3.9 (2H, m), 4.9 (2H, s), 6.9 (23 d, J=8.5 Hz), 7.0 (2H, d, J=8.5 Hz), 7.2 (2H, m), 7.9 (2H, d, J=8.1 Hz).
[0289] Yield: 97%
Example 9
Methyl-5-cis-[4-(2-carbazol-9-yl-ethoxy)-benzyl]-2-methyl-[1,3]dioxane-2-carboxylate
[0290] 1 H NMR: 1.5 (3H, s), 2.2 (3H, m), 3.4 (2H, t, J=10.2 Hz), 3.8 (3H, s), 3.9 (2H, m), 4.3 (2H, t, J=6.0 Hz), 4.7 (2H, t, J=6.0 Hz), 6.7 (2H, d, J=8.4 Hz), 6.9 (2H, d, J=8.4 Hz), 7.2 (2H, m), 7.5 (4H, m), 8.1 (2H, d, J=7.7 Hz).
[0291] Yield: 77%
Example 10
Methyl-5-cis-[4-(2-indol-1-yl-ethoxy)-benzyl]-2-methyl-[1,3]dioxane-2-carboxylate
[0292] 1 H NMR: 1.5 (3H, s), 2.26 (3H, m), 3.4 (2H, m), 3.9 (5H, m), 4.2 (2H, t, J=5.57 Hz), 4.5 (2H, t, J=5.66 Hz), 6.5 (1H, d, J=2.5 Hz), 6.7 (2H, d, J=7.1 Hz), 6.9 (2H, d, J=8.3 Hz), 7.1 (1H, t, J=7.4 Hz), 7.2 (2H, d, J=3.3 Hz), 7.4 (1H, m), 7.6 (1H, d, J=7.8 Hz).
[0293] Yield: 55.5%
Example 11
Methyl-5-{4-[2-(2,3-dihydro-benzo[1,4]oxazin-4-yl)-ethoxy]-benzyl}-2-methyl-[1,3]dioxane-2-carboxylate
[0294] 1 H NMR: 1.5 (3H, s), 2.2 (3H, m), 2.9 (2H, m), 3.5 (2H, m), 3.7 (2H, t, J=5.7 Hz), 3.77 (2H, m), 3.8 (5H, m), 3.9 (2H, m), 4.1 (2H, m), 4.2 (2H, t, J=4.4 Hz), 6.6 (1H, m), 6.7 (1H, m), 6.7-6.8 (4H, complex), 7.0 (1H, d, J=8.5 Hz), 7.1 (1H, d, J=8.5 Hz).
[0295] Yield: 97%
Example 12
Methyl-2-methyl-5-cis-{4-[5-methyl-2-(5-methyl-thiophen-2-yl)-oxazol-4-ylmethoxy]-benzyl}-[1,3]dioxane-2-carboxylate
[0296] 1 H NMR: 1.6 (3H, s), 2.2 (3H, m), 2.3 (3H, s), 2.5 (3H, s), 3.5 (2H, t, J=11 Hz), 3.8 (3H, s), 3.9 (2H, dd, J=12 & 3.6 Hz), 4.9 (2H, s), 6.7 (1H, m), 6.9 (2H, d, J=8.6 Hz), 7.0 (2H, d, J=8.6 Hz), 7.4 (1H, d, J=3.5 Hz).
[0297] Yield: 80%
Example 13
Methyl-2-methyl-5-cis-(4-{2-[5-methyl-2-(5-methyl-thiophen-2-yl)-oxazol-4-yl]-ethoxy)-benzyl}-[1,3]dioxane-2-carboxylate
[0298] 1 H NMR: 1.5 (3H, s), 2.2 (3H, m), 2.3 (3H, s), 2.5 (3H, s), 2.9 (2H, t, J=6.5 Hz), 3.4 (2H, m), 3.9 (5H, m), 4.2 (2H, t, J=6.6 Hz), 6.7 (1H, m), 6.8 (2H, d, J=8.5 Hz), 7.0 (2H, d, J=8.5 Hz), 7.3 (1H, d, J=3.6 Hz).
[0299] Yield: 55.5%
Example 14
Methyl-2-methyl-5-cis-{4-[3-(4-phenoxy-phenoxy)-propoxy]-benzyl}-[1,3]dioxane-2-carboxylate
[0300] 1 H NMR: 1.49 (3H, s), 2.21-2.35 (5H, m), 3.46 (2H, t, J=10.86 Hz), 3.82-3.91 (5H, m), 4.13 (4H, t, J=6.03 Hz), 6.81-7.06 (1H, m), 7.30 (2H, m)
[0301] Yield: 72.7%
Example 15
Methyl-5-cis-{4-[2-(4-Methanesulfonyloxy-phenyl)-ethoxy]-benzyl}-2-methyl-[1,3]dioxane-2-carboxylate
[0302] 1 H NMR: 1.49 (3H, s), 2.27 (3H, s), 3.09 (2H, t, J=6.57 Hz), 3.13 (3H, s), 3.45 (2H, t, J=11.73 Hz), 3.82-3.92 (5H, m), 4.13 (2H, t, J=6.15 Hz), 6.79 (2H, d, J=8.46 Hz), 7.00 (2H, d, J=3.46 Hz), 7.23 (2H, d, J=8.55 Hz), 7.33 (2H, d, J=8.43 Hz).
[0303] Yield: 100%
Example 16
Methyl-5-cis-[4-(2-tert-Butyl-5-methyl-oxazol-4-ylmethoxy)-benzyl]-2-methyl-[1,3]dioxane-2-carboxylate
[0304] 1 H NMR: 1.37 (9H, s), 1.57 (3H, s), 6.29 (6H, d, J=7.29 Hz), 3.46 (2H, m), 3.84-3.90 (5H, m), 4.85 (2H, s), 6.88 (2H, d, J=8.31 Hz), 7.00 (2H, d, J=8.01 Hz).
[0305] Yield: 100%
Example 17
Methyl-2-methyl-5-cis-{4-[4-methyl-2-(4-trifluoromethyl-phenyl)-thiazol-5-ylmethoxy]-benzyl}-[1,3]dioxane-2-carboxylate
[0306] 1 H NMR: 1.50 (3H, s), 2.28 (3H, m), 2.50 (3H, s), 3.47 (2H, t, J=5.73 Hz), 3.84 (3H, s), 3.86-3.90 (2H, m), 5.17 (2H, s), 6.72-6.97 (2H, d, J=8.6 Hz), 7.05 (2H, d, J=8.54 Hz), 7.67 (2H, d, J=8.19 Hz), 8.01 (2H, d, J=8.28 Hz).
[0307] Yield: 95.1%
Example 18
Methyl-2-methyl-5-cis-{4-[2-(4-phenoxy-phenoxy)-ethoxy]-benzyl}-[1,3]dioxane-2-carboxylate
[0308] 1 H NMR: 1.5 (3H, s), 2.3 (3H, m), 3.4-3.5 (2H, t, J=10.45 Hz), 3.8 (3H, s), 3.9 (2H, m), 4.3 (4H, s), 6.8-7.0 (11H, complex), 7.3 (2H, m).
[0309] Yield: 66%
Example 19
Methyl-5-cis-[4-(2-fluoro-benzyloxy)-benzyl]-2-methyl-[1,3]dioxane-2-carboxylate
[0310] 1 H NMR: 1.5 (3H, s), 2.3 (3H, m), 3.4-3.5 (2H, t, J=10.8 Hz), 3.8 (3H, s), 3.9 (2H, m), 5.1 (2H, s), 6.9 (2H, d, J=8.5 Hz), 7.0 (2H, d, J=8.5 Hz), 7.1 (2H, m), 7.3 (1H, m), 7.5 (1H, m).
[0311] Yield: 79%
Example 20
Methyl-2-methyl-5-[4-(2-phenoxazin-10-yl-ethoxy)-benzyl]-[1,3]dioxane-2-carboxylate
[0312] 1 H NMR: 1.5 (3H, s), 2.27 (3H, m), 3.4 (2H, t, J=10.7 Hz), 3.9-4.0 (7H, m), 4.1 (2H, t, J=6.6 Hz), 6.6 (6H, m), 6.7 (4H, m), 7.0 (2H, d, J=8.4 Hz).
[0313] Yield: 93%
Example 21
Methyl-2-methyl-5-cis-[4-(2-oxo-3-phenyl-oxazolidin-5-ylmethoxy)-benzyl]-[1,3]dioxane-2-carboxylate
[0314] 1 H NMR: 1.5 (3H, s), 2.28 (3H, m), 3.4 (2H, s), 3.8 (5H, m), 4.0 (1H, m), 4.2 (31H, m), 4.9 (1H, m), 6.8 (2H, d, J=8.4 Hz), 7.0 (2H, d, J=8.3 Hz), 7.1 (1H, t, J=7.3 Hz), 7.4 (2H, t, J=7.5 Hz), 7.5 (2H, d, J=7.9 Hz).
[0315] Yield: 75.0%
Example 22
Methyl-5-cis-{4-[2-(2,3-dihydro-benzo[1,4]thiazin-4-yl)-ethoxy]-benzyl}-2-methyl-[1,3]dioxane-2-carboxylate
[0316] 1 H NMR: 1.49 (3H, s), 2.25 (3H, s), 3.04 (2H, d, J=5.11 & 2.83 Hz), 3.5 (2H, t), 3.70-3.90 (9H, m), 4.14 (2H, t, J=5.85 Hz), 6.62 (1H, t), 6.71 (1H, d, J=7.98 Hz), 6.79 (2H, d, J=8.58 Hz), 6.95-7.10 (4H, m).
[0317] Yield: 88.2%
Example 23
Methyl-2-methyl-5-cis-[4-(2-phenothiazin-10-yl-ethoxy)-benzyl]-[1,3]dioxane-2-carboxylate
[0318] 1 H NMR: 1.49 (3H, s), 2.26 (3H, s), 3.45 (2H, t, J=10.89 Hz), 3.77-3.94 (5H, m), 4.29 (4H, s), 6.80 (2H, d, J=8.58 Hz), 6.91-6.97 (6H, m), 7.09-7.31 (4H, m).
[0319] Yield: 100%
Example 24
Methyl-5-cis-{4-[2-(4-hexyl-3-oxo-3,4-dihydro-2H-benzo[1,4]oxazin-2-yl)-ethoxy]-benzyl}-2-methyl-[1,3]dioxane-2-carboxylate
[0320] 1 H NMR: 0.88 (3H, m), 1.33 (6H, m), 1.50 (3H, s), 1.65 (2H, m), 2.19-2.27 (5H, m), 3.48 (2H, m), 3.84-3.93 (7H, m), 4.15-4.20 (2H, m), 4.77 (1H, m), 6.81 (2H, d, J=8.58 Hz), 6.91-7.32 (6H, m).
[0321] Yield: 60%
Example 25
Methyl-2-methyl-5-cis-(4-{2-[2-methyl-5-(4-methylsulfanyl-phenyl)-pyrrol-1-yl]-ethoxy}-benzyl)-[1,3]dioxane-2-carboxylate
[0322] 1 H NMR: 1.49 (3H, s), 2.24 (3H, s), 2.36 (3H, s), 2.51 (3H, s), 3.44 (2H, t, J=10.8 Hz) 3.83 (3H, s), 3.87-3.93 (4H, m), 4.26 (2H, t, J=6.57 Hz), 5.95 (it d, J=3.12 Hz), 6.03 (1H, d, J=3.36 Hz), 6.58 (2H, d, J=8.49 Hz), 6.93 (2H, d, J=3.43 Hz), 7.26-7.33 (4H, m).
[0323] Yield: 47.6%.
Example 26
Methyl-5-cis-{4-[2-(2-tert-Butyl-5-methyl-oxazol-4-yl)-ethoxy]-benzyl}-2-methyl-[1,3]dioxane-2-carboxylate
[0324] 1 H NMR: 1.33 (9H, s), 1.49 (3H, s), 2.20 (3H, s), 2.23 (3H, s), 2.86 (2H, t, J=6.75 Hz), 3.45 (2H, t, J=10.44 Hz), 3.84-3.90 (5H, m), 4.12 (2H, t, J=6.63 Hz), 6.76 (2H, dd, J=13.71 & 8.55 Hz), 6.94-7.00 (2H, m).
[0325] Yield: 100%.
Example 27
(Z)-Methyl-2-methyl-5-cis-{4-[2-(phenyl-pyridin-2-yl-methyleneaminooxy)-ethoxy]-benzyl}-[1,3]dioxane-2-carboxylate
[0326] 1 H NMR: 1.49 (3H, s), 2.04 (3H, s), 3.46 (2H, t, J=10.65 Hz), 3.84 (3H, s), 3.88 (2H, dd, J=11.7 & 3.27 Hz), 4.25 (2H, t, J=5.07 Hz), 4.57 (2H, t, J=4.62 Hz), 6.83 (2H, d, J=8.58 Hz), 6.99 (2H, d, J=8.55 Hz), 7.27-7.29 (1H, m), 7.40 (5H, m), 7.66-7.73 (2H, m), 8.61 (1H, d, J=4.59 Hz).
[0327] Yield: 72.5%.
Example 28
(E)-Methyl-2-methyl-5-cis-{4-[2-(phenyl-pyridin-2-yl-methyleneaminooxy)-ethoxy]-benzyl}-[1,3]dioxane-2-carboxylate
[0328] 1 H NMR: 1.49 (3H, s), 2.04 (3H, s), 3.46 (21, J=10.65 Hz), 3.84 (3H, s), 3.88 (2H, dd, J=11.7 & 3.27 Hz), 4.23 (21, J=5.10 Hz), 4.50 (2H, t, J=4.86 Hz), 6.83 (2H, d, J=8.58 Hz), 6.99 (2H, d, J=8.55), 7.29-7.36 (41H, m), 7.45 (2H, dd, J=7.44 & 1.56 Hz), 7.53 (1H, d, J=7.8 Hz) 7.60 (1H, m), 8.70 (1H, d, J=4.8 Hz).
[0329] Yield: 66%.
Example 29
Methyl-2-methyl-5-{4-[2-(5-methyl-2-p-tolyl-oxazol-4-yl)-ethoxy]-benzyl}-[1,3]dioxane-2-carboxylate
[0330] 1 H NMR: 1.49 (3H, s), 2.04 (3H, s), 2.35 (3H, s), 2.38 (3H, s), 2.95 (2H, t, J=6.69 Hz) 3.45 (2H, t, J=9.0 Hz), 3.84-3.90 (5H, m), 4.20 (2H, t, J=13.5 Hz), 6.74 (2H, d, J=8.43 Hz), 6.80 (2H, d, J=8.55 Hz), 6.97 (2H, dd, J=8.37 & 6.12 Hz), 7.85 (2H, d, J=8.16 Hz).
[0331] Yield: 79%
Example 30
Methyl-5-cis-[4-(5-tert-Butyl-2-p-tolyl-2H-pyrazol-3-ylmethoxy)-benzyl]-2-methyl-[1,3]dioxane-2-carboxylate
[0332] 1 H NMR: 1.3 (9H, s), 1.5 (3H, s), 2.3 (3H, m), 2.4 (3H, s), 3.5 (2H, t, J=11 Hz), 3.8 (3H, s), 3.9 (2H, dd, J=12 & 3 Hz), 4.8 (2H, s), 6.4 (1H, s), 6.8 (2H, d, J=8.5 Hz), 7.0 (2H, d, J=8.5 Hz), 7.2 (2H, d, J=8.2 Hz), 7.4 (2H, d, J=8.3 Hz).
[0333] Yield: 50%.
Example 31
Methyl-5-[6-(2-fluoro-benzyloxy)-naphthalen-2-ylmethyl]-2-methyl-[1,3]dioxane-2-carboxylate
[0334] 1 H NMR: 1.50 (2H, s), 1.61 (1H, s), 2.44-2.46 (2H, m), 3.14 (1H, d, J=7.95 Hz), 3.53 (1H, t, J=10.92 Hz), 3.80-3.97 (6H, m), 5.24 (2H, s), 7.08-7.34 (6H, m), 7.47 (1H, s), 7.53-7.69 (3H, s).
[0335] Yield: 60%.
Example 32
Methyl-5-[6-(benzyloxy)-naphthalen-2-ylmethyl]-2-methyl-[1,3]dioxane-2-carboxylate
[0336] 1 H NMR: 1.50 (2H, s), 1.61 (1H, s), 2.48 (2H, m), 3.12 (1H, d, J=7.68 Hz), 3.53 (1H, t, J=10.77 Hz), 3.80-3.97 (6H, m), 5.17 (2H, s), 7.20-7.68 (11H, m).
[0337] Yield: 60%.
Example 33
Methyl-2-methyl-5-cis-[4-(5-methyl-2-phenyl-oxazol-4-ylmethoxy)-phenyl]-[1,3]dioxane-2-carboxylate
Step 1: Preparation of Methyl-5-cis-(4-benzyloxy-phenyl)-2-methyl-[1,3]dioxane-2-carboxylate
[0338] 2-(4-Benzyloxy-phenyl)-propane-1,3-diol (40 g) was dissolved in 200 mL of acetonitrile, and 56.4 mL of methyl pyruvate was added. To the mixture, 39.2 mL of boron trifluoride diethyl ether complete (98%) was added with stirring at ambient temperature, and stirring was continued for 2 hours at ambient temperature. The reaction mixture was poured into an aqueous solution of sodium bicarbonate and extracted with ethyl acetate. The organic extract was washed with water, dried over sodium sulfate and evaporated under reduced pressure. The crude product was flash chromatographed over silica gel using 7% ethyl acetate in petroleum ether as eluent and the fractions eluted earlier were evaporated to obtain 19.3 g of pure product.
Step 2: Preparation of Methyl-5-cis-(4-hydroxy-phenyl)-2-methyl-[1,3]dioxane-2-carboxylate
[0339] To a suspension of 10% palladium on charcoal (2.0 g) in methanol (100 mL) was added Methyl-5-cis-(4-benzyloxy-phenyl)-2-methyl-[1,3]dioxane-2-carboxylate (19.3 g) prepared in step 1 above followed by ammonium formate (14.2 g) and the reaction mixture was heated to reflux and continued heating. The reaction mixture was cooled to ambient temperature and the catalyst was filtered off. The filtrate was evaporated, the residue was taken in ethyl acetate and washed with water. The organic extract was dried over sodium sulfate and evaporated under reduced pressure to yield 13.7 g of product.
Step 3: Methyl-2-methyl-5-cis-[4-(5-methyl-2-phenyl-oxazol-4-ylmethoxy)-phenyl]-[1,3]dioxane-2-carboxylate
[0340] A mixture of Methyl-5-cis-(4-hydroxy-phenyl)-2-methyl-[1,3]dioxane-2-carboxylate (prepared in step 2 above) (600 mg) 4-Chloromethyl-5-methyl-2-phenyl-oxazole (494 mg) and potassium carbonate (657 mg) in anhydrous dimethyl formamide wag stirred at 55° C. for 18 hours in an inert atmosphere. The reaction mixture was cooled to ambient temperature, poured into ice cold water and extracted with ethyl acetate. The combined organic extract was washed with water, brine solution, dried over sodium sulphate and evaporated under reduced pressure. Crude product was flash chromatographed over silica gel using ethyl acetate in petroleum ether as eluent to obtain 850 mg of pure product.
[0341] 1 H NMR: 1.58 (3H, s), 2.42 (3H, s), 3.2 (1H, m), 3.8 (2H, d, J=11.8 Hz), 3.88 (3H, s), 4.05 (2H, dd, J=4.6 & 11.8 Hz), 4.96 (2H, s), 6.95 (2H, d, J=8.6 Hz), 7.0 (2H, d, J=8.6 Hz), 7.4 (3H, m), 8.00 (2H, m).
[0342] Yield: 34%
Example 34
Methyl-2-methyl-5-trans-[4-(5-methyl-2-phenyl-oxazol-4-ylmethoxy)-phenyl]-[1,3]dioxane-2-carboxylate
Step 1: Preparation of Methyl-5-trans-(4-benzyloxy-phenyl)-2-methyl-[1,3]dioxane-2-carboxylate
[0343] The fractions eluted later in step 1 of example 33 were evaporated to obtain 24.0 g of pure product.
Step 2: Preparation of Methyl-5-trans-(4-hydroxy-phenyl)-2-methyl-[1,3]dioxane-2-carboxylate
[0344] To a suspension of 10% palladium on charcoal (2.6 g) in methanol (100 mL) was added Methyl-5-trans-(4-benzyloxy-phenyl)-2-methyl-[1,3]dioxane-2-carboxylate (26 g) prepared in step 1 above followed by ammonium formate (19.16 g) and the reaction mixture was heated to reflux for 1 hour. The reaction mixture was cooled to ambient temperature and the catalyst was filtered off. The filtrate was evaporated, the residue was taken in ethyl acetate and washed with water. The organic extract was dried over sodium sulfate and evaporated under reduced pressure to yield 17.2 g of product.
Step 3: Methyl-2-methyl-5-trans-[4-(5-methyl-2-phenyl-oxazol-4-ylmethoxy)-phenyl]-[1,3]dioxane-2-carboxylate
[0345] A mixture of Methyl-5-trans-(4-hydroxy-phenyl)-2-methyl-[1,3]dioxane-2-carboxylate (prepared in step 2 above) (1.2 g) 4-Chloromethyl-5-methyl-2-phenyl-oxazole (1.0 g) and potassium carbonate (1.3 g) in anhydrous dimethyl formamide (10 mL) was stirred at 55° C. for 18 hours in an inert atmosphere. The reaction mixture was cooled to ambient temperature, poured into ice cold water and extracted with ethyl acetate. The combined organic extract was washed with water, brine solution, dried over sodium sulphate and evaporated under reduced pressure. The crude product was recrystallised from a mixture of ethyl acetate and petroleum ether to obtain 1.3 g of pure product.
[0346] 1 H NMR: 1.6 (3H, s), 2.43 (3H, s), 2.7 (1H, m), 3.86 (3H, s), 4.1 (2H, dd, J=2.9 & 12.3 Hz), 4.25 (2H, dd, J=3.7 & 12.0 Hz), 4.99 (2H, s), 6.98 (2H, d, J=8.7 Hz), 7.4 (5H, m), 8.0 (2H, m).
[0347] Yield: 68.9%.
[0348] The following compounds are prepared by procedure similar to that described in example 33 or 34 with appropriate variations of reactants, reaction conditions and quantities of reagents.
Example 35
Methyl-2-methyl-5-cis-{4-[2-(5-methyl-2-phenyl-oxazol-4-yl)-ethoxy]-phenyl}-[1,3]dioxane-2-carboxylate
[0349] 1 H NMR: 1.57 (3H, s), 2.36 (3H, s), 2.95 (2H, d, J=6.6 Hz), 3.21 (1H, m), 3.8 (2H, d, J=11.8 Hz), 3.87 (3H, s), 4.05 (2H, dd, J=4.7 & 11.8 Hz), 4.2 (2H, t, J=6.6 Hz), 6.8 (2H, d, J=8.6 Hz), 7.0 (2H, d, J=8.6 Hz), 7.4 (3H, m), 7.98 (2H, m).
[0350] Yield: 57.7%.
Example 36
Methyl-2-methyl-5-cis-[4-(2-phenoxazin-10-yl-ethoxy)-phenyl]-[1,3]dioxane-2-carboxylate
[0351] 1 H NMR: 1.57 (3H, s), 3.2 (1H, m), 3.8 (2H, d, J=11.76 Hz), 3.88 (3H, s), 3.95 (2H, t, J=6.5 Hz), 4.05 (2H, dd, J=4.6 & 11.8 Hz), 4.15 (2H, t, J=6.5 Hz), 6.6 (6H, m), 6.8 (4H, m), 7.0 (2H, d, J=8.5 Hz).
[0352] Yield: 38.3%.
Example 37
Methyl-2-methyl-5-cis-[4-(3-methyl-4-oxo-3,4-dihydro-quinazolin-2-ylmethoxy)-phenyl]-[1,3]dioxane-2-carboxylate
[0353] 1 H NMR: 1.57 (3H, s), 3.2 (1H, m), 3.72 (3H, s), 3.80 (2H, d, J=11.8 Hz), 3.87 (3H, s), 4.05 (2H, dd, J=4.6 & 11.9 Hz), 5.16 (2H, s), 6.99 (2H, d, J=8.7 Hz), 7.08 (2H, d, J=8.7 Hz), 7.5 (1H, m), 7.75 (2H, m), 8.3 (1H, d, J=7.8 Hz).
[0354] Yield: 61.4%.
Example 38
Methyl-5-cis-[4-(2-indol-1-yl-ethoxy)-phenyl]-2-methyl-[1,3]dioxane-2-carboxylate
[0355] 1 H NMR: 1.57 (3H, s), 3.15 (1H, m), 3.8 (2H, d, J=11.79 Hz), 3.87 (3H, s), 4.0 (2H, dd, J=4.6 & 11.8 Hz), 4.23 (2H, t, J=6.5 Hz), 4.5 (2H, t, J=5.6 Hz), 6.5 (1H, d, J=3.0 Hz), 6.78 (2H, d, J=9.5 Hz), 7.0 (2H, d, J=8.5 Hz), 7.1 (1H, t, J=7.4 Hz), 7.2 (2H, m), 7.39 (1H, d, J=8.19 Hz), 7.6 (1H, d, J=7.8 Hz).
[0356] Yield: 53.2%.
Example 39
Methyl-5-cis-{4-[2-(5-ethyl-pyridin-2-yl)-ethoxy]-phenyl}-2-methyl-[1,3]dioxane-2-carboxylate
[0357] 1 H NMR: 1.23 (3H, t, J=7.6 Hz), 1.57 (3H, s), 2.63 (2H, q, J=7.6 Hz), 3.20 (3H, m), 3.79 (2H, d, 11.78 Hz), 3.87 (3H, s), 4.0 (2H, dd, J=4.6& 11.9 Hz), 4.3 (2H, t, J=6.6 Hz), 6.82 (2H, d, J=8.56 Hz), 7.06 (2H, d, J=8.56 Hz), 7.18 (1H, d, J=8.09 Hz), 7.45 (1H, dd, J=1.85 & 7.83 Hz), 8.38 (1H, s).
[0358] Yield: 27.27%
Example 40
Methyl-2-methyl-5-cis-[4-(5-methyl-2-p-tolyl-oxazol-4-ylmethoxy)-phenyl]-[1,3]dioxane-2-carboxylate
[0359] 1 H NMR: 1.58 (3H, s), 2.40 (3H, s), 2.42 (3H, s), 3.2 (1H, m), 3.8 (2H, d, 11.6 Hz), 3.88 (3H, s), 4.05 (2H, dd, J=4.6 & 11.8 Hz), 5.00 (2H, s), 6.95 (2H, d, J=8.6 Hz), 7.0 (2H, d, J=8.6 Hz), 7.25 (2H, d, J=7.65 Hz), 7.96 (2H, d, J=8.0 Hz).
[0360] Yield: 90%.
Example 41
Methyl-2-Methyl-5-cis-{4-[2-(5-methyl-2-p-tolyl-oxazol-4-yl)-ethoxy]-phenyl}-[1,3]dioxane-2-carboxylate
[0361] 1 H NMR: 1.58 (3H, s), 2.35 (3H, s), 2.38 (3H, s), 2.95 (2H, t, J=6.6 Hz), 3.2 (1H, m), 3.8 (2H, t, J=11.9 Hz), 3.88 (3H, s), 4.05 (2H, dd, J=4.7 & 12.0 Hz), 4.2 (2H, t, J=6.7 Hz), 6.8 (2H, d, J=8.6 Hz), 7.0 (2H, d, J=8.6 Hz), 7.24 (2H, d, J=8.0 Hz), 7.86 (2H, d, J=8.16 Hz).
[0362] Yield: 42.8%
Example 42
Methyl-5-cis-{4-[2-(4-methanesulfonyloxy-phenyl)-ethoxy]-phenyl}-2-methyl-[1,3]dioxane-2-carboxylate
[0363] 1 H NMR: 1.58 (3H, s), 3.0 (2H, t, J=6.6 Hz), 3.13 (3H, s), 3.2 (1H, m), 3.8 (2H, d, J=11.8 Hz), 3.88 (3H, s), 4.0 (2H, dd, J=4.6 & 11.9 Hz), 4.13 (2H, t, J=6.6 Hz), 6.8 (2H, d, J=8.5 Hz), 7.0 (2H, d, J=8.5 Hz), 7.2 (2H, d, J=8.5 Hz), 7.33 (2H, d, J=8.5 Hz).
[0364] Yield: >99%.
Example 43
Methyl-2-methyl-5-trans-[4-(5-methyl-2-p-tolyl-oxazol-4-ylmethoxy)-phenyl]-[1,3]dioxane-2-carboxylate
[0365] 1 H NMR: 1.6 (3H, s), 2.39 (3H, s), 2.42 (3H, t, s), 2.7 (1H, m), 3.86 (3H, s), 4.1 (2H, dd, J=2.9 & 12.3 Hz), 4.25 (2H, dd, J=3.7 & 12.0 Hz), 4.97 (2H, s), 7.0 (2H, d, J=3.64 Hz), 7.22 (2H, d, J=−8.1 Hz), 7.4 (2H, d, J=8.61 Hz), 7.9 (2H, d, J=8.64 Hz).
[0366] Yield: 98.3%.
Example 44
Methyl-2-methyl-5-trans-{4-[2-(5-methyl-2-phenyl-oxazol-4-yl)-ethoxy]-phenyl}-[1,3]dioxane-2-carboxylate
[0367] 1 H NMR: 1.59 (3H, s), 2.38 (3H, s), 2.7 (1H, m), 3.0 (2H, t, J=6.6 Hz), 3.86 (3H, s), 4.0 (2H, dd, J=2.8 & 12.1 Hz), 4.2 (4H, m), 6.8 (2H, d, J=8.6 Hz), 7.4 (5H, m), 7.99 (2H, m).
[0368] Yield: 80.7%.
Example 45
Methyl-2-methyl-5-trans-{4-[2-(5-methyl-2-p-tolyl-oxazol-4-yl)-ethoxy]-phenyl}-[1,3]dioxane-2-carboxylate
[0369] 1 H NMR: 1.6 (3H, s), 2.35 (3H, s), 2.37 (3H, s), 2.7 (1H, m), 2.9 (2H, m), 3.86 (3H, s), 4.04 (2H, dd, J=2.16 & 11.97 Hz), 4.2 (4H, m), 6.8 (2H, d, J=8.6 Hz), 7.2 (2H, d, J=8.0 Hz), 7.3 (2H, d, J=9.1 Hz), 7.87 (2H, d, J=−8.1 Hz).
[0370] Yield: 87.4%.
Example 46
Methyl-2-methyl-5-trans-{4-[4-methyl-2-(4-trifluoromethyl-phenyl)-thiazol-5-ylmethoxy]-phenyl}-[1,3]dioxane-2-carboxylate
[0371] 1 H NMR: 1.6 (3H, s), 2.52 (3H, s), 2.7 (1H, m), 3.87 (3H, s), 4.1 (2H, dd, J=2.2 & 12.12 Hz), 4.2 (2H, dd, J=3.6 & 11.9 Hz), 5.2 (2H, s), 6.9 (2H, d, J=8.6 Hz), 7.5 (2H, d, J=8.6 Hz), 7.6 (2H, d, J=8.2 Hz), 8.0 (2H, d, J=8.1 Hz).
[0372] Yield: 61.2%.
Example 47
Methyl-2-methyl-5-cis-{4-[4-methyl-2-(4-trifluoromethyl-phenyl)-thiazol-5-ylmethoxy]-phenyl}-[1,3]dioxane-2-carboxylate
[0373] 1 H NMR: 1.53 (3H, s), 2.5 (3H, s), 3.2 (1H, m), 3.8 (5H, m), 4.0 (2H, m), 5.1 (2H, s), 6.9 (2H, d, J=8.5 Hz), 7.0 (2H, d, J=8.5 Hz), 7.6 (2H, d, J=8.1 Hz), 8.0 (2H, d, J=8.1 Hz).
[0374] Yield: 57.5%.
Example 48
Methyl-2-methyl-5-cis-(4-(2-[2-methyl-5-(4-methylsulfanyl-phenyl)-pyrrol-1-yl]-ethoxy)-phenyl)-[1,3]dioxane-2-carboxylate
[0375] 1 H NMR: 1.56 (3H, s), 2.35 (3H, s), 2.52 (s, 3H), 3.15 (1H, m), 3.9 (7H, m), 4.0 (2H, dd, J=4.6 & 11.9 Hz), 4.25 (2H, t, J=6.6 Hz), 5.95 (1H, d, J=2.8 Hz), 6.08 (1H, d, J=3.3 Hz), 6.5 (2H, d, J=8.6 Hz), 6.9 (2H, d, J=3.6 Hz), 7.3 (4H, m).
[0376] Yield: 74.5%
Example 49
Methyl-5-cis-[4-(2-tert-Butyl-5-methyl-oxazol-4-ylmethoxy)-phenyl]-2-methyl-[1,3]dioxane-2-carboxylate
[0377] 1 H NMR: 1.36 (9H, s), 1.58 (3H, s), 2.30 (s, 3H), 3.2 (1H, m), 3.80 (2H, d, J=11.8 Hz), 3.95 (3H, s), 4.0 (2H, dd, J=4.5 & 11.8 Hz), 5.3 (2H, s), 6.9 (2H, d, J=8.6 Hz), 7.0 (2H, d, J=8.6 Hz).
[0378] Yield: 95.3%.
Example 50
Methyl-5-trans-[4-(2-tert-Butyl-5-methyl-oxazol-4-ylmethoxy)-phenyl]-2-methyl-[1,3]dioxane-2-carboxylate
[0379] 1 H NMR: 1.37 (9H, s), 1.6 (3H, s), 2.31 (s, 3H), 2.7 (1H, m), 3.86 (3H, s), 4.0 (2H, dd, J=2.7 & 12.1 Hz), 4.2 (2H, dd, J=3.7 & 12.1 Hz), 4.88 (2H, s), 6.9 (2H, d, J=8.7 Hz), 7.4 (2H, d, J=8.6 Hz).
[0380] Yield: 94.5%.
Example 51
Methyl-2-methyl-5-cis-{4-[2-(4-phenoxy-phenoxy)-ethoxy]-phenyl}-[1,3]dioxane-2-carboxylate
[0381] 1 H NMR: 1.58 (3H, s), 3.2 (1H, m), 3.8 (2H, t, J=11.8 Hz), 3.88 (3H, s), 4.0 (2H, dd, J=4.65 & 11.9 Hz), 4.29 (4H, s), 6.88-6.99 (7H, m), 7.0 (4H, d, J=8.5 Hz), 7.3 (2H, m).
[0382] Yield: 86.83%
Example 52
Methyl-2-methyl-5-trans-{4-[2-(4-phenoxy-phenoxy)-ethoxy]-phenyl}-[1,3]dioxane-2-carboxylate
[0383] 1 H NMR: 1.60 (3H, s), 2.7 (1H, m), 3.87 (3H, s), 4.0 (2H, d, J=12.0 Hz), 4.25 (2H, dd, J=3.5 & 11.98 Hz), 4.31 (3H, s), 6.92-7.07 (9H, m), 7.3 (21H, m), 7.43 (2H, d, J=8.6 Hz).
[0384] Yield: 85.33%
Example 53
Methyl-5-cis-[4-(2-fluoro-benzyloxy)-phenyl]-2-methyl-[1,3]dioxane-2-carboxylate
[0385] 1 H NMR: 1.58 (3H, s), 3.2 (1H, m), 3.8 (2H, d, J=11.77 Hz), 3.88 (3H, s), 4.08 (2H, dd, J=4.6 & 11.9 Hz), 5.1 (2H, s), 6.9 (2H, d, J=8.6 Hz), 7.0 (3H, d, J=8.6 Hz), 7.1 (1H, m), 7.3 (1H, m), 7.45 (1H, t, 7.3 Hz).
[0386] Yield: 78.8%.
Example 54
Methyl-5-trans-[4-(2-fluoro-benzyloxy)-phenyl]-2-methyl-[1,3]dioxane-2-carboxylate
[0387] 1 H NMR: 1.60 (3H, s), 2.7 (1H, m), 3.86 (3H, s), 4.0 (2H, d, J=12.01 Hz), 4.25 (2H, dd, J=3.57 & 11.97 Hz), 5.1 (2H, s), 6.9 (2H, d, J=8.6 Hz), 7.05-7.18 (2H, m), 7.3 (1H, m), 7.4 (2H, d, J=8.6 Hz), 7.5 (1H, t, 7.3 Hz).
[0388] Yield: 78.5%.
Example 55
Methyl-5-cis-[4-(5-tert-Butyl-2-p-tolyl-2H-pyrazol-3-ylmethoxy)-phenyl]-2-methyl-[1,3]dioxane-2-carboxylate
[0389] 1 H NMR: 1.35 (9H, t, s), 1.58 (3H, s), 2.38 (3H, s), 3.2 (1H, m), 3.85 (2H, d, J=11.64 Hz), 3.88 (3H, s), 4.0 (2H, dd, J=4.56 & 11.61 Hz), 4.8 (2H, s), 6.39 (1H, s), 6.88 (2H, d, J=8.43 Hz), 7.06 (2H, d, J=8.43 Hz), 7.2 (2H, d, J=8.1 Hz), 7.4 (2H, d, J=8.1 Hz).
[0390] Yield: 61.3%.
Example 56
Methyl-5-trans-[4-(5-tert-Butyl-2-p-tolyl-2H-pyrazol-3-ylmethoxy)-phenyl]-2-methyl-[1,3]dioxane-2-carboxylate
[0391] 1 H NMR: 1.36 (9H, s), 1.60 (3H, s), 2.36 (3H, s), 2.7 (1H, m), 3.87 (3H, s), 4.06 (2H, d, J=11.1 Hz), 4.25 (2H, d, J=9.18 Hz), 4.9 (2H, s), 6.41 (1H, s), 6.90 (2H, d, J=8.4 Hz), 7.22 (2H, d, J=7.86 Hz), 7.4 (4H, t, J=7.4 Hz).
[0392] Yield: 59.9%.
Example 57
Methyl-2-methyl-5-trans-[4-(2-oxo-3-phenyl-oxazolidin-5-ylmethoxy)-phenyl]-[1,3]dioxane-2-carboxylate
[0393] 1 H NMR: 1.59 (3H, s), 2.69 (1H, m), 3.86 (3H, s), 4.0 (3H, m), 4.2 (5H, m), 4.99 (1H, m), 6.9 (2H d, J=8.2 Hz), 7.15 (1H, m), 7.4 (4H, m), 7.59 (2H, d, J=7.78 Hz).
[0394] Yield: 66.1%.
Example 58
Methyl-2-methyl-5-cis-[4-(2-oxo-3-phenyl-oxazolidin-5-ylmethoxy)-phenyl]-[1,3]dioxane-2-carboxylate
[0395] 1 H NMR: 1.58 (3H, s), 3.2 (1H, m), 3.84 (2H, d, J=11.82 Hz), 3.88 (3H, s), 4.0 (3H, m), 4.2 (3H, m), 4.9 (1H, m), 6.8 (2H, d, J=8.6 Hz), 7.0 (2H, d, J=8.6 Hz), 7.1 (1H, t, J=7.4 Hz), 7.3 (2H, m), 7.5 (2H, d, J=7.98 Hz).
[0396] Yield: 73.9%
Example 59
Methyl-5-trans-{4-[2-(4-Methanesulfonyloxy-phenyl)-ethoxy]-phenyl}-2-methyl-[1,3]dioxane-2-carboxylate
[0397] 1 H NMR: 1.59 (3H, s), 2.69 (1H, m), 3.1 (5H, m), 3.86 (3H, s), 4.05 (2H, d, J=11.0 Hz), 4.14-4.25 (4H, m), 6.8 (2H, d, J=8.4 Hz), 7.2 (2H, d, J=8.4 Hz), 7.33-7.41 (4H, m).
[0398] Yield: 68.9%.
Example 60
Methyl-{2-methyl-5-trans-[4-(3-methyl-4-oxo-3,4-dihydro-quinazolin-2-ylmethoxy)-phenyl]-[1,3]dioxane-2 carboxylate
[0399] 1 H NMR: 1.59 (3H, s), 2.7 (1H, m), 3.72 (3H, s), 3.86 (3H, s), 4.0 (2H, dd, J=2.2 & 12.17 Hz), 4.2 (2H, dd, J=3.6 & 12.69 Hz), 5.18 (2H, s), 7.0 (2H, d, J=8.7 Hz), 7.4 (2H, d, J=8.7 Hz), 7.5 (1H, m), 7.7 (2H, m), 8.3 (1H, d, J=7.83 Hz).
[0400] Yield: 59.43%
Example 61
2-Methyl-5-{4-[2-(5-methyl-2-phenyl-oxazol-4-yl)-ethoxy]-benzyl}-[1,3]dioxane-2-carboxylic acid
[0401] To a solution of Methyl-2-methyl-5-{4-[2-(5-methyl-2-phenyl-oxazol-4-yl)-ethoxy]-benzyl}-[1,3]dioxane-2-carboxylate (263 mg) in methanol was added a solution of sodium hydroxide (46.5 mg) in water and the reaction mixture was stirred at ambient temperature for 15 hours. The solvents were evaporated and the residue was dissolved in water, acidified with 1N HCl and extracted with ethyl acetate. The combined organic extract was washed with water, brine, dried over sodium sulphate and evaporated under reduced pressure. The crude product was flash chromatographed over silica gel using 2% methanol in chloroform as eluent to obtain 160 mg of pure product.
[0402] 1 H NMR: 1.54 (3H, s), 2.25 (3H, s), 2.38 (3H, s), 2.86 (1H, m), 2.96-3.03 (2H, m), 3.52-3.57 (2H, m), 3.90-3.93 (2H, m), 4.21 (2H, t, J=6.9 Hz), 6.82 (2H, d, J=3.43 Hz), 7.07 (2H, d, J=8.49 Hz), 7.32-7.43 (3H, m), 7.96-7.99 (2H, m).
[0403] Yield: 63.0%
[0404] The following compounds were prepared by a procedure similar to those described in example 57 with appropriate variations of reactants, reaction conditions and quantities of reagents.
Example 62
2-Methyl-5-{4-[2-(5-methyl-2-p-tolyl-oxazol-4-yl)-ethoxy]-benzyl}-[1,3]dioxane-2-carboxylic acid
[0405] 1 H NMR: 1.55 (3H, s), 2.24 (2H, s), 2.37 (3H, s), 2.38 (3H, s), 2.86 (1H, d, J=7.77 Hz), 2.96-3.03 (2H, m), 3.49-3.72 (2H, m), 3.87-3.92 (2H, m), 4.20 (2H, t, J=6.72 Hz), 6.78-6.85 (2H, m), 6.93-7.09 (2H, m), 7.22 (2H, m), 7.85-7.87 (2H, m).
[0406] Yield: 58.4%
Example 63
2-Methyl-5-cis-[4-(5-methyl-2-phenyl-oxazol-4-ylmethoxy)-benzyl]-[1,3]dioxane-2-carboxylic acid
[0407] 1 H NMR: 1.52 (3H, s), 2.29 (3H, m), 2.43 (3H, s), 3.6 (2H, t, J=10.8 Hz), 3.9 (2H, m), 4.96 (2H, s), 6.9 (2H, d, J=8.5 Hz), 7.0 (2H, d, J=8.5 Hz), 7.4 (3H, m), 8.0 (2H, m).
[0408] Yield: 85.0%
Example 64
2-Methyl-5-cis-[4-(1-pyridin-2-yl-pyrrolidin-2-ylmethoxy)-benzyl]-[1,3]dioxane-2-carboxylic acid
[0409] 1 H NMR: 1.5 (3H, s), 2.1 (3H, m), 2.2 (4H, m), 3.6 (4H, m), 3.8 (21H, m), 3.9 (1H, t), 4.1 (1H, m), 4.5 (1H, m), 6.5 (1H, d, J=8.5 Hz), 6.6 (1H, t, J=5.9 Hz), 6.8 (2H, d, J=8.31 Hz), 6.9 (2H, d, J=8.22 Hz), 7.5 (1H, t, J=7.2 Hz), 8.2 (1H, m).
[0410] Yield: 65.0%
Example 65
2-Methyl-5-cis-{4-[2-(methyl-pyridin-2-yl-amino)-ethoxy]-benzyl}-[1,3]dioxane-2-carboxylic acid
[0411] 1 H NMR: 1.5 (3H, s), 2.2 (3H, m), 3.1 (3H, s), 3.6 (2H, t, J=10.52 Hz), 3.8 (2H, m), 4.0 (2H, t, J=5.0 Hz), 4.2 (2H, m), 6.6 (2H, m), 6.7 (2H, d, J=8.28 Hz), 6.9 (2H, d, J=8.4 Hz), 7.5 (1H, m), 8.2 (1H, m).
[0412] Yield: 55.5%
Example 66
2-Methyl-5-[4-(3-methyl-4-oxo-3,4-dihydro-quinazolin-2-ylmethoxy)-benzyl]-[1,3]dioxane-2-carboxylic acid
[0413] 1 H NMR: 1.3 (3H, s), 2.1 (1H, m), 2.2 (2H, d, J=6.9 Hz), 3.4 (2H, t, J=1.3 Hz), 3.6 (3H, s), 3.7 (2H, dd, J=11.7 & 4.2 Hz), 5.2 (2H, s), 7.0 (2H, d, J=8.5 Hz), 7.1 (2H, d, J=8.3 Hz), 7.5 (1H, t, J=7.5 Hz), 7.6 (1H, d, J=8.04 Hz), 7.8 (1H, t, J=7.1 Hz), 8.1 (1H, d, J=7.8 Hz).
[0414] Yield: 95%
Example 67
2-Methyl-5-[4-(2-phenoxazin-10-yl-ethoxy)-benzyl]-[1,3]dioxane-2-carboxylic acid
[0415] 1 H NMR: 1.5 (3H, s), 2.26 (3H, m), 3.5 (2H, t, J=10.4 Hz), 3.9-4.0 (41H, m), 4.1 (2H, t, J=6.5 Hz), 6.6 (6H, m), 6.7 (4H, m), 7.0 (2H, d, J=8.5 Hz), 7.1 (2H, d, J=8.5 Hz).
[0416] Yield: 57.0%
Example 68
2-Methyl-5-cis-[4-(5-methyl-2-p-tolyl-oxazol-4-ylmethoxy)-benzyl]-[1,3]dioxane-2-carboxylic acid
[0417] 1 H NMR: 1.3 (3H, s), 2.1 (1H, m), 2.2 (2H, d, J=6.9 Hz), 2.3 (3H, s), 2.4 (3H, s), 3.4 (2H, t, J=11.4 Hz), 3.7 (2H, dd, J=11.55 & 4.1 Hz), 4.9 (2H, s), 6.9 (2H, d, J=8.4 Hz), 7.1 (2H, d, J=8.4 Hz), 7.3 (2H, d, J=8.1 Hz), 7.8 (2H, d, J=8.1 Hz).
[0418] Yield: 95.0%
Example 69
5-cis-[4-(2-Carbazol-9-yl-ethoxy)-benzyl]-2-methyl-[1,3]dioxane-2-carboxylic acid
[0419] 1 H NMR: 1.5 (3H, s), 2.2 (3H, m), 3.5 (2H, t, J=10.7 Hz), 3.9 (2H, m), 4.3 (2H, t, J=5.9 Hz), 4.7 (2H, t, J=5.9 Hz), 6.7 (2H, d, J=8.5 Hz), 6.9 (2H, d, J=8.5 Hz), 7.2 (2H, m), 7.5 (4H, m), 8.1 (2H, d, J=7.8 Hz).
[0420] Yield: 35.0%
Example 70
5-cis-[4-(2-Indol-1-yl-ethoxy)-benzyl]-2-methyl-[1,3]dioxane-1-carboxylic acid
[0421] 1 H NMR: 1.5 (3H, s), 2.2 (31H, m), 3.5 (2H, t, J=10.7 Hz), 3.9 (2H, dd, J=17.9 & 4.6 Hz), 4.2 (2H, t, J=−5.6 Hz), 4.5 (2H, t, J=5.6 Hz), 6.5 (1H, d, J=3.3 Hz), 6.7 (2H, d, J=8.6 Hz), 6.9 (2H, d, J=8.5 Hz), 7.1 (1H, m), 7.2 (2H, m), 7.4 (1H, d, J=8.1 Hz), 7.6 (1H, d, J=7.8 Hz).
[0422] Yield: 39.0%
Example 71
5-{4-[2-(2,3-Dihydro-benzo[1,4]oxazin-4-yl)-ethoxy]-benzyl}-2-methyl-[1,3]dioxane-2-carboxylic acid
[0423] 1 H NMR: 1.2 (3H, s) (trans), 1.5 (3H, s), 2.3 (3H, m), 2.9 (2H, m) (trans), 3.4 (2H, m) (trans), 3.5 (2H, t, J=4.2 Hz), 3.7 (2H, t, J=5.6 Hz), 3.8 (2H, m), 3.9 (2H, m), 4.1 (2H, t, J=5.6 Hz), 4.2 (2H, t, J=4.3 Hz), 6.6 (1H, t, J=7.5 Hz), 6.7 (1H, d, J=7.3 Hz), 6.7-6.8 (4H, complex), 7.1 (1H, d, J=8.4 Hz).
[0424] Yield: 66%.
Example 72
2-Methyl-5-cis-{4-[5-methyl-2-(5-methyl-thiophen-2-yl)-oxazol-4-ylmethoxy]-benzyl}-[1,3]dioxane-2-carboxylic acid
[0425] 1 H NMR: 1.5 (3H, s), 2.2 (3H, m), 2.4 (3H, s), 2.5 (3H, s), 3.5 (2H, t, J=11.1 Hz), 3.9 (2H, m), 4.9 (2H, s), 6.7 (1H, d, J=2.8 Hz), 6.9 (2H, d, J=8.6 Hz), 7.0 (2H, d, J=8.55 Hz), 7.4 (1H, d, J=3.6 Hz).
[0426] Yield: 64.0%
Example 73
5-cis-{4-[2-(2,3-Dihydro-benzo[1,4]thiazin-4-yl)-ethoxy]-benzyl}-2-methyl-[1,3]dioxane-2-carboxylic acid
[0427] 1 H NMR: 1.56 (3H, s), 2.26-2.31 (3H, m), 3.02-3.05 (2H, m), 3.54 (2H, t, J=6 Hz), 3.70-3.79 (4H, m), 3.93 (2H, dd, J=13.38 & 4.14), 4.14 (2H, t, J=5.67 Hz), 6.64 (1H, d, J=0.96 Hz), 6.71 (1H, d, J=7.74 Hz), 6.80 (2H, d, J=8.589 Hz), 6.95-7.05 (4H, m).
[0428] Yield: 76.0%
Example 74
2-Methyl-5-cis-[4-(2-phenothiazin-10-yl-ethoxy)-benzyl]-[1,3]dioxane-2-carboxylic acid
[0429] 1 H NMR: 1.55 (3H, s), 2.30 (3H, s), 3.50 (2H, m), 3.91 (2H, dd, J=9.69 & 4.17 Hz), 4.29 (4H, s), 6.81 (2H, d, J=3.58 Hz), 6.91-7.01 (6H, m), 7.13-7.13 (4H, m).
[0430] Yield: 64.0%
Example 75
5-cis-{4-[2-(4-Hexyl-3-oxo-3,4-dihydro-2H-benzo[1,4]oxazin-2-yl)-ethoxy]-benzyl}-2-methyl-[1,3]dioxane-2-carboxylic acid
[0431] 1 H NMR: 0.88 (3H, t, J=6.81 Hz), 1.25-1.37 (6H, m), 1.56 (3H, s), 1.64 (2H, m), 2.20-2.27 (5H, m), 2.32 (1H, m), 3.53 (2H, t, J=10.77 Hz), 3.88-3.95 (4H, m), 4.14-4.19 (2H, m), 4.78 (1H, dd, J=9.24 & 3.99 Hz), 6.81 (2H, d, J=8.58 Hz), 6.95-7.05 (6H, m).
[0432] Yield: 60.2%
Example 76
2-Methyl-5-cis-(4-{2-[5-methyl-2-(5-methyl-thiophen-2-yl)-oxazol-4-yl]-ethoxy}-benzyl)-[1,3]dioxane-2-carboxylic acid
[0433] 1 H NMR: 1.55 (3H, s), 2.2 (3H, m), 2.3 (3H, s), 2.5 (3H, s), 2.9 (2H, m), 3.5 (2H, m), 3.9 (2H, d, J=9.96 Hz), 4.2 (2H, t, J=6.3 Hz), 6.7 (1H, s), 6.8 (2H, d, J=8.2 Hz), 6.9 (2H, d, J=8.0 Hz), 7.4 (1H, s).
[0434] Yield: 46%
Example 77
2-Methyl-5-{4-[2-(5-methyl-2-phenyl-oxazol yl)-ethoxy]-benzyl}-[1,3]dioxane-2-carboxylic acid
[0435] 1 H NMR: 1.54 (3H, s), 2.29 (3H, s), 2.37 (3H, s), 2.97 (2H, t, J=6.69 Hz), 3.51-3.55 (2H, m), 3.91 (2H, dd, J=12.57 & 4.2 Hz), 4.21 (2H, t, J=6.72 Hz), 6.82 (2H, d, J=8.55 Hz), 6.99 (2H, d, J=8.52 Hz), 7.41 (3H, m), 7.95-7.99 (24 dd, J=7.83 & 2.88 Hz).
[0436] Yield: 32%
Example 78
2-Methyl-5-cis-{4-[3-(4-phenoxy-phenoxy)-propoxy]-benzyl}-[1,3]dioxane-2-carboxylic acid
[0437] 1 H NMR: 1.55 (3H, s), 2.25-2.31 (5H, m), 3.52 (2H, t, J=10.29 Hz), 3.91 (2H, d, J=9.57 Hz), 4.14 (4H, t, J=5.71 Hz), 6.82-7.05 (1H, m), 7.28 (2H, s).
[0438] Yield: 77%
Example 79
5-cis-{4-[2-(4-Methanesulfonyloxy-phenyl)-ethoxy]-benzyl}-2-methyl-[1,3]dioxane-2-carboxylic acid
[0439] 1 H NMR: 1.55 (3H, s), 2.27 (3H, s), 3.07-3.11 (2H, t, J=6.72 Hz), 3.13 (3H, s), 3.44-3.55 (2H, m), 3.90 (2H, dd, J=13.74 & 4.2 Hz), 4.16 (2H, t, J=6.69 Hz), 6.80 (2H, d, J=8.49 Hz), 6.99 (2H, d, J=8.49 Hz), 7.23 (2H, d, J=8.61 Hz), 7.33 (2H, d, J=8.49 Hz).
[0440] Yield: 73.1%
Example 80
5-cis-[4-(2-tert-Butyl-5-methyl-oxazol 4-ylmethoxy)-benzyl]-2-methyl-[1,3]dioxane-2-carboxylic acid
[0441] 1 H NMR: 1.38 (9H, s), 1.51 (3H, s), 2.12 (2H, d, J=7.2 Hz), 2.26 (1H, m), 2.33 (3H, s), 3.43 (2H, t, J=11.28 Hz), 3.82 (2H, dd, J=11.82 & 4.11 Hz), 4.90 (2H, s), 6.92 (4H, dd, J=19.11 & 3.67 Hz).
[0442] Yield: 49%
Example 81
2-Methyl-5-cis-{4-[4-methyl-2-(4-trifluoromethyl-phenyl)-thiazol-5-ylmethoxy]-benzyl}-[1,3]dioxane-2-carboxylic acid
[0443] 1 H NMR: 1.55 (3H, s), 2.33 (3H, s), 2.50 (3H, s), 3.53 (2H, d, J=11.01 Hz), 3.93 (2H, dd, J=14.28 & 3.87 Hz), 5.18 (2H, s), 6.90 (2H, d, J=8.55 Hz), 7.01 (2H, d, J=8.55 Hz), 7.68 (2H, d, J=8.18 Hz), 8.01 (2H, d, J=8.07 Hz).
[0444] Yield: 52.1%
Example 82
2-Methyl-5-cis-{4-[2-(4-phenoxy-phenoxy)-ethoxy]-benzyl}-[1,3]dioxane-2-carboxylic acid
[0445] 1 H NMR: 1.56 (3H, s), 2.3 (3H, s), 3.54 (2H, t, J=10.59 Hz), 3.93 (2H, d, J=9.33 & 3.54 Hz), 4.00 (4H, s), 6.86-7.07 (1H, m), 7.27-7.32 (2H, m).
[0446] Yield: 94%
Example 83
5-cis-[4-(2-Fluoro-benzyloxy)-benzyl]-2-methyl-[1,3]dioxane-2-carboxylic acid
[0447] 1 H NMR: 1.56 (3H, s), 2.32 (3H, s), 3.54 (2H, t, J=10.5 Hz), 3.91-3.94 (2H, m), 5.11 (2H, s), 6.90 (2H, d, J=8.5 Hz), 7.01-7.18 (4H, m), 7.30-7.32 (1H, m), 7.49 (1H, t, J=6.78 Hz).
[0448] Yield: 99%
Example 84
2-Methyl-5-cis-(4-{2-[2-methyl-5-(4-methylsulfanyl-phenyl)-pyrrol-1-yl]-ethoxy}-benzyl)-[1,3]dioxane-2-carboxylic acid
[0449] 1 H NMR: 1.54 (3H, s), 2.27 (3H, s), 2.36 (3H, s), 2.52 (3H, s), 3.51 (2H, t J=10.62 Hz), 3.91 (4H, t, J=6.48 Hz), 4.26 (2H, t, J=8.82 Hz), 5.96 (1H, d, J=2.55 Hz), 6.09 (1H, d, J=3.3 Hz), 6.60 (2H, d, J=9.0 Hz), 6.92 (2H, d, J=8.43 Hz), 7.21-7.33 (4H, m).
[0450] Yield: 79.9%
Example 85
5-cis-{4-[2-(2-tert-Butyl-5-methyl-oxazol-4-yl)-ethoxy]-benzyl}-2-methyl-[1,3]dioxane-2-carboxylic acid
[0451] 1 H NMR: 1.35 (9H, s), 1.54 (3H, s), 2.24 (3H, s), 2.27 (3H, s), 2.89-2.96 (2H, dd, J=15.03 & 8.13 Hz), 3.50 (2H, t, J=9.48 Hz), 3.84-3.89 (2H, m), 4.12 (2H, t, J=6.66 Hz), 6.78 (2H, d, J=8.34 Hz), 6.92 (2H, d, J=8.1 Hz).
[0452] Yield: 20%
Example 86
(Z)-2-Methyl-5-cis-{4-[2-(phenyl-pyridin-2-yl-methyleneaminooxy)-ethoxy]-benzyl}-[1,3]dioxane-2-carboxylic acid
[0453] 1 H NMR: 1.50 (3H, s), 2.36 (3H, d, J=6.12 Hz), 3.50 (2H, t, J=11.49 Hz), 3.88 (2H, dd, J=8.79 Hz), 4.29 (2H, t), 4.55 (2H, t), 6.85 (2H, d, J=8.49 Hz), 6.97 (2H, d, J=8.25 Hz), 7.29 (3H, m), 7.39 (3H, m), 7.67-7.74 (2H, m), 8.63 (1H, d, J=4.2 Hz).
[0454] Yield: 72.4%
Example 87
(E)-2-Methyl-5-cis-{4-[2-(phenyl-pyridin-2-yl-methyleneaminooxy)-ethoxy]-benzyl}-[1,3]dioxane-2-carboxylic acid
[0455] 1 H NMR: 1.50 (3H, s), 2.38 (3H, s), 3.49 (2H, t, J=7.62 Hz), 3.87 (2H, dd, J=9.06 Hz), 4.24 (2H, t), 4.50 (2H, t), 6.82 (2H, d, J=8.37 Hz), 6.97 (2H, d, J=8.31 Hz), 7.34 (4H, m), 7.43 (2H, d, J=7.56 Hz), 7.53 (1H, d, J=7.74 Hz), 7.80 (1H, t, J=6.54 Hz), 8.74 (1H, d, J=6.54 Hz).
[0456] Yield: 56%
Example 88
2-Methyl-5-cis-[4-(5-methyl-2-phenyl-oxazol-4-ylmethoxy)-phenyl]-[1,3]dioxane-2-carboxylic acid
[0457] 1 H NMR: 1.61 (3H, s), 2.46 (3H, s), 3.07 (1H, m), 3.64 (2H, t, J=11.5 Hz), 3.75 (2H, dd, J=4.8 & 11.7 Hz), 5.05 (2H, s), 69 (4H, m), 7.47 (31 ml), 3.05 (2H, m).
[0458] Yield: 51.72%
Example 89
2-Methyl-5-cis{4-[2-(5-methyl-2-phenyl-oxazol-4-yl)-ethoxy]-phenyl}-[1,3]dioxane-2-carboxylic acid
[0459] 1 H NMR: 1.63 (3H, s), 2.40 (3H, s), 3.06 (2H, t, J=6.5 Hz), 3.17 (1H, m), 3.89 (2H, t, J=11.5 Hz), 4.01 (2H, dd, J=4.8 & 11.6 Hz), 4.2 (2H, t, J=6.6 Hz), 6.76 (2H, d, J=8.5 Hz), 6.95 (21, J=8.5 Hz), 7.42 (3H, m), 8.00 (2H, m).
[0460] Yield: 80.93%
Example 90
2-Methyl-5-cis-[4-(2-phenoxazin-10-yl-ethoxy)-phenyl]-[1,3]dioxane-2-carboxylic acid
[0461] 1 H NMR: 1.65 (3H, s), 3.22 (1H, m), 3.86-3.97 (4H, m), 4.05-4.17 (4H, m), 6.6 (6H, m), 6.7-6.85 (4H, m), 7.0 (2H, d, J=8.13 Hz).
[0462] Yield: 89.2%
Example 91
2-Methyl-5-cis-[4-(3-methyl-4-oxo-3,4-dihydro-quinazolin-2-ylmethoxy)-phenyl]-[1,3]dioxane-2-carboxylic acid
[0463] 1 H NMR: 1.41 (3H, s), 3.1 (1H, m), 3.59 (3H, s), 3.75 (2H, t, J=11.5 Hz), 3.9 (2H, dd, J=4.5 & 11.5 Hz), 5.25 (2H, s), 7.05 (2H, d, J=8.6 Hz), 7.1 (2H, d, J=8.6 Hz), 7.56 (1H, t, J=7.4 Hz), 7.65 (1H, d, J=8.0 Hz), 7.83 (1H, t, J=7.0 Hz), 8.16 (1H, d, J=9.0 Hz).
[0464] Yield: 70.8%
Example 92
5-cis-[4-(2-Indol-1-yl-ethoxy)-phenyl]-2-methyl-[1,3]dioxane-2-carboxylic acid
[0465] 1 H NMR: 1.63 (3H, s), 3.21 (1H, m), 3.87 (2H, t, J=11.6 Hz), 4.0 (2H, dd, J=4.6 & 11.9 Hz), 4.25 (2H, J=5.6 Hz), 4.5 (2H, t, J=5.6 Hz), 6.5 (1H, d, J=7.76 Hz), 6.76 (2H, d, J=8.6 Hz), 7.0 (2H, d, J=8.6 Hz), 7.1 (1H, t, J=7.2 Hz), 7.2 (2H, m), 7.4 (1H, d, J=8.1 Hz), 7.64 (1H, d, J=7.86 Hz).
[0466] Yield: 69.13%
Example 93
5-cis-{4-[2-(5-Ethyl-pyridin-2-yl)-methoxy]-phenyl}-2-methyl-[1,3]dioxane-2-carboxylic acid
[0467] 1 H NMR: 1.3 (3H, t, J=7.1 Hz), 1.63 (3H, s), 2.7 (2H, m), 3.1 (1H, m), 3.5 (2H, m), 3.96 (4H, m), 4.3 (2H, m), 6.7 (2H, d, J=8.1 Hz), 6.95 (2H, d, J=8.1 Hz), 7.5 (1H, d, J=7.8 Hz), 7.8 (1H, d, J=6.9 Hz), 8.6 (1H, s).
[0468] Yield: 68.66%
Example 94
2-Methyl-5-cis-[4-(5-methyl-2-p-tolyl-oxazol-4-ylmethoxy)-phenyl]-[1,3]dioxane-2-carboxylic acid
[0469] 1 H NMR: 1.6 (3H, s), 2.4 (3H, s), 2.45 (3H, s), 3.0 (1H, m), 3.5-3.7 (4H, m), 5.05 (2H, s), 6.86 (2H, d, J=8.6 Hz), 6.96 (2H, d, J=8.6 Hz), 7.29 (2H d, J=8.0 Hz), 7.95 (2H, d, J=8.0 Hz).
[0470] Yield: 90.2%
Example 95
2-Methyl-5-cis-{4-[2-(5-methyl-2-p-tolyl-oxazol-4-yl)-ethoxy]-phenyl}[1,3]dioxane-2-carboxylic acid
[0471] 1 H NMR: 1.64 (3H, s), 2.38 (3H, s), 2.39 (3H, s), 3.07 (21, J=6.5 Hz), 3.16 (1H, m), 3.88 (2H, t, J=11.5 Hz), 4.00 (2H, dd, J=4.8 & 11.7 Hz), 4.19 (2H, d, J=6.6 Hz), 6.75 (2H, d, J=8.5 Hz), 6.93 (2H, d, J=8.5 Hz), 7.22 (2H, d, J=9.96 Hz), 7.86 (2H, d, J=8.1 Hz).
[0472] Yield: 94.23%
Example 96
5-cis-{4-[2-(4-Methanesulfonyloxy-phenyl)-ethoxy]-phenyl}-2-methyl-[1,3]dioxane-2-carboxylic acid
[0473] 1 H NMR: 1.65 (3H, s), 3.1 (2H, t, J=6.7 Hz), 3.13 (3H, s), 3.2 (1H, m), 3.9 (2H, t, J=11.7 Hz), 4.0-4.15 (4H, m), 6.8 (2H, d, J=8.5 Hz), 7.0 (2H, d, J=8.5 Hz), 7.2 (2H, d, J=8.5 Hz), 7.3 (2H, d, J=8.5 z).
[0474] Yield: 82.6%
Example 97
2-Methyl-5-trans-[4-(5-methyl-2-phenyl-oxazol-4-ylmethoxy)-phenyl]-[1,3]dioxane-2-carboxylic acid
[0475] 1 H NMR: 1.62 (3H, s), 2.44 (3H, s), 2.67 (1H, m), 4.05 (2H, dd, J=2.5 & 11.67 Hz), 4.2 (2H, dd, J=3.2 & 11.8 Hz), 5.02 (2H, s), 7.01 (2H, d, J=8.5 Hz), 7.5 (2H, d, J=8.5 Hz), 7.45 (3H, m), 8.02 (2H, m).
[0476] Yield: 75.85%
Example 98
2-Methyl-5-trans-[4-(5-methyl-2-p-tolyl-oxazol-4-ylmethoxy)-phenyl]-[1,3]dioxane-2-carboxylic acid
[0477] 1 H NMR: 1.63 (3H, s), 2.39 (3H, s), 2.43 (3H, s), 2.68 (1H, m), 4.05 (2H, dd, J=3.3 &, 11.9 Hz), 4.2 (2H, dd, J=3.7 & 11.9 Hz), 5.01 (2H, s), 7.00 (2H, d, J=8.6 Hz), 7.2 (2H, d, J=6.8 Hz), 7.39 (2H, d, J=8.6 Hz), 7.9 (2H, d, J=8.1 Hz).
[0478] Yield: 86.8%
Example 99
2-Methyl-5-trans-{4-[2-(5-methyl-2-phenyl-oxazol-4-yl)-ethoxy]-phenyl}-[1,3]dioxane-2-carboxylic acid
[0479] 1 H NMR: 1.65 (3H, s), 2.39 (3H, s), 2.7 (1H, m), 3.0 (2H, t, J=6.6 Hz), 4.0 (2H, dd, J=3.7 & 11.8 Hz), 4.2 (4H, t, J=6.7 Hz), 6.9 (2H, d, J=8.5 Hz), 7.3 (2H, d, J=8.5 Hz), 7.4 (3H, m), 8.0 (2H, m).
[0480] Yield: 94.9%
Example 100
2-Methyl-5-trans-{4-[2-(5-methyl-2-p-tolyl-oxazol-4-yl)-ethoxy]-phenyl}-[1,3]dioxane-2-carboxylic acid
[0481] 1 H NMR (CD 3 OD): 1.5 (3H, s), 2.35 (3H, s), 2.37 (3H, s), 2.67 (1H, m), 2.9 (2H, t, J=6.5 Hz), 3.9 (2H, d, J=9.9 Hz), 4.2 (4H, m), 6.85 (2H, d, J=8.5 Hz), 7.26 (2H, d, J=8.1 Hz), 7.4 (2H, d, J=8.5 Hz), 7.8 (2, d, J=8.1 Hz).
[0482] Yield: 45.25%
Example 101
2-Methyl-5-trans-{4-[4-methyl-2-(4-trifluoromethyl-phenyl)-thiazol-5-ylmethoxy]-phenyl}-[1,3]dioxane-2-carboxylic acid
[0483] 1 H NMR: 1.67 (3H, s), 2.52 (3H, s), 2.81 (1H, m), 4.1 (2H, dd, J=3.2 & 11.7 Hz), 4.3 (2H, dd, J=3.5 & 11.9 Hz), 5.2 (2H, s), 6.95 (2H, J=8.5 Hz), 7.4 (2H, d, J=8.5 Hz), 7.66 (2H, d, J=8.1 Hz), 8.01 (2H, d, J=8.1 Hz).
[0484] Yield: 44.41%
Example 102
2-Methyl-5-cis-{4-[4-methyl-2-(4-fluoromethyl-phenyl)-thiazol-5-ylmethoxy]-phenyl}-[1,3]dioxane-2-carboxylic acid
[0485] 1 H NMR: 1.65 (3H, s), 2.51 (3H, s), 3.2 (1H, m), 3.9 (2H, t, J=11.6 Hz), 4.1 (2H, dd, J=4.5 & 11.8 Hz), 5.17 (2H, s), 6.9 (2H, d, J=8.55 Hz), 7.1 (2H, d, J=8.55 Hz), 7.68 (2H, d, J=8.1 Hz), 8.0 (2H, d, J=8.0 Hz).
[0486] Yield: δ 09.93%
Example 103
2-Methyl-5-cis-(4-{2-[2-methyl-5-(4-methylsulfanyl-phenyl)-pyrrol-1-yl]-ethoxy}-phenyl)-[1,3]dioxane-2-carboxylic acid
[0487] 1 H NMR 1.65 (3H, s), 2.35 (3H, s), 2.51 (s, 3H), 3.2 (1H, m), 3.9 (4H, m), 4.05 (2H, dd, J=4.6 & 11.9 Hz), 4.25 (2H, t, J=6.6 Hz), 5.95 (1H, d, J=3.3 Hz), 6.07 (1H, d, J=3.3 Hz), 6.55 (2H, d, J=8.6 Hz), 6.99 (2H, d, J=8.6 Hz), 7.3 (4H, m).
[0488] Yield: 88.7%
Example 104
5-cis-[4-(2-tert-Butyl-5-methyl-oxazol-4-ylmethoxy)-phenyl]-2-methyl-[1,3]dioxane-2-carboxylic acid
[0489] 1 H NMR: 1.41 (9H, s), 1.62 (3H, s), 2.34 (s, 3H), 3.0 (1H, m), 3.5 (2H, t, J=11.5 Hz), 3.66 (2H, dd, J=4.8 & 11.6 Hz), 4.95 (2H, s), 6.8 (2H, d, J=8.6 Hz), 6.9 (2H, d, J=8.6 Hz).
[0490] Yield: 85.5%.
Example 105
5-trans-[4-(2-tert-Butyl-5-methyl-oxazol-4-ylmethoxy)-phenyl]-2-methyl-[1,3]dioxane-2-carboxylic acid
[0491] 1 H NMR: 1.38 (9H, s), 1.62 (3H, s), 2.32 (3H, s), 2.71 (1H, m), 4.0 (2H, dd, J=3.8 & 11.8 Hz), 4.2 (2H, dd, J=3.7 & 11.9 Hz), 4.9 (2H, s), 6.9 (2H, d, J=8.6 Hz), 7.3 (2H, d, J=8.6 Hz).
[0492] Yield: 80.3%
Example 106
2-Methyl-5-cis-{4-[2-(4-phenoxy-phenoxy)-ethoxy]-phenyl}-[1,3]dioxane-2-carboxylic acid
[0493] 1 H NMR: 1.65 (3H, s), 3.22 (1H, m), 3.9 (2H, t, J=11.5 Hz), 4.1 (2H, dd, J=4.3 & 11.6 Hz), 4.29 (4H, s), 6.9 (8H, m), 7.0 (3H, t, J=8.6 Hz), 7.29 (2H, t, J=8.2 Hz).
[0494] Yield: 84.4%
Example 107
2-Methyl-5-trans-{4-[2-(4-phenoxy-phenoxy)-ethoxy]-phenyl}-[1,3]dioxane-2-carboxylic acid
[0495] 1 H NMR (DMSO-D 6 ): 1.39 (3H, s), 2.7 (1H, m), 3.9 (2H, d, J=11.4 Hz), 4.1 (2H, d, J=11.7 Hz), 4.28 (4H, s), 6.9-7.12 (9H, m), 7.36 (2H, t, J=8.0 Hz), 7.4 (2H, t, J=8.5 Hz).
[0496] Yield: 74.74%
Example 108
5-cis-[4-(2-Fluoro-benzyloxy)-phenyl]-2-methyl-[1,3]dioxane-2-carboxylic acid
[0497] 1 H NMR: 1.66 (3H, s), 3.2 (1H, m), 3.9 (2H, J=11.7 Hz), 4.1 (2H, dd, J=4.5 & 11.9 Hz), 5.1 (2H, s), 6.9 (2H, d, J=8.6 Hz), 7.05-7.17 (4H, m), 7.3 (1H, m), 7.45 (1H, t, J=7.4 Hz).
[0498] Yield: 93.7%
Example 109
5-trans-[4-(2-Fluoro-benzyloxy)-phenyl]-2-methyl-[1,3]dioxane-2-carboxylic acid
[0499] 1 H NMR: 1.68 (3H, s), 2.8 (1H, m), 4.1 (21 dd, J=3.9 & 11.4 Hz), 4.25 (2H, dd, J=3.7 & 11.9 Hz), 5.1 (2H, s), 6.99 (2H, d, J=8.6 Hz), 7.06-7.19 (2H, m), 7.30 (1H, m), 7.38 (2H, d, J=8.6 Hz), 7.5 (1H, t J=7.3 Hz).
[0500] Yield: 69.4%
Example 110
5-cis-[4-(5-tert-Butyl-2-p-tolyl-2H-pyrazol-3-ylmethoxy)-phenyl]-2-methyl-[1,3]dioxane-2-carboxylic acid
[0501] 1 H NMR: 1.36 (9H, s), 1.6 (3H, s), 2.3 (3H, s), 3.2 (1H, m), 3.8 (2H, t, J=11.7 Hz), 4.0 (2H, dd, J=4.62 & 11.7 Hz), 4.86 (2H, s), 6.4 (1H, s), 6.88 (2H, d, J=8.6 Hz), 7.0 (2H, d, J=8.6 Hz), 7.15 (2H, d, J=8.1 Hz), 7.4 (2H, d, J=8.2 Hz).
[0502] Yield: 63.24%
Example 111
5-tram-[4-(5-tert-Butyl-2-p-tolyl-2H-pyrazol-3-ylmethoxy)-phenyl]-2-methyl-[1,33]dioxane-2-carboxylic acid
[0503] 1 H NMR: 1.37 (9H, s), 1.6 (3H, s), 2.36 (3H, s), 2.8 (1H, m), 4.1 (2H, dd, J=3.8 & 11.9 Hz), 4.2 (2H, dd, J=3.8 & 11.9 Hz), 4.9 (2H, s), 6.4 (1H, s), 6.9 (2H, d, J=8.6 Hz), 7.2 (2H, d, J=8.16 Hz), 7.3 (2H, d, J=8.6 Hz), 7.4 (2H, d, J=8.2 Hz).
[0504] Yield: 51.23%
Example 112
2-Methyl-5-trans-[4-(2-oxo-3-phenyl-oxazolidin-5-ylmethoxy)-phenyl]-[1,3]dioxane-2-carboxylic acid
[0505] 1 H NMR (DMSO-d 6 ): 1.39 (3H, s), 2.7 (1H, m), 3.9 (3H, m), 4.1-4.28 (5H, m), 5.0 (1H, m), 6.9 (2H, d, J=8.4 Hz), 7.1 (1H, t, J=7.2 Hz), 7.4 (4H, m), 7.57 (2H, d, J=7.8 Hz).
[0506] Yield: 66.8%
Example 113
2-Methyl-5-cis-[4-(2-oxo-3-phenyl-oxazolidin-5-ylmethoxy)-phenyl]-[1,3]dioxane-2-carboxylic acid
[0507] 1 H NMR (DMSO-d 6 ): 1.40 (3H, s), 3.1 (1H, m), 3.7 (2H, t, J=1.6 Hz), 3.9 (3H, m), 4.2 (3H, m), 5.0 (1H, m), 6.9 (2H, d, J=8.5 Hz), 7.1 (3H, m), 7.38 (2H, t, J=8.0 Hz), 7.55 (2H, d, J=8.3 Hz).
[0508] Yield: 70.44%.
Example 114
5-trans-{4-[2-(4-Methanesulfonyloxy-phenyl)-ethoxy]-phenyl}-2-methyl-[1,3]dioxane-2-carboxylic acid
[0509] 1 H NMR: 1.67 (3H, s), 2.8 (1H, m), 3.08 (2H, d, J=6.7 Hz), 3.13 (3H, s), 4.10 (2H, dd, J=3.8 & 11.9 Hz), 4.14 (2H, t, J=6.7 Hz), 4.27 (2H, dd, J=3.75 & 11.9 Hz), 6.88 (2H, d, J=8.6 Hz), 7.24 (2H, d, J=8.56 Hz), 7.35 (4H, dd, J=3.4 & 8.66 Hz).
[0510] Yield: 86.6%
Example 115
2-Methyl-5-trans-[4-(3-methyl-4-oxo-3,4-dihydro-quinazolin-2-ylmethoxy)-phenyl]-[1,3]dioxane-2-carboxylic acid
[0511] 1 H NMR (DMSO-d 6 ): 1.38 (3H, s), 2.7 (1H, m), 3.67 (3H, s), 3.9 (2H, d, J=11.37 Hz), 4.1 (2H, m), 5.25 (2H, s), 7.07 (2H, d, J=8.6 Hz), 7.4 (2H, d, J=8.6 Hz), 7.55 (1H, t, J=7.6 Hz), 7.66 (1H, d, J=8.1 Hz), 7.82 (1H, t, J=7.1 Hz), 8.16 (1H, d, J=7.83 Hz).
[0512] Yield: 92.04%
Example 116
5-cis-[6-(2-Fluoro-benzyloxy)-naphthalen-2-ylmethyl]-2-methyl-[1,3]dioxane-2-carboxylic acid
[0513] 1 H NMR: 1.57 (3H, s), 2.40-2.53 (3H, m), 3.60 (2H, t, J=10.95 Hz), 3.96 (2H, dd, J=12.39 & 4.35 Hz), 5.24 (2H, s), 7.11-7.34 (6H, m), 7.48 (1H, s), 7.55-7.56 (1H, m), 7.69 (21H, m).
[0514] Yield: 42%
Example 117
5-cis-[6-(Benzyloxy)-naphthalen-2-ylmethyl]-2-methyl-[1,3]dioxane-2-carboxylic acid
[0515] 1 H NMR: 1.56 (3H, s), 2.41-2.52 (3H, m), 3.60 (2H, t, J=10.95 Hz), 3.96 (2H, dd, J=12.39 &e; 4.35 Hz), 5.17 (2H, s), 7.20-7.24 (3H, m), 7.34-7.43 (3H, m), 7.49 (3H, d, J=7.23 Hz), 7.66 (2H, dd, J=8.67 & 4.17 Hz).
[0516] Yield: 47%
Example 118
2-Methyl-5-cis-{4-[2-(5-methyl-2-phenyl-oxazol-4-yl)-ethoxy]-benzyl}-[1,3]dioxane-2-carboxylic acid
[0517] 1 H NMR: 1.54 (3H, s), 2.29 (3H, s), 2.37 (3H, s), 2.97 (2H, t, J=6.69 Hz), 3.51-3.55 (2H, m), 3.91 (2H, dd, J=12.57 & 4.2 Hz), 4.21 (2H, t, J=6.72 Hz), 6.82 (2H, d, J=8.55 Hz), 6.99 (2H, d, J=8.52 Hz), 7.41 (3H, m), 7.95-7.99 (2H, dd, J=7.83 & 2.88 Hz).
[0518] Yield: 32%.
Example 119
5-cis-[4-(5-tert-Butyl-2-p-tolyl-2H-pyrazol-3-ylmethoxy)-benzyl]-2-methyl-[1,3]dioxane-2-carboxylic acid
[0519] 1 H NMR: 1.3 (9H, s), 1.5 (3H, s), 2.3 (3H, m), 2.35 (3H, s), 3.5 (2H, t, J=10.9 Hz), 3.9 (2H, m), 4.9 (2H, s), 6.4 (1H, s), 6.8 (2H, d, J=8.5 Hz), 7.0 (2H, d, J=8.5 Hz), 7.2 (2H, d, J=8.1 Hz), 7.4 (2H, d, J=8.3 Hz).
[0520] Yield: 72%.
Example 120
2-Methyl-5-cis-{4-[2-(5-methyl-2-p-tolyl-oxazol-4-yl)-ethoxy]-benzyl}-[1,3]dioxane-2-carboxylic acid
[0521] 1 H NMR: 1.54 (3H, s), 2.27 (3H, s), 2.36 (3H, s), 2.38 (3H, s), 2.98 (2H, t, J=6.72 Hz), 3.52 (2H, t, J=10.74 Hz), 3.90 (2H, m), 4.20 (2H, t, J=6.66 Hz), 6.81 (2H, d, J=8.46 Hz), 6.95 (2H, d, J=8.46 Hz), 7.23 (2H, d, J=8.34 Hz), 7.85 (2H, d, J=8.13 Hz).
[0522] Yield: 32%.
Example 121
2-Methyl-5-trans-{4-[2-(5-methyl-2-phenyl-oxazol-4-yl)-ethoxy]-benzyl}-[1,3]dioxane-2-carboxylic acid
Step 1: Preparation of Methyl-2-methyl-5-trans-{4-[2-(5-methyl-2-phenyl-oxazol-4-yl)-ethoxy]-benzyl}-[1,3]dioxane-2-carboxylate
[0523] A mixture of Methyl-5-trans-(4-hydroxy-benzyl)-2-methyl-[1,3]dioxane-2-carboxylate (isolated from the mother liquor after the crystallization of cis isomer in step 2 of example 2 above) (750 mg), 12-(5-methyl-2-phenyl-oxazol-4-yl)-ethyl methane sulfonate (790 mg) and potassium carbonate (780 mg) in anhydrous dimethyl formamide (10 mL) was stirred at 80° C. for extended periods in an inert atmosphere. Reaction mixture was cooled to ambient temperature, poured into ice cold water and extracted with ethyl acetate. The combined organic extract was washed with water, brine solution, dried over sodium sulphate and evaporated under reduced pressure. Crude product was flash chromatographed over silica gel using a mixture of ethyl acetate and petroleum ether as eluent to obtain 971 mg of pure product.
Step 2: Preparation of 2-Methyl-5-trans-{4-[2-(5-methyl-2-phenyl-oxazol-4-yl)-ethoxy]-benzyl}-[1,3]dioxane-2-carboxylic acid
[0524] To a solution of Methyl-2-methyl-5-trans-{4-[2-(5-methyl-2-phenyl-oxazol-4-yl)-ethoxy]-benzyl}-[1,3]dioxane-2-carboxylate (263 mg) in methanol was added another solution of sodium hydroxide (46.5 mg) in water and the reaction mixture was stirred at ambient temperature for 15 hours. Solvents were evaporated and the residue was dissolved in water, acidified with 1N HCl and extracted with ethyl acetate. The combined organic extract was washed with water, brine, dried over sodium sulphate and evaporated under reduced pressure. Crude product was flash chromatographed over silica gel using 2% methanol in chloroform as eluent to obtain 160 mg of pure product.
[0525] 1 H NMR: 1.61 (3H, s), 2.38 (4H, s), 2.87 (2H, d, J=7.8 Hz), 3.01 (2H, t, J=6.90 Hz), 3.72 (2H, d, J=10.95 Hz), 3.92 (2H, d, J=9.51 Hz), 4.21 (2H, t, J=6.99 Hz), 6.82 (2H, d, J=8.55 Hz), 7.06 (2H, d, J=8.511 Hz), 7.41-7.45 (3H, m), 7.96 (2H, dd, J=4.35 & 7.74 Hz).
[0526] Yield: 52%
[0527] The following compounds were prepared by procedure similar to those described in example 121 with appropriate variations of reactants, reaction conditions and quantities of reagents.
Example 122
2-Methyl-5-trans-[4-(5-methyl-2-phenyl-oxazol-4-ylmethoxy)-benzyl]-[1,3]dioxane-2-carboxylic acid
Example 123
2-Methyl-5-trans-[4-(5-pyridin-2-yl-pyrrolidin-2-ylmethoxy)-benzyl]-[1,3]dioxane-2-carboxylic acid
Example 124
2-Methyl-5-trans-{4-[2-(methyl-pyridin-2-yl-amino)-ethoxy]-benzyl}-[1,3]dioxane-2-carboxylic acid
Example 126
2-Methyl-5-trans-[4-(5-methyl-2-p-tolyl-oxazol-4-ylmethoxy)-benzyl]-[1,3]dioxane-2-carboxylic acid
Example 127
5-trans-[4-(2-Carbazol-9-yl-ethoxy)-benzyl]-2-methyl-[1,3]dioxane-2-carboxylic acid
Example 128
5-trans-[4-(2-Indol-1-yl-ethoxy)-benzyl]-2-methyl-[1,3]dioxane-2-carboxylic acid
Example 129
2-Methyl-5-trans-{4-[5-methyl-2-(5-methyl-thiophen-2-yl)-oxazol-4-ylmethoxy]-benzyl}-[1,3]dioxane-2-carboxylic acid
Example 130
15-trans-{4-[2-(2,3-Dihydro-benzo[1,4]thiazin-4-yl)-ethoxy]-benzyl}-2-methyl-[1,3]dioxane-2-carboxylic acid
Example 131
2-Methyl-5-trans-[4-(2-phenothiazin-10-yl-ethoxy)-benzyl]-[1,3]dioxane-2-carboxylic acid
Example 132
5-trans-{4-[2-(4-Hexyl-3-oxo-3,4-dihydro-2H-benzo[1,4]oxazin-2-yl)-ethoxy]-benzyl}-2-methyl-[1,3]dioxane-2-carboxylic acid
Example 133
2-Methyl-5-trans-(4-{2-[5-methyl-2-(5-methyl-thiophen-2-yl)-oxazol-4-yl]-ethoxy}-benzyl)-[1,3]dioxane-2-carboxylic acid
Example 134
2-Methyl-5-trans-{4-[2-(5-methyl-2-phenyl-oxazol-4-yl)-ethoxy]-benzyl}-[1,3]dioxane-2-carboxylic acid
Example 135
2-Methyl-5-trans-{4-[2-(5-methyl-2-phenyl-oxazol-4-yl)-ethoxy]-benzyl}-[1,3]dioxane-2-carboxylic acid
Example 136
2-Methyl-5-trans-{4-[3-(4-phenoxy-phenoxy)-propoxy]-benzyl}-[1,3]dioxane-2-carboxylic acid
Example 137
5-trans-{4-[2-(4-Methanesulfonyloxy-phenyl)-ethoxy]-benzyl}-2-methyl-[1,3]dioxane-2-carboxylic acid
Example 138
5-trans-[4-(2-tert-Butyl-5-methyl-oxazol-4-ylmethoxy)-benzyl]-2-methyl-[1,3]dioxane-2-carboxylic acid
Example 139
2-Methyl-5-trans-{4-[4-methyl-2-(4-trifluoromethyl-phenyl)-thiazol-5-ylmethoxy]-benzyl}-[1,3]dioxane-2-carboxylic acid
Example 140
2-Methyl-5-trans-{4-[2-(4-phenoxy-phenoxy)-ethoxy]-benzyl}-[1,3]dioxane-2-carboxylic acid
Example 141
5-trans-[4-(2-Fluoro-benzyloxy)-benzyl]-2-methyl-[1,3]dioxane-2-carboxylic acid
Example 142
2-Methyl-5-trans-(4-{2-[2-methyl-5-(4-methylsulfanyl-phenyl)-pyrrol-1-yl]-ethoxy}-benzyl)-[1,3]dioxane-2-carboxylic acid
Example 144
5-trans-{4-[2-(2-tert-Butyl-5-methyl-oxazol-4-yl)-ethoxy]-benzyl}-2-methyl-[1,3]dioxane-2-carboxylic acid
Example 145
5-trans-[6-(2-Fluoro-benzyloxy)-naphthalen-2-ylmethyl]-2-methyl-[1,3]dioxane-2-carboxylic acid
Example 146
5-trans-[6-(Benzyloxy)-naphthalen-2-ylmethyl]-2-methyl-[1,3]dioxane-2-carboxylic acid
Example 147
(Z)-2-Methyl-5-trans-{4-[2-(phenyl-pyridin-2-yl-methyleneaminooxy)-ethoxy]-benzyl}-[1,3]dioxane-2-carboxylic acid
Example 149
(2)-2-Methyl-5-trans-{4-[2-(phenyl-pyridin-2-yl-methyleneaminooxy)-ethoxy]-benzyl}-[1,3]dioxane-2-carboxylic acid
Example 150
5-trans-[4-(5-tert-Butyl-2-p-tolyl-2H-pyrazol-3-ylmethoxy)-benzyl]-2-methyl-[1,3]dioxane-2-carboxylic acid
Example 151
2-Methyl-5-trans-{4-[2-(5-methyl-2-p-tolyl-oxazol-4-yl)-ethoxy]-benzyl}-[1,3]dioxane-2-carboxylic acid
Preparation of Salts
[0528] Sodium and potassium sales of the compounds described above were prepared by following the general procedure described below.
[0529] To a solution of carboxylic acid derivatives of the novel compounds (1 mmol) in alcoholic solvent like methanol, ethanol, propanol, isopropanol, butanol, t-butanol and the like was added a solution of sodium or potassium alkoxide (0.95 mmol) in alcoholic solvent and the reaction mixture was stirred for 3 hours at 25-30° C. Solvent was evaporated and the residue was triturated with dry diethyl ether or diisopropyl ether to obtain the salt of the corresponding carboxylic acid.
[0530] The compounds of the present invention lowered triglyceride, total cholesterol, LDL, VLDL and increased HDL and lowered serum glucose levels. This was demonstrated by in vitro as well as in vivo animal experiments.
A) Demonstration of In Vitro Efficacy of Compounds:
[0531] In vitro hPPAR α & hPPARγ activities were determined as per in-house protocols and the results of representative compounds are provided below as a proof of the efficacies of the novel class of compounds disclosed above.
[0000]
Example No.
EC 50 (PPAR alpha)
EC 50 (PPAR gamma)
61
1.09 μM
0.096 μM
66
0.072 μM
0.015 μM
70
0.6 μM
0.0198 μM
B) Demonstration of In Vivo Efficacy of Compounds:
[0532] i) Serum Triglyceride and Total Cholesterol Lowering Activity in Swiss Albino Mice:
[0533] Male Swiss albino mice (SAM) were bred in Zydus animal house. All these animals were maintained under 12 hour light and dark cycle at 25±1° C. Animals were given standard laboratory chow (NIN, Hyderabad, India) and water ad libitum. SAM of 20-30 g body weight range was used. The protocol approved by Institutional Animal Ethics Committee is being used.
[0534] The test compounds were administered orally to Swiss albino mice at 0.001 to 50 mg/kg/day dose for 6 days. The compound was administered after suspending it in 0.25% CMC or dissolving it in water, when compound is water-soluble. Control mice were treated with vehicle (0.25% of Carboxymethyl cellulose; dose 10 ml/kg).
[0535] The blood samples were collected on 0 th day and in fed state 1 hour after drug administration on 6 th day of the treatment. The blood was collected in non heparinised capillary and the serum was analyzed for triglyceride and total cholesterol (Wieland, O. Methods of Enzymatic analysis. Bergermeyer, H., O., Ed., 1963. 211-214; Trinder, P. Ann. Clin. Biochem. 1969. 6: 24-27). Measurement of serum triglyceride and total cholesterol was done using commercial kits (Zydus-Cadila, Pathline, Ahmedabad, India).
[0536] Formula for Calculation:
[0000] Percentage reduction in triglycerides/total cholesterol were calculated according to the formula:
[0000]
Percentage
reduction
(
%
)
=
1
-
[
TT
/
OT
TC
/
OC
]
×
100
OC=Zero day control group value OT=Zero day treated group value
TC=Test day control group TT=Test day treated group
[0000]
TABLE 1
Triglyceride lowering activity in Swiss albino mice:
Dose
Example No.
(mg/kg/day)
% Triglyceride lowering
61
10
23
66
10
40
100
10
44
[0539] ii) Serum triglyceride and total cholesterol lowering activity in Hamster of Syrian golden stain:
[0540] Male and Female Hamster of Syrian golden stain were bred in Zydus animal house. All these animals were maintained under 12-hour light and dark cycle at 22±3 degree C. The protocol approved by Institutional Animal Ethics Committee is being used. Animals of 3-12 weeks age (80-150 gm body weight) were taken for study. Near the end of the acclimatization period, animals judged to be suitable for testing will bee weighed. Six animals will be selected for normal NIN (NIN, Hyderabad, India) diet average bodyweight was not significantly different from the rest of the animals. Other animals were put on HF-HC (High fat and high cholesterol) diet for 14 days. On day 14 all the HF-HC diet fed animals were selected which had gained their body weight significantly more than the normal diet group animals. The selected animals were divided into different groups in such a way that the average bodyweight of the animals in each group was not significantly different from the other groups.
[0541] Each animal received a single dose of ZY compounds at 0.001 to 50 mg/kg/ as a carbomethoxy cellulose or polyethylene glycol in the evening administered as an oral gavage daily for 15 days. On day 14, after 1 hr of dose administration, non-fasted blood samples were collected in non heparinized capillary from animals for determination of total cholesterol (TC), triglyceride (TG) (Wieland, O. Methods of Enzymatic analysis. Bergermeyer, H., O., Ed., 1963. 211-214; Trinder, P. Ann. Clin. Biochem. 1969. 6: 24-27). Measurement of serum triglyceride and total cholesterol was done using commercial kits (Pointe Scientific.Inc.USA.) And on day 14 night all animals will be kept for fasting for 12-16 hours. On day 15, after 1 hour of dose administration fasted blood samples will be collected from animals for determination of high density lipoprotein (HDL), and low density lipoprotein (LDL) in serum. The animals will then be euthanized by carbon-dioxide asphyxia (and cervical dislocation, if necessary) and heart, kidney and liver will be resected and weighed.
Formula for Calculation:
[0542] Percentage reduction in triglycerides/total cholesterol were calculated according to the formula:
[0000] Percentage reduction(%)=( TT−TC )/ TC* 100
[0000] TC=Test day control group TT=Test day treated group.
[0000] TABLE 2 Dose Example No. (mg/kg/day) % Triglyceride lowering 61 3 30 96 3 41 106 3 50
The compounds of the present invention improves insulin sensitivity, impaired glucose tolerance and reduced serum glucose levels, TG, FFA and cholesterol in db/db, ob/ob mice and zucker fa/fa rats.
[0543] No adverse effects were observed for any of the mentioned compounds of invention. The compounds of the present invention showed good serum glucose, lipid and cholesterol lowering activity in the experimental animals used. These compounds are useful for the testing/prophylaxis of diseases caused by hyperlipidemia, hypercholesterolemia, hyperinsulinemia, hyperglycemia such as NIDDM, cardiovascular diseases, stroke, hypertension, obesity since such diseases are interlinked to each other.
|
Disclosed are novel compounds of general formula (I) where the symbols are as defined in the specification, their tautomeric forms, their stereoisomers, their pharmaceutically acceptable salts, pharmaceutical compositions containing them, methods for their preparation, use of these compounds in medicine and the intermediates involved in their preparation. The compounds are useful in the treatment of diabetes and related diseases.
| 2
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BACKGROUND OF THE INVENTION
TF (typhoid fever) in man is the clinical manifestation of a generalized or systemic infection by Salmonella typhi, a gram-negative bacterium which penetrates the organism through the gastrointestinal tract, usually by ingestion of water or food contaminated by human feces. S. typhi belongs to the serotype 9, 12, d, Vi, defined by the repeated sugar units (9, 12) of the O antigen, that together with lipid A constititutes the lipopolysaccharide (LPS) of the outer membrane; by the H antigen (d) constituted by the flagellar protein or flagellin, and by the Vi antigen or K capsular polysaccharide (Calva, E. et al., 1988, Research opportunities in typhoid fever: Epidemiology and Molecular Biology. BioEssays 9: 173-177).
As other gram-negative bacteria, S. typhi has three envelopes, constituted by two membranes, the internal and external, and an intermediate cell wall or peptidoglycan.
One of the major S. typhi outer membrane proteins (mOMPs) is OmpC (Puente J.L. et al., 1987, Isolation of an OmpC-like outer membrane protein gene from Salmonella typhi. Gene 61: 75-83.) The composition of the gene that codifies OmpC is very similar to that from E. coli (Puente, J.L. et al.) Comparative analysis of the Salmonella typhi and Escherichia coli OmpC genes. Gene 83: 197-206). OmpC (a porin) in E. coli forms a trimer that constitutes a 1.1 amstrong-diameter pore, which allows the passing of hydrophilic molecules. In E. coli, OmpF (a porin) forms trimers that constitute 1.2 amstrong-diameter pores. Another mOMP is OmpA which is a structural monomer.
In addition, in both: E. coli and in S. typhimurium exist a variety of proteins, some of which are regulated by metabolites such as calcium, phosphate, iron, maltose and others. To this respect, in the case of iron (Fe) it has been observed that there is a competition for this metal, between the host and the invader in such a way that both have developed different mechanisms for its acquisition or its sequestering during infection (Bullen, J.J., 1981, The significance of iron in infection. Rev. Infect. Dis. 3: 1127-1138; Weinberg, E.D., 1978, Iron and Infection. Microbiol. Rev. 42: 45-66).
It is evident that typhoid fever affects individuals from different geographical areas, ages and socioeconomical levels; thus there is in consequence a great need for new, highly sensitive and specific, rapid, and easy to perform diagnostic tests, for detecting TF in such a manner that it can be easily distinguished from other febrile diseases. This is even more important for children, in view that they tend to develop mild forms of the disease (Ferreccio, C. et al., 1984, Benign bacteremia caused by S. typhi and S. paratyphi in children younger than two years. J. Pediatr. 104: 899-901). Due to the fact that the majority of the population in areas where TF is endemic has high levels of serum antibodies against S. typhi, induced by its continuous exposure to the microorganism, the serological tests performed in these areas are of low specificity for the diagnosis of TF. Moreover, a significant increase in the antibody titers against the O antigen usually is detected until the second or third week after onset of fever. (Calva et. al. 1988 Research Opportunities in typhoid Fever: Epidemiology and Molecular Biology. Bioessays 9:173-177).
To date, the most exact diagnostic test for TF is the isolation of S. typhi from bone marrow aspirates, which has a 70 to 90% sensitivity and specificity. Nevertheless, it is an aggressive procedure and can only be performed in some hospitals, thus it is an impractical test. Blood cultures or hemocultures are more commonly used and easy to perform, although their sensitivity is also 70-90% when three consecutive cultures are done, at 1-2 day intervals. The important disadvantages related to this method are that the isolation and identification of S. typhi takes at least 72 hours and that the hemocultures might not be highly sensitive, due to a low concentration of circulating S. typhi in blood (approximately 20 cells/ml or less), especially when the patients have taken antibiotics before the culture, a common situation in many countries (Edelman, R. and Levine M.M., 1986, Summary of an international workshop on typhoid fever. Rev. Infect. Dis. 8: 329-350).
In some investigations performed with different antigenic reagents, of non-proteic nature, and with different methodologies, varied results have been observed. For instance, one of the most used serodiagnostic methods for TF, and one of the oldest, is the Widal test or "febrils reactions", that consists in the detection of agglutination in a suspect serum with the O and H antigens. With this test it is possible to diagnose enteric fever mainly by S. typhi and S. paratyphi. Nevertheless, due to the elevated background titers in healthy individuals in endemic areas, its use is recommended for individuals from non-endemic areas and to persons below ten years of age in endemic areas (Levine M.M. et al., 1978, Diagnostic value of the Widal test in areas endemic for typhoid fever. Am. J. Trop. Med. Hyg. 27: 795-800).
The counter immuno electrophoresis (CIE) method has also been used, utilizing various antigenic extracts. With an antigenic extract obtained by sonication, the best results were obtained, i.e. a sensitivity and specificity for TF of 70 and 96%, respectively (Talwar, V. et al, 1986, Counter ion immuno electrophoresis (CIEP) for serological diagnosis of typhoid fever. Indian J. Med. Res. 84: 353-357). By solid-phase radioimmuno assay (RIA), positive values were obtained among 94% and none of TF patients and healthy controls, respectively. In contrast, the same values for the Widal test were 81 and 25% (Tsang, R.S.W. et al., 1981, Antibody response to the lipopolysoccharide and protein antigens of S. typhi during typhoid infection. Clin. Exp. Immunol. 46: 508-514). Another group found that CIEP had a sensitivity of 90% for diagnosing TF in culture-negative clinically diagnosed TF patients, as compared with 48% obtained with the Widal test (Srivastava, V.K. et al., 1986, Comparison of counter current immunoelectrophoresis and Widal tests in the diagnosis of typhoid fever in childhood. Indian J. Pathol. Microbiol. 29: 21-26).
The ELISA (enzyme-linked immunosorbent assay) has been used by different groups interested in the diagnosis of TF, using practically all the surface antigens described, treated or obtained by variable ways, has led to the obtention of variable results.
Beasley, W.J. et al. (1981, Improved serodiagnosis of Salmonella enteric fevers by an enzyme-linked immunosorbent assay. J. Clin. Microbiol. 13: 106-114), performed an ELISA using a proteic antigen. In their work they developed tests with TF and paratyphoid (PTF) patients; they could detect as positives some samples that appeared to be false negatives by the Widal (agglutination) test. Nevertheless, the percent of positive values was indistinct for TF and for PTF and, on the other hand, there was great dispersion among the positive values; for this reason it was not possible to propose a cutoff line at one serum dilution. Also, when the immune response was evaluated by immunoglobulin G (IgG) and by immunoglobulin M (IgM), no significant difference was observed in the IgM and IgG titers between sera from acute and convalescent phase individuals. Lastly, sera from persons with other kinds of infections different from enteric fever were not evaluated.
Calderon, I. et al. (1986, Antibodies to porin antigens of S. typhi induced during typhoid fever in humans. Infect. Immun. 52: 209-212), titrated the immune response to S. typhi OMPs with IgG and IgM by ELISA, and found that the absorbance values obtained with porins, presumably free of lipopolysaccharide (LPS), with sera positive for TF, differed significantly from control sera of clinically healthy individuals from an endemic area. They also compared this response with that obtained against the LPS and flagellin, observing a greater response against the porins. Nevertheless, in their assay they did not evaluate subjects with other kinds of infections.
Appassakij, H. et al. (1987, Enzyme-linked immunosorbent assay for detection of S. typhi protein antigen. J. Clin. Microbiol. 25: 273-277), designed an ELISA method for the determination of proteic antigen in serum. When they tried it on groups of subjects with TF, PTF, other febrile diseases, as well as in healthy controls, they observed a great dispersion in the TF and PTF groups and a certain degree of crossing-over when a cutoff value was established. They obtained an 84% sensitivity and an 89% specificity.
The ELISA was tested by Banchuin, N. S. et al. (1987Detection of S. typhi protein antigen in serum and urine: a value for diagnosis of typhoid fever in an endemic area. Asian Pacific J. Allergy Immunol. 5: 155-159), for detecting antigen in serum and in urine; and they compared it with the Widal test. With this assay they obtained a predictive positive value of 33% in serum and 64% in urine; against 17% in Widal-O and 13% in Widal-H. Their negative predictive value was 97% in serum and urine, and of 97% in the Widal reactions. With these results, they demonstrated that the assay was significantly superior to the Widal test in the positive predictive value, and that the Widal is of low value for adults in endemic areas, as previously pointed out by Levine, M.M. et al. (1978, Diagnostic value of the Widal test in areas endemic for typhoid fever. Am. J. Trop. Med. Hyg. 27: 795-800), and Lambertucci, J.R. et al. (1985, The value of the Widal test in the diagnosis of prolonged septicemic salmonellosis. Rev. Inst. Med. Trop. Sao Paulo 27: 82-85).
Use of the ELISA for detecting antibodies to Salmonella typhi lipopolysaccharide (LPS) has been reported. In two reports the LPS-ELISA was found to be more specific and more sensitive, respectively than the Widal test. In one study, the % of serum samples positive for LPS immunoglobulins ranged between 83 and 97% versus 0 to 4% in healthy controls; for the Widal test these values ranged between 41 and 90%, and 0 and 4%, respectively, although they were obtained at lower dilution of the test serum. Nevertheless, there was wide scattering of the data, making it difficult to set a cutoff value between positive and negative values. In addition, lower dilutions of the test serum, than the ones reported below in the FT-ELISA described in this invention, were used for the LSP-ELISA (Nardiello, S. et al., 1984, Serodiagnosis of typhoid fever by enzyme-linked immunosorbent assay determination of anti-Salmonella typhi lipopolysaccharide antibodies. J. Clin. Microbiol. 20: 718-721). In another report, even lower dilutions of the test serum were used, wide scattering of the data was obtained, and positive values for only 73 to 82% of the bacteriologically proven cases were obtained. Nevertheless, positive values with the Widal test were present in only 41% of the samples (Srivastava, L. and Srivastava, V.K., 1986, Serological diagnosis of typhoid fever by enzyme-linked immunosorbent assay [ELISA]. Annals of Tropical Paediatrics 6: 191-194).
After analyzing the above mentioned data with respect to the protein-ELISAs, one can conclude that, in spite of the various investigations in this field, performed mainly in areas where TF is endemic, and of the important efforts that have been made for diagnosing efficiently this disease, there is still no diagnostic system for TF that is rapid, sensitive, specific, reproducible, practical, and economical. Thus, a process has been developed for obtaining and utilizing an antigenic reagent that, due to its characteristics, allows the indirect determination of Salmonella typhi, the casual agent of TF.
SUMMARY OR THE INVENTION
The invention presented here refers to a process for obtaining an antigenic reagent useful for determining indirectly Salmonella typhi. Growth of the bacteria is done in a culture medium, with an added free-iron chelating agent, up to late logarithmic phase of growth. Afterwards, the culture is centrifuged, and the resulting pellet is resuspended in a buffer solution; this solution is subjected to sonication in ice with seven pulses of 30 sec each; the sonicated suspension is centrifuged, the resulting supernatant is collected and centrifuged at 3° to 10° C., the resulting pellet is resuspended in a buffer solution, with triton X-100 at 1 to 4%; the suspension is incubated for 10 to 25 min at 20° to 41° C., it is centrifuged at 3° to 10° C., and the resulting pellet is resuspended in a buffer solution.
The above suspension is centrifuged for 20 to 40 min at a temperature of 3° to 10° C. The resulting pellet is resuspended in 400 microliters of a buffering solution, with a pH of 7.0 to 7.8, which is made 0.5 to 2.0% in 2-mercaptoethanol, and 0.5 to 2.0% in sodium dodecyl sulphate (SDS). Thus the desired antigen is obtained (outer membrane protein preparation).
The free-iron chelating agent in the culture medium has the purpose of providing one condition similar to that found in the bloodstream; this results in a characteristic OMP electrophoretic pattern which has a selective influence on the antibodies detected by the ELISA.
An objective of the present invention is to provide the methodology for obtaining a proteic reagent for the indirect determination of Salmonella typhi by ELISA, which presents some advantages, such as: rapid detection, since the maximum time for observing a result is five-and-a-half hours; small sample size (less than 0.1 ml), which is obtained by a single venous puncture; and that no serial sampling has to be done.
Another of the objectives of the invention is to provide the methodology for the treatment of the OMP preparation such that protein denaturation is favored, previous to the sensitization of the ELISA microplate, so that there is a selective effect over the variance increment between the immunoresponse from positive and negative subjects to TF.
One more objective of the invention is to provide an antigen with which defined results can be obtained, since it is possible to propose a cutoff value at a defined serum dilution where the positive sera present slight dispersion, that is: a geometric mean of 1.41, with a standard deviation of 0.122 and maximum and minimum values of 1.58 and 1.22, respectively. This geometric mean was 2.47 to 2.76-fold greater (2.6 on the average) than the mean values in the control groups. The sensitivity and specificity is 100%.
DETAILED DESCRIPTION OF THE INVENTION
Upon describing in detail the process for preparing an antigenic reagent useful for detecting Salmonella typhi indirectly, the object of this invention, the observation is made that this description illustrates the form and manner of making such preparation, but that this process can undergo modifications in detail without varying fundamentally and thus without altering the essence of the procedure. In practice, if the circumstances warrant a modification, these will be performed without losing the true objective of the invention. The results obtained by the applying party, for diagnosing efficiently TF, validate the OMP-ELISA as rapid, sensitive, specific, practical, and economic, through treatment of the antigen by the procedure subject of the invention.
Salmonella typhi Ty2 (serotype 9, 12, d, Vi), American Type Culture Collection No. 19430, was used as reference strain.
Two basic culture media were used for growing Salmonella typhi. One was medium "A" (nutrient) and the other was medium "T" (minimal medium); containing the following ingredients:
______________________________________MEDIUM "A"Nutrient broth (Difco) 7 gYeast extract (Difco) 1 gGlycerol 2 mlK.sub.2 HPO.sub.4 3.7 gKH.sub.2 PO.sub.4 1.3 gH.sub.2 O up to one literMEDIUM "T"NaCl 5.8 gKCl 3.7 gCaCl.sub.2.2H.sub.2 O 0.15 gMgCl.sub.2.7H.sub.2 O 0.10 gNH.sub.4 Cl 1.1 gFeCl.sub.3 2.7 × 10.sup.-4 gNa.sub.2 PO.sub.4 0.142 gKH.sub.2 PO.sub.4 0.272 g50% glucose 10 mlTris-HCl 12.1 gH.sub.2 O up to one liter______________________________________ The pH is adjusted to 7.4 with concentrated HCl
The phosphate-buffered saline (PBS) contains:______________________________________NaCl 16 gNa.sub.2 HPO.sub.4 5.8 gKH.sub.2 PO.sub.4 6.4 gKCl 0.4 gdouble-distilled H.sub.2 O up to two liters______________________________________ The pH is adjusted to 7.4 or 7.8 with concentrated HCl
The antigen, subject of this invention, was obtained using methods based on those described by Schnaitman C.A. (1971, Effect of ethylene diamine tetracetic acid, triton X-100, and lysozyme on the morphology and chemical composition of isolated cell walls of Escherichia coli. J. Bacteriol. 108: 553-556) or METHOD I; and by Matsuyama, S.I. et al. (1984, Promoter exchange between ompF and ompC genes for osmoregulated major outer membrane protein genes of Escherichia coli K-12. J. Bacteriol. 158: 1041-1047) or METHOD II.
The above published methods are for obtaining outer membrane protein preparations from Escherichia coli; having modified them for use on Salmonella typhi is not known as described herein.
The new technique includes the use of some additional compounds, thus some unexpected results have been produced. These additional compounds are:
sucrose
human transferrin
conalbumin or egg-white transferrin
2,2' dipyridyl, and
FeCl 3
Sucrose is used for rendering a change in osmolarity in the culture medium, 10% being equivalent to 300 mM NaCl, i.e. corresponding to the osmolarity found in human serum. The transferrins and 2,2', dipyridyl were used for chelating and thus diminishing the levels of free iron; FeCl 3 was for increasing the level of iron in the culture medium.
METHOD I
a) Cells were grown in 50 ml of culture medium "A", incubating at a temperature between 20° and 41° C., up to late logarithmic phase of growth.
b) A cell pellet is obtained by centrifugation for 5 min at 20 krpm, utilyzing a Beckman A-20 rotor.
c) The pellet is resuspended in 15 to 30 ml of N-2 hydroxy ethyl piperazine N'-2-ethanesulfonic acid (HEPES), pH 6.5 to 8.0; preferably from 7.0 to 7.8.
d) The suspension is centrifuged for 10 to 20 min at 6 krpm.
e) The pellet is resuspended in 15 to 30 ml of a buffer solution. HEPES 10-15 mM, at pH 7.0 to 7.8.
f) The suspension is centrifuged for 10 to 20 min at 6 krpm.
g) The pellet is resuspended in 15 to 30 ml of HEPES 10-15 mM, at pH 7.0 to 7.8.
h) The suspension is sonicated in ice with seven pulses (180 watts), of 30 sec each, with intervals of the same duration, in an MSE Soniprep 150 sonicator.
In between the 4th and 5th pulses, when the O.D.660 of the suspension is around 0.6-0.7, the following compounds are added:
50 microliters of 1M MgCl 2
2 microliters of 10 mg/ml DNase
5 microliters of 10 mg/ml DNase
i) The sonicated suspension is centrifuged twice for 15 to 25 min at 5 krpm; collecting each time the supernatant.
j) The supernatant is centrifuged for 30 min at 50 krpm at a temperature of 3° to 10° C., utilyzing a Beckman 55.1 Ti rotor.
k) The pellet is resuspended in 15 to 30 ml of 10 mM HEPES, pH 7.0 to 7.8.
l) The suspension is centrifuged for 30 to 50 min at 45 krpm at a temperature of 3° to 10° C.
m) The pellet is resuspended in 5 to 20 ml of HEPES, pH 7.0 to 7.8.
n) The supension is centrifuged at 45 krpm for 30 to 50 min, at a temperature of 3° to 10° C.
o) The pellet is resuspended in 5 to 20 ml of 10 mM HEPES, 1 to 4% triton X-100.
p) The suspension is centrifuged for 30 to 50 min at 45 krpm at a temperature of 3° to 10° C.
q) The pellet is resuspended in 10 ml of 5 mM EDTA (ethylene diamine tetracetic acid), 50 mM Tris-HCl pH 7.8, triton x-100 1 to 4%.
r) The suspension is incubated for 10 to 25 min at a temperature of 20° to 41° C.
s) The suspension is centrifuged for 30 to 50 min at 45 krpm at a temperature of 20° to 41° C.
t) The pellet is resuspended in 0.5 to 2 ml of 10 mM HEPES, pH 7.0 to 7.8; thus the desired antigen is obtained.
METHOD II
a) The cells were grown in 50 ml of culture medium "A" incubating at a temperature of 20° to 41° C., up to late logarithmic phase of growth.
b) The culture is centrifuged for 5 to 20 min at 10 krpm, using a Beckman JA-20 rotor.
c) The pellet is resuspended in 15 to 30 ml of 10-15 mM phosphate (Na 2 HPO 4 ) buffer, pH 6.5 to 8.0; preferably between 7.0 and 7.5.
d) The suspension is centrifuged for 5 to 20 min at 10 krpm at a temperature of 3° to 10° C.
e) The pellet is resuspended in 15 to 30 ml of a 10-15 mM phosphate buffer, pH 7.0 to 7.5.
f) The suspension is sonicated over ice with seven pulses of 30 sec each, with 30 sec intervals, in an MSE Soniprep 150 sonicator.
g) The sonicated suspension is centrifuged for 5 to 20 min at 3 krpm at a temperature of 3° to 10° C., and the supernatant is collected.
h) The supernatant is centrifuged for 20 to 40 min at 40 krpm at a temperature of 3° to 10° C.
i) The pellet is resuspended in 15 to 30 ml of a 10-15 mM phosphate buffer, pH 7.0 to 7.5, 1-4% triton X-100.
j) The suspension is incubated for 10 to 25 min at a temperature of 20° to 41° C.
k) The suspension is centrifuged for 20 to 40 min at 40 krpm at a temperature of 3° to 10° C., in A Beckman 55.1 Ti rotor.
l) The pellet is resuspended in 15 to 30 ml of 10 mM phosphate buffer, pH 7.0 to 7.5.
m) The suspension is centrifuged for 20 to 40 min at 40 krpm at a temperature of 3° to 10° C.
n) The pellet is resuspended in 400 microliters of PBS, pH 7.0 to 7.5, containing 0.5 to 2.0% 2-mercaptoethanol and 0.5 to 2.0% SDS, thus the desired antigen is obtained.
When the OMP preparations (the above mentioned desired antigen) were analyzed by SDS-polyacrylamide gel electrophoresis, three main bands were observed, which correspond to the following proteins: OmpC of 38.5 kDa apparent molecular weight (Puente et al., 1987, op. cit.), OmpF of 37.5 kDa, and OmpA 31.5 kDa.
VARIATIONS IN GROWTH CONDITIONS
Osmolarity
With the purpose of identifying which bands corresponded to the OmpC and OmpF proteins, we analyzed the outer membrane proteins from cultures grown in high and low osmolarity. Thus, the bacteria grew in nutrient broth with 20% sucrose, which increases the culture osmolarity; a lower expression of a 37.5 kDa band was observed, which was denominated OmpF, on the basis of what has been reported for E. coli (Nakae, 1986).
When growth was performed in 10% sucrose, equivalent to the osmolarity of 0.87% NaCl found in human serum, the same efect for OmpF was found, although to a lesser extent.
Temperature
The cultures were normally incubated at 20° C. In nutrient broth incubated between 20° and 41° C., the late logarithmic phase was reached after seven hours, while at 20° C. it took 15 hours, having started with the same size inoculum. The cellular mass obtained at 20° C. represented 82.6% relative to that obtained at 41° C., as measured by absorbance at a wavelength of 660 nm.
Level of Free Iron
In order to analyze the effect of the levels of free iron (Fe) in OMP expression, two conditions were evaluated: limiting free iron against excess free iron, excess being considered the quantity present in the culture media utilized. In order to limit the access of this metal to the bacteria in the culture medium, different strategies were used.
a) No addition of iron to medium "T" or to minimal medium.
b) Trapping of traces of this metal with an inorganic chelator, 2,2' dipyridyl.
c) Utilization of two organic chelators, human transferrin and hen egg transferrin or conalbumin.
Bacterial growth in "T" medium with no added iron did not present important differences when compared with medium with added iron; if any, there was a greater expression of OmpA with respect to OmpC and OmpF.
With respect to the addition of chelators, utilization of 2,2' dipyridyl at concentrations of 100 μm and 150 μm in both culture media used, resulted in the overexpression or expression of several proteins with the following approximate molecular weigths: 48, 72, 77, 82, 92, 97 and 103 kDa.
The straining intensity of some bands corresponding to these proteins was a reflection of their higher level of expression, thus the 77 and 82 kDa proteins were considered as principal, and the rest as secondary. A band that appears to be present only in low free iron conditions was one of 48 kDa; although the 72 and 82 kDa protein bands were at a very low level in excess free iron.
With respect to the relationship chelator-culture medium, utilization of transferrin in "T" medium appears not to have a different effect on the above mentioned proteins than 2,2' dipyridyl; also, 2,2' dipyridyl produces a lower effect in nutrient medium with respect to that observed, at the same concentration, in minimal medium (Table 1).
The immune response was evaluated using OMPs from S. typhi grown in the selected media, with the following characteristics:
a) Low osmolarity
b) High osmolarity (10% sucrose)
c) Excess free iron
d) Limited free iron by:
2,2' dipyridyl
human tranferrin
conalbumin
The obtained results are shown in Table 1.
TABLE 1______________________________________GROWTH OF Salmonella typhi IN DIFFERENTFREE-IRON CONDITIONS.Culture FeCl.sub.3 2,2'Dip Trans Sacmedium 1 μM 10 μM 100 μM * ** ***Times (hrs) required for reaching late exponential phase______________________________________"A" medium 7.5 7.5 6 7 8 6"B" medium 11 11 10 10 23 23______________________________________ * 2,2'- dipyridyl: growth was apparently the same at 100 or 150 μM. ** Transferrin: Concentration was 2.5 mg/ml. Growth was apparently the same using either human transferrin or conalbumin. *** Sucrose: growth was apparently the same in either 10 or 20% sucrose.
The initial inoculum was 100 μl of a 16 hour overnight culture per 50 ml of culture medium.
The immune response associated to the antigen obtained from bacteria grown in different conditions presented a greater variance with antigen from high osmolarity cultures, when compared to that obtained from low osmolarity conditions. In the same manner, a greater variance was observed with antigen synthesized under free iron limitation than under excess free iron. Nevertheless, in both cases the differences were not statistically significant.
The antigen was resuspended in either of the following three different solutions, previous to its immobilization in the ELISA microplates:
a) 10 mM Na 2 HPO 4 , pH 7.0 to 7.8.
b) Alkaline phosphate buffer (PBS), pH 7.0 to 7.8.
c) Alkaline phosphate buffer (PBS), pH 7.0 to 7.8, plus 0.5 to 2.0% sodium dodecyl sulphate (SDS), and 0.5 to 2.0% 2-mercaptoethanol (B-1).
The results obtained by these treatments revealed that there was no difference between using Na 2 HPO 4 or PBS alone. In contrast, it was observed that the variance between positive and negative subjects for TF increased when B-1 was used. Furthermore, when the OMP preparations were boiled during 3 to 8 min in B-1, the variance increased further. The results obtained with sera from patients positive for TF show a standard deviation of 0.122 with an arithmetic mean of 1.41. B-1 probably has a denaturing effect over the proteins. The concentration of antigen in the ELISA microplates was 5 μg per ml.
In order to evaluate the optimum serum dilution in the immune response, by variance analysis, inverse dilutions of 125, 625, 3 125, and 15 625 were evaluated, comparing sera of subjects positive to TF against sera of two groups of subjects negative to TF. The latter were adults infected with enterotoxigenic Escherichia coli, and 1-2 year old children infected by Campylobacter jejuni. The reciprocal dilution that presented the greatest variance was 3 125. The enzyme-substrate reaction time was evaluated by a variance analysis at 5, 10, 20 and 30 min; 20 min was the selected time.
In summary, the following conditions were selected for the ELISA:
______________________________________antigen concentration (OMP preparations) 5 μg/mlserum dilution reciprocal of 3 125conjugate dilution reciprocal of 1 000enzyme-substrate reaction time 20 minresuspension of the antigen in alkaline phosphate buffer (PBS),pH 7.0 to 7.8, plus 0.5 to 2.0% sodium dodecyl sulphate (SDS),and 0.5 to 2.0% 2-mercaptoethanol (B-1); and boiled for 3 to 8min.absorbancy (wave length) 492 nm.______________________________________
The utilized sera were classified in the following manner: GROUP 1: TYPHOID FEVER; sera from 15 adults, symptomatic for typhoid fever and with a positive Salmonella typhi hemoculture, all during the first week of disease.
Controls
GROUP 2: sera from 15 adults, with diarrhea and positive stool cultures for enterotoxigenic Escherichia coli. GROUP 3: sera from 15 children, 1 to 2 years old, from a semi-urban cohort study, with positive stool cultures for Campylobacter jejuni. GROUP 4: sera from 15 clinically healthy adults. GROUP 5: sera from 15 adults bacteremic for: Proteus spp., Salmonella enteritidis, Salmonella spp., Salmonella group "B", Candida albicans, Escherichia coli.
The results obtained are presented in Table 2.
TABLE 2______________________________________ELISA-OMP IN PATIENTS WITH TFAND OTHER INFECTIONS Standard StandardGroup Average Deviation Error Minimum Maximum______________________________________1 1.41 0.122 0.032 1.22 1.582 0.57 0.084 0.022 0.46 0.733 0.55 0.162 0.042 0.33 0.864 0.51 0.089 0.023 0.32 0.655 0.53 0.260 0.070 0.22 1.02______________________________________ Groups 1 to 5 are as described previously.
The results obtained from the five groups were subjected to a variance analysis, and the probability of TF in group 1 versus groups 2, 3, and 4, was 0.001.
The absorbance values were read at a wavelength of 492 nm.
From the above results, a statistically significant difference can be observed between the absorbance values obtained with sera from individuals positive for TF and the values obtained from sera of individuals negative for TF. This indicates a highly specific humoral response to the antigen during TF.
Therefore, the antigen obtained by the procedure described herein can be employed for selectively detecting antibodies by ELISA for the diagnosis of TF in an endemic area.
In the following examples different procedures for preparing the antigenic reagent of this invention, used for determining Salmonella typhi, are described. The various modes of preparation do not alter in essence the properties of the product antigen.
EXAMPLE 1
50 ml of culture medium "A" are made 1 μM in FeCl 3 . This medium is inoculated with 0.1 ml of an S. typhi overnight culture, and is incubated at a temperature of 20° to 41° C., until the culture reaches late logarithmic phase of growth. The culture is centrifuged for 5 to 20 min at 10 krpm, utilizing the Beckman rotor JA-20; the pellet is resuspended in 15 to 30 ml of 10 mM Na 2 HPO 4 pH 7.0 to 7.5; and the suspension is centrifuged 5 to 20 min at 10 krpm at a temperature of 3° to 10° C. The pellet is resuspended in 15 to 30 ml of 10 mM Na 2 HPO 4 pH 7.0 to 7.5; the suspension is sonicated over ice with seven pulses of 30 sec each, at 30 sec intervals. The sonicate is centrifuged for 5 to 15 min at 3 krpm at a temperature of 3° to 10° C.; the supernatant is collected and centrifuged for 20 to 40 min at 40 krpm at a temperature of 3° to 10° C. The resulting pellet is resuspended in 15 to 30 ml of 10 mM Na 2 HPO 4 pH 7.0 to 7.5, containing triton X-100 at 1-4%, and incubated for 10 to 25 min at a temperature of 20° to 41° C., and centrifuged for 20 to 40 min at 40 krpm at a temperature of 3° to 10° C. The pellet is resuspended in 15 to 30 ml of 10 mM Na 2 HPO 4 pH 7.0 to 7.5; the suspension is centrifuged during 20 to 40 min at 40 krpm at a temperature of 3° to 10° C. The pellet is resuspended in 400 μl of alkaline PBS, pH 7.0 to 7.5 containing 0.2 to 2% 2-mercaptoethanol and 1% SDS. Thus the desired antigen is obtained.
EXAMPLE 2
The same procedure as for EXAMPLE 1 was followed, except that medium "A" was made 10 μM in FeCl 3 .
EXAMPLES 3 AND 4
The same procedure as for EXAMPLE 1 was followed, but culture medium "A" was made 100 μM in 2,2 ' dipyridyl, instead of adding FeCl 3 . The procedure is repeated adding 2,2' dipyridyl up to 150 μM.
EXAMPLES 5 AND 6
The same conditions for the procedure in EXAMPLE 1 were followed, with the exception that 2.5 mg/ml of human transferrin instead of FeCl 3 is added to culture medium "A". Alternatively, the procedure is repeated adding 2.5 mg/ml conalbumin or egg white transferrin. With the procedures for EXAMPLES 5 and 6 an antigen with 10% more efficacy was obtained than that from procedures in EXAMPLES 1 through 4.
EXAMPLES 7 AND 8
The same conditions were followed as for EXAMPLE 1, but 10% sucrose if added to culture medium "A" instead of FeCl 3 . This provides a substantial change in medium osmolarity. The procedure is similarly repeated, except that the medium is made 20% in sucrose.
EXAMPLES 9 TO 11
The same procedure as for EXAMPLE 1 is followed, except that S. typhi is grown in culture medium "T", adding every time that the procedure is done either 1 μM, 10 μM, or 100 μM FeCl 3 .
EXAMPLES 12 TO 17
The same procedure as for EXAMPLE 1 is followed, except that culture medium "T" is used; and to which either of the compounds signaled in EXAMPLES 3 to 8 are added.
EXAMPLE 18
The OMPs obtained in examples 1 through 17 are resuspended in alkaline PBS, pH 7.0 to 7.8; SDS is added to a final concentration of 0.5 to 2.0%, and 2-mercaptoethanol to 0.5 to 2.0%. The suspension is boiled for 5 min, thus obtaining the desired antigen.
EXAMPLE 19
Fifty ml of culture medium "A" are made 1 μM in FeCl 3 , are inoculated with 0.1 ml of an overnight culture of S. typhi, are incubated at a temperature of 20° to 41° C. up to late logarithmic phase of growth, and are centrifuged for 5 to 20 min at 6 krpm, using rotor Beckman JA-20. The resulting pellet is resuspended in in 15 to 30 ml of 10 mM N-(2-hidroxyethyl) piperazine-N-(2-ethanesulfonic acid) (HEPES), pH 7.0 to 7.8 and centrifuged for 10 to 20 min at 6 krpm at a temperature of 3° to 10° C. The resulting pellet is resuspended in 15 to 30 ml of 10 mM HEPES, pH 7.0 to 7.8, and centrifuged for 10 to 20 min at 6 krpm. The resulting pellet is resuspended in 15 to 30 ml of 10 mM HEPES, pH 7.0 to 7.8. It is sonicated over ice with seven pulses (180 watts) of 30 sec each, at 30 sec intervals, in an MSE Soniprep 150 sonicator. Between the fourth and fifth pulse, when the OD at 660 nm is approximately 0.6 to 0.7, the following compounds are added: 50 μl of 1M MgCl 2 , 2 μl of 10 μg/ml DNase, and 5 μl of 10 μg/ml RNase. The sonicated suspension is centrifuged twice for 15 to 25 min at 5 krpm, collecting each time the supernatant.
The resulting supernatant is centrifuged for 30 to 50 min at 45 krpm at a temperature of 3° to 10° C., in a Beckman 55.1 Ti rotor. The pellet is resuspended in 15 to 30 ml of 10 mM HEPES, pH 7.0 to 7.8, and centrifuged for 30 to 50 min at 45 krpm at 3° to 10° C. The pellet is resuspended in 5 to 20 ml of 10 mM HEPES, pH 7.0 to 7.8, and centrifuged for 30 to 50 min at 45 krpm at a temperature of 3° to 10° C. The resulting pellet is resuspended in 5 to 20 ml of 10 mM HEPES, with triton X-100 at 1-4%. The suspension is centrifuged for 30 to 50 min at 45 krpm at 3° to 10° C. The pellet is resuspended in 5 mM ethylene diamino tetra acetic acid (EDTA), 50 mM Tris-HCl (pH 7.0 to 7.8), triton X-100 at 1 to 4%, and incubated for 10 to 25 min at 20° to 41° C. The suspension is centrifuged for 30 to 50 min at 45 krpm at 20° to 41° C. and the resulting pellet is resuspended in 0.5 to 2.0 ml of 10 mM HEPES, pH 7.0 to 7.8, thus obtaining the desired antigen.
EXAMPLE 20
The same procedure as for EXAMPLE 19, except that culture medium "A" is made 10 μM in FeCl 3 .
EXAMPLES 21 AND 22
The same procedure as for EXAMPLE 19, except that instead of adding FeCl 3 to culture medium "A", 2,2' dipyridyl is added at 100 μM. The procedure is repeated adding 2,2' dipyridyl at 150 μM.
EXAMPLES 23 AND 24
The same procedure as for EXAMPLE 19, except that instead of adding FeCl 3 to culture medium "A", 2.5 mg/ml of human transferrin are added. The procedure is repeated adding 2.5 mg/ml of conalbumin or egg white transferrin.
EXAMPLES 25 AND 26
The same procedure as for EXAMPLE 19, except that instead of adding FeCl 3 to culture medium "A", sucrose to 10% is added in order to provide a change in culture osmolarity. The procedure is repeated adding sucrose to 20%.
EXAMPLES 27 TO 29
The same procedure as for EXAMPLE 19, except that the culture is done in medium "T", and the procedure is repeated twice, adding once 10 μM FeCl 3 , and 100 μM FeCl 3 the second time.
EXAMPLES 30 TO 35
The same procedure as for EXAMPLE 19, except that culture medium "T" is used, to which compounds pointed out in EXAMPLES 21 to 26 are added, respectively.
It must be understood that the examples described above in detail can suffer some changes and modifications, without losing the essence of the invention or the perspective of the annexed claims.
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The invention described herein consists of a process for preparing an antigenic reagent useful for the indirect determination of Salmonella typhi, the organism that is the causal agent of typhoid fever (TF). The invention consists on the following steps: to grow Salmonella typhi in a culture medium, characterized by containing a free-iron chelator, which generates a specific S. typhi outer membrane protein (OMP) pattern, OMPs that are used as a selective antigen for the detection of specific serum antibodies, by an immunoassay technique (ELISA).
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BACKGROUND OF THE INVENTION
1. Technical Field
The invention relates to a jacket for flexible heat-insulated conduits.
2. Description of the Background Art
EP 0 897 788 discloses a heat-insulated conduit that is made up of an internal tube, a heat-insulating layer based on polyurethane foam and surrounding the internal tube, and an external jacket. The known conduit can be manufactured in long lengths in one continuous working step. The external jacket, manufactured by extrusion, is made of polyethylene and has a corrugated surface.
One important field of application for the known conduit is the transport of district heat, in which context the conduit is installed in the ground.
The jacket of the conduit is exposed to considerable mechanical loads during both manufacture and installation. By being wound onto cable drums, the jacket is stressed by tensile and flexural forces. Upon installation in the ground, the jacket is stressed by frictional forces. These forces are handled by a conventional jacket made of polyethylene.
On the other hand, the good mechanical strength values of the jacket also result in greater stiffness of the conduit, so that the bending radius cannot fall below a certain value. The known conduit is transported to the utilization site either on commercially available cable drums or coiled into a ring. Large diameters for the cable drums on which the conduit is wound, or large-diameter rings, create problems upon transport to the installation site. A conduit having little flexibility proves disadvantageous during installation as well, since the conduit cannot be curved around tight radii.
SUMMARY OF THE INVENTION
The object of the present invention is therefore to improve the conduit of the kind mentioned initially in such a way that bendability or flexibility is enhanced without substantially degrading the mechanical properties of the jacket.
This object is achieved by providing a jacket for flexible heat-insulated conduits, in particular district heat transport lines, comprising a foamed or inflated polyethylene-based thermoplastic with a modulus of elasticity between 90 and 300 MPa and a density between 0.560 and 0.850 g/cm 3 .
In addition to the advantages directly evident from the statement of the object, the invention yields the additional advantage that the conduit is lighter in weight than the known conduit. A considerable cost saving furthermore results due to economization of material, this saving increasing as the degree of foaming increases, i.e. as the proportion of cells in the jacket becomes greater.
Particularly suitable materials for the jacket are low density polyethylene (LDPE), linear low density polyethylene (LLDPE), and ethylene copolymers based on low density polyethylene.
The degree of foaming of the material for the jacket is preferably between 10 and 60%, i.e. 10 to 60% of the volume is made up of gas-filled cells. The cells are cells having a diameter of less than 0.5 mm.
For the manufacture of a jacket for a heat-insulated conduit, a method that has proven particularly advantageous is one in which a mixture of a polyethylene-based granulated material, and a granulated material based on polyethylene into which a propellant in the form of spherules has been mixed, is produced; this mixture is introduced into an extruder and melted therein, and the melt is extruded in the form of a tube; and the spherules foam up or inflate upon or after emergence from the extruder die.
In particular, the ratio between the polyethylene-based granulated material and the granulated material based on polyethylene to which spherules have been added is between 90:10 and 99:1. The advantage resulting therefrom is that the spherules can be precisely metered in, and the desired degree of foaming can thus be accurately adjusted. The spherules are advantageously hollow spheres that are filled with a gas.
The invention is explained in more detail with reference to the exemplifying embodiment depicted schematically in the FIGURE.
BRIEF DESCRIPTION OF THE DRAWING
The FIGURE is a perspective view of a heat-insulated conduit with a jacket embodying the present invention.
DETAILED DESCRIPTION OF THE INVENTION
In the FIGURE, an internal tube is labeled 1 , a heat-insulating layer based on polyurethane foam is labeled 2 , and a polyethylene-based external jacket is labeled 3 .
The tube and the manufacturing method are known per se from EP 0 897 788 B1.
Instead of the single internal tube 1 , as many as four internal tubes can be provided. The internal tube or tubes is/are preferably made of crosslinked polyethylene. Also provided between heat-insulating layer 2 and external jacket 3 is a film, not depicted in detail, that serves on the one hand as a mold for the polyurethane foam that develops during manufacture, and on the other hand also as a diffusion barrier layer to prevent the escape of the cell gas present in the cells of the polyurethane foam.
According to the teaching of the invention, external jacket 3 is made of a foamed polyethylene-based plastic. A low density polyethylene such as, for example, LDPE, VLDPE, and LLDPE is preferred. An LDPE-based copolymer can, however, also be used.
For manufacture of the external jacket, firstly 97 to 99 parts LDPE are made available in granulated form. One to three parts of a granulated plastic that contains a large proportion of hollow spherules made of plastic are then mixed into the granulated LDPE prior to introduction into the jacket extruder. However, the granulated plastic can also be introduced into the jacket extruder together with the granulated LDPE. In the jacket extruder, the granulated LDPE is increasingly heated and caused to melt. The granulated plastic is, in this context, intimately mixed with the granulated LDPE or LDPE melt. Upon emergence from the die of the jacket extruder, the gas present in the hollow spherules expands and inflates the LDPE melt. After the external jacket cools, it exhibits a cellular structure. The casing of the hollow spherules is retained; no connection occurs to the LDPE jacket material forming the matrix.
An external jacket according to the teaching of the invention exhibits the following values:
Modulus of elasticity
135-162
MPa
Density
0.560-0.750
g/cm 3
The weight savings of the conduit according to the teaching of the invention with respect to the conduit according to EP 0 897 788 is approx. 3-15%, depending on the degree of foaming.
The flexibility of the conduit is 10-30% greater than in the case of a conduit having a conventional PE jacket, the flexibility also being determined by way of the energy expenditure necessary for bending to a defined radius.
It is believed that the many advantages of this invention will now be apparent to those skilled in the art. It will also be apparent that a number of variations and modifications may be made therein without departing from its spirit and scope. Accordingly, the foregoing description is to be construed as illustrative only, rather than limiting. This invention is limited only by the scope of the following claims.
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A jacket ( 3 ) for flexible heat-insulated conduits, in particular district heat transport lines, comprising a foamed or inflated polyethylene-based thermoplastic with a modulus of elasticity between 90 and 300 MPa and a density between 0.560 and 0.850 g/cm 3 .
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CROSS REFERENCE TO RELATED APPLICATION
[0001] The present application claims the priority benefit of U.S. provisional patent application Ser. No. 60/590,776, filed Jul. 23, 2004, entitled “FLUID FILTER SYSTEM AND RELATED METHOD” of the same named inventors. The entire contents of that prior application are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to systems for filtering contaminants from fluids such as drain water and stormwater. More particularly, the present invention relates to a filter system and related method for removing contaminants from a fluid stream by forcing upward and/or radial flow of the fluid through the filter means.
[0004] 2. Description of the Prior Art
[0005] Fluid transfer systems have been and will remain an important aspect of municipal services and commercial facilities management. The protection of ground water and natural bodies of water requires systems for diverting and/or treating water that contacts roadways, parking lots, and other man made structures. If such diversion or treatment systems are not provided, particulate and contaminants located on or forming part of such structures may be carried by drain water or stormwater to the natural water bodies and contaminate them. Local, state and federal laws and rules require municipalities, businesses, and in some instances, private entities, to establish means to reduce particulate and dissolved pollutant levels permissibly transferred to natural bodies of water from property under their control. Particular requirements may vary from jurisdiction to jurisdiction, but all are likely to become more stringent.
[0006] Previously, municipal water transfer and treatment facilities provided the only mechanism for diverting contaminated water away from natural bodies of water, either for holding or treatment for subsequent transfer to natural settings. In general, that process involved, and continues to involve, the establishment of a system of drains, such as in a parking lot or at a street curb, by which water enters a system of pipe conduits. Eventually, the water received from the drains reaches either a final outlet destination or is directed to a treatment system for contaminant removal. For purposes of the description of the present invention, “contaminated water” is to be understood to mean any water including floating particulate, such as Styrofoam™ containers and oil, for example; non-floating particulate, such as sand and silt, for example; and suspended and dissolved contaminants, such as fine solids, oil, grease, organic contaminants including fertilizers, herbicides, and pesticides, and metals, for example.
[0007] Land development produces increased quantities of drain water and stormwater runoff, resulting in increased strain on existing water transfer and treatment infrastructure and an increased likelihood of natural water contamination. In an effort to reduce the impact of development on natural resources and municipal services, initial upstream fluid treatment has become a requirement in many land development, restoration and repair projects. That is, requirements in various forms have been established to ensure that before contaminated water enters the municipal water transfer and/or treatment system or a natural body of water, it must be treated in a manner that reduces the level of contaminants entering the municipal system or the natural body of water. Therefore, most new land development plans and upgrades to existing paved surfaces involve the insertion of a preliminary separation system, generally for connection to the municipal water-handling infrastructure. In other cases, the outflow from the separation system may be transferred directly to a natural body of water.
[0008] Any preliminary separation system must be designed with the capability to receive fluid flowing in at a wide range of rates. For example, a mild rainfall resulting in rain accumulation of less than 0.25 inches over a span of 24 hours produces a relatively low flow rate through the system. On the other hand, for example, a torrential rainfall resulting in rain accumulation of more than two inches over a span of three hours produces relatively high flow rates through the system. It is desirable, then, to have a separation system capable of handling variable fluid flow rates with reduced likelihood of backup and flooding of the surface above.
[0009] In addition to having a reasonable fluid flow throughput capacity, the separation system must be capable of performing the separation function for which it is intended. Relatively large floating particulate and relatively heavy non-floating particulate have been, and are, handled in a number of ways. For example, biofiltration swales, settling ponds, fluid/particle density separators, mechanical separators and media absorbers and filters are employed to remove such types of contaminants. Swales and settling ponds take up significant real estate and are therefore generally not particularly desirable in many settings. The separators require less space to operate, but are relatively costly and require considerable servicing on a regular basis. Existing absorbers and filter mechanisms may be effective at removing specified contaminants; however, they tend to do so at the expense of flow through rates. That is, the filtration efficiency is relatively low in comparison to the required water flow through desired. That may be acceptable under relatively low flow rates; but not so under relatively high flow rates. More efficient systems such as the one described in U.S. Pat. No. 5,759,415 issued to Adams on Jun. 2, 1998, assigned to Vortechnics, Inc. and entitled METHOD AND APPARATUS FOR SEPARATING FLOATING AND NON-FLOATING PARTICULATE FROM RAINWATER DRAINAGE, have been developed and employed to treat water in areas where treatment space is limited. However, regulations regarding the removal of suspended/fine solid particulates and/or dissolved and un-dissolved chemical contaminants have resulted in the need for supplemental removal arrangements.
[0010] There is an increasing need and requirement for separation systems associated with drain water and stormwater introduction to municipal water handling systems and natural bodies of water to remove a substantial portion of all forms of contaminants entering the municipal systems or bodies of water at a point closer to the source. However, it is important that the separation systems not be prohibitively expensive in order to ensure that meeting those needs and requirements is feasible. It is also of importance that such separation systems are relatively easy to maintain. It is becoming increasingly important that these separation systems include means for removing suspended solids and/or chemical contaminants, but without sacrificing the other desired characteristics. Fluid filter systems that are configured to allow for loading of the filter by all floating and nonfloating particulates require maintenance over relatively short intervals. In subsequent fluid treatment cycles, contaminants that remain caked-on the filter surface reduce fluid flow through effectiveness and must therefore be removed relatively frequently. In addition, wet, caked filters are very heavy and therefore require the use of assistive equipment, such as cranes, when they are to be removed for maintenance.
[0011] Therefore, what is needed is a separation system and related method for removing suspended and/or chemical contaminants from a fluid stream as part of a separation system that may or may not be part of a larger fluid handling system, wherein the separation system is effective in accommodating varied fluid flow rates. What is also needed is such a separation system that is cost effective and configured for ease of maintenance, including, for example, addressing the limitations of contaminant retention on the filter and filter device weight that shorten maintenance cycles and increase maintenance difficulty. Further, what is needed is such a separation system that includes a filter system capable of removing identified contaminants with minimal impact on fluid flow rates.
SUMMARY OF THE INVENTION
[0012] It is an object of the present invention to provide a separation system that is effective in accommodating varied fluid flow rates. It is also an object of the present invention to provide such a separation system that conforms or substantially conforms with established contaminant removal requirements. Further, it is an object of the present invention to provide such a separation system that is cost effective and configured for ease of maintenance. In that regard, it is an object of the present invention to maximize contaminant retention within the system while minimizing retention on the surface of the filter and to reduce filter device weight at the time of maintenance activities. The separation system preferably includes a filter system capable of removing identified contaminants with minimal impact on fluid flow rates.
[0013] These and other objectives are achieved with the present invention. The invention is a fluid separation system and related method for removing an array of contaminants from a fluid stream with minimal impact on the passage of the fluid stream through the system. The method involves the transfer of contaminated water through the separation system and the separation of contaminants therein. The separation system includes a filter system arranged to remove suspended and/or dissolved contaminants from the fluid stream.
[0014] The separation system is preferably established in a treatment chamber having an inlet, an outlet, one or more filter units, and a pretreatment sump referred to herein as a containment chamber. The inlet may be in direct contact with a fluid or it may be connectable to an upstream fluid transfer conduit. The outlet may be in direct contact with a surface water location or it may be connectable to a downstream fluid transfer conduit. If applicable, the upstream fluid transfer conduit and the downstream fluid transfer conduit may be part of a common municipal water handling system. For example, the upstream conduit may be associated with a drain arranged for water on a surface, such as a parking lot surface, to be removed from the surface, and the downstream conduit may form part of the water transfer mechanism designed to divert that water from the drain to a municipal treatment plant or natural surface waters. The separation system of the present invention is designed to remove contaminants from the water before the water reaches the treatment plant or natural surface waters. The containment chamber of the separation system provides a means to remove much or all of the floating and nonfloating particulates from the fluid prior to contacting the filter unit, or alternatively, to allow for sloughing off of some portion of loaded contaminants from the filter unit in a manner that keeps the contaminants away from the filter unit. The filter unit of the present invention is designed for upward and/or radial flow of the fluid into and through the filter unit. That configuration, coupled with the use of the containment chamber, allows sloughing off of bulk contaminants that may be retained thereon when the fluid flow subsides. As a result, the filter unit of the present invention experiences much less contaminant loading over a given period as compared to prior devices that allow for loading of all or substantially all contaminants to the filter system, or that otherwise impose excessive amounts of contaminants on the filter system. As a result, maintenance cycles are lengthened for the separation system of the present invention. The filter unit of the present invention further allows for any filter media contained therein to be released prior to removal of the filter device from the treatment chamber. This allows for simple maintenance without the need for assistive removal equipment.
[0015] In one aspect of the invention, a separation system is provided for removing suspended and/or dissolved contaminants from a fluid. As noted, the system includes a tank having an inlet, an outlet, a confinement deck, and a containment chamber below the confinement deck and one or more filters removably retained to the confinement deck, wherein the fluid entering the containment chamber through the inlet passes through the one or more filters to the outlet, and wherein the one or more filters are configured to remove a portion or all of the suspended and/or dissolved contaminants in the fluid prior to the fluid passing through to the outlet. The outlet may be part of an outflow chamber above the confinement deck, wherein fluid exiting the one or more filters enters the outflow chamber before passing to the outlet. The outlet may also simply be any sort of container, port, flow conveyance conduit, siphon conduit, opening, or arrangement in direct or indirect fluid communication with the filter unit discharge(s). The confinement deck may include one or more openings to allow fluid entering the containment chamber under excess flow conditions to bypass the one or more filters and pass to the outlet. The openings may include standpipes extending into the containment chamber and into the outflow chamber. The number of filters employed may be selected as a function of desired flow rate and/or contaminant level and/or content of the fluid passing from the inlet to the outlet. The filters include a retainer with a floor and a perimeter retainer wall, either or both of which may be porous, arranged to define an interior retainer space in fluid communication with the outlet of the filter and arranged to allow fluid to flow through the perimeter wall into the interior retainer space. The retainer may include a porous interior conduit spaced within the interior retainer space and in fluid communication with the outlet. In that arrangement, the retainer may retain one or more filter media within the interior retainer space but not within the interior conduit. The filter media may be releasably retained within the retainer. For example, the retainer floor may have one or more media retention plates hingedly affixed to the perimeter retainer wall. The filter unit may also include a housing containing the retainer therein. When a porous retainer perimeter wall is used, the housing is preferably spaced therefrom to allow fluid to flow therebetween. The filter unit with the housing may be configured for the retainer floor to have one or more media retention plates pivotably hinged to the housing perimeter wall.
[0016] In another aspect of the invention a method is provided for treating a fluid to remove suspended and/or dissolved contaminants therefrom to produce a treated fluid having the suspended and/or dissolved contaminants substantially removed. The method includes the steps of directing the fluid to a confinement chamber of a tank where pretreatment occurs, directing the pretreated fluid to one or more filters, wherein the pretreated fluid passes into each of the one or more filters radially and/or upwardly for treatment to produce the treated fluid, and allowing the treated fluid to pass from the one or more filters to an outlet. Additionally, the method may further include the steps of releasably retaining within one or more of the one or more filters one or more filter media. A method is also provided for removing a fluid, filter media, and/or contaminants from a separation system having a tank with a containment chamber separated from and spaced below an outlet by a confinement deck, wherein the confinement deck includes one or more releasably retained filter units, each retaining therein the filter medium and removably retained, either by positioning within filter unit sockets therein, or by connecting to the confinement deck by other means. The method includes the steps of accessing the containment chamber with removal means, removing a portion or all of the fluid, filter media, and/or contaminants contained within the containment chamber, removing the one or more filter units from the confinement deck, accessing the containment chamber through the filter unit sockets and/or any overflow means or port, such as a standpipe, and removing the remainder of the fluid, filter media, and/or contaminants from the containment chamber. The removal method may also include the steps of releasing the filter media from the filter units prior to the step of accessing the containment chamber with the removal means, inserting new filter media into the one or more filter units released from the confinement deck, and re-inserting the filled filter units into the confinement deck sockets after the step of removing the remainder of the fluid, filter media, and/or contaminants from the containment chamber.
[0017] These and other features of the invention are set forth in the accompanying drawings and the description below. Other features, objects, and advantages of the invention will be apparent from the description and drawings, and from the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1 is a perspective view of the separation system of the present invention, showing a partial cut-away view of the tank to expose the tank interior.
[0019] FIG. 2 is a perspective view of the interior of the tank of the separation system showing a partial cut-away view of the confinement deck with filter units.
[0020] FIG. 3 is a close-up perspective view of the confinement deck of the separation system showing the standpipe and two filter units in partial cross-section.
[0021] FIG. 4 is a perspective view of a cylindrical version of the tank of the present invention.
[0022] FIG. 5 is an exploded view of the filter unit. FIG. 5A is a perspective view of the optional porous interior conduit. FIG. 5B is a perspective view of a first retainer floor door. FIG. 5C is a perspective view of a second retainer floor door.
[0023] FIG. 6 is a perspective view of the filter unit of the present invention, showing a portion of the exterior of the retainer.
[0024] FIG. 7 is a perspective view of the filter unit showing a partial cut-away view of the housing and retainer to show the retainer filled with filter media and showing the interior conduit.
[0025] FIG. 8 is a simplified elevation view of a cross-section of the filter unit of the present invention.
[0026] FIG. 9 is a perspective view of the filter unit shown retained in the confinement deck with a partial cut-away view of the housing and retainer.
[0027] FIG. 10A is a perspective view of the housing from the top. FIG. 10B is a perspective view of the housing from the bottom.
[0028] FIG. 11 is a cross sectional view of the housing.
[0029] FIG. 12 is a perspective view of a portion of the separation system of the present invention, showing the interior of the tank including the confinement deck and a plurality of filter units with media retention plates open.
[0030] FIG. 13 is a perspective view of the separation system of the present invention, showing a partial cut-away view of the tank to expose the tank interior during filter unit removal from the containment chamber.
[0031] FIG. 14 is a perspective view of the separation system of the present invention, showing a partial cut-away view of the tank to expose the tank interior with filter units removed, and showing the access hatch open for fluid and filter media removal.
[0032] FIG. 15 is an overhead view of the exterior of the separation tank showing a removed filter unit thereon overturned for filter media filling.
[0033] FIG. 16A is a plan view of the separation tank of the present invention showing an alternative containment chamber outlet arrangement. FIG. 16B is an elevation view of the separation tank showing the alternative containment chamber outlet arrangement of FIG. 16A .
[0034] FIG. 17 is an elevation view of an alternative embodiment of the separation tank including a forebay.
[0035] FIG. 18A is a plan view of the separation tank of the present invention showing alternative positioning of the filter units with respect to the confinement deck. FIG. 18B is a cross-sectional elevation view of the separation tank showing the alternative filter unit positioning of FIG. 18A at section A-A.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0036] A separation system 100 of the present invention is illustrated in the accompanying drawings. As shown in FIGS. 1-3 , the system 100 includes a tank 110 having an outflow chamber 111 and a containment chamber 112 spaced below the outflow chamber 111 by a confinement deck 200 . The containment chamber 112 includes a tank inlet port 113 through which a fluid to be treated enters the containment chamber 112 from an inlet conduit 120 . The outflow chamber 111 includes a tank outlet port 114 through which a treated fluid exits the outflow chamber 111 via an outlet conduit 130 . The tank 110 also preferably includes an access hatch 115 for accessing the interior of the tank 110 at the outflow chamber 111 , and a manhole 116 with cover 117 . While the preferred embodiment of the present invention describes the separation system 100 with a specific outflow chamber 111 above the confinement deck 200 , it is to be understood that in an alternative embodiment, the fluid may pass from the containment chamber 112 through the one or more filter units to be described herein directly to the outlet conduit 130 or some other form of treated fluid exit means.
[0037] The tank 110 is preferably made of concrete but may alternatively be fabricated in whole or in parts of metal, plastic, such as fiberglass, or other suitable materials. It may be rectangular, round, oval or other suitable shape. The inlet conduit 120 may be used to connect the tank 110 to an upstream fluid transfer system. Similarly, the outlet conduit 130 may be used to connect the tank 110 to a downstream fluid transfer system. For example, the upstream fluid transfer system may include a drainage system from a roadway or a parking lot, or a preliminary separation system, and the downstream fluid transfer system may include a municipal water treatment plant or natural or artificial surface waters.
[0038] With continuing reference to FIGS. 1-3 , the confinement deck 200 includes one or more openings 210 that allow for overflow fluid to pass directly from the containment chamber 112 to the outflow chamber 111 under relatively very high fluid flow conditions. Preferably, the one or more openings 210 retain therein a standpipe 220 . The standpipe 220 also allows excess untreated fluid to pass directly from the containment chamber 112 to the outflow chamber 111 without being treated, for example when fluid flow rates through the inlet conduit 120 are excessively high. However, the standpipe additionally builds driving head on one or more filter units 300 and preferably extends into the containment chamber 112 far enough to ensure that under such conditions, floating contaminants cannot pass directly from the containment chamber 112 to the outflow chamber 111 . The standpipe 220 may also be used as a portal for the removal of fluid and/or particulates from the containment chamber 112 when accessed through the manhole 116 . The confinement deck 200 also includes one or more filter sockets 230 for removably retaining in each one thereof a filter unit 300 . One or more filter clamps 240 are used for that purpose. In general consideration of the intended operation of the separation system 100 , untreated fluid entering containment chamber 112 passes through the one or more filter units 300 where undesirable entrained and/or dissolved matter is filtered out. The treated water then passes out of the filter unit(s) 300 into the outflow chamber 111 from which it exits. While the tank 110 of FIGS. 1-3 is shown to be rectangular in shape, it is to be understood that the tank may be of another shape, such as cylindrical, as shown by tank 110 ′ of FIG. 4 . The inlet to a tank such as tank 110 ′ may be arranged to impart a swirling motion of the fluid entering the containment chamber so as to further enhance separation of floating and non-floating matter by directing it to the center of the tank. The advantages of inducing fluid swirl are described in U.S. Pat. No. 5,759,415 issued to Adams on Jun. 2, 1998, assigned to Vortechnics, Inc. and entitled METHOD AND APPARATUS FOR SEPARATING FLOATING AND NON-FLOATING PARTICULATE FROM RAINWATER DRAINAGE. The contents of that patent are incorporated herein by reference.
[0039] An important aspect of the present invention is the design of the filter unit 300 . With reference to FIGS. 5-11 , the filter unit 300 preferably includes a housing 301 with a housing lid 302 and a housing perimeter wall 303 . The filter unit 300 further includes a retainer 305 positionable within the housing 301 . The retainer 305 includes a retainer perimeter wall 306 , a retainer floor 307 , and, optionally, a porous interior conduit 308 . The housing lid 302 includes a discharge port 309 at the top surface of thereof. The housing 301 optionally includes one or more lifting handles 310 for insertion and removal of the filter unit 300 with respect to the filter socket 230 . The housing 301 may be fabricated of any material, but is preferably fabricated of a nonmetallic material, such as plastic. The housing lid 302 may be formed integrally with the housing perimeter wall 303 , or it may be removably affixed to the housing perimeter wall 303 . The housing 301 is designed to be easily insertable into and removable from the filter socket 230 of the confinement deck 200 for ease of maintenance of the tank 110 as well as the filter unit 300 . A gasket 304 may be employed to seal the housing 301 to the confinement deck 200 . In an alternative embodiment of the invention, there may be no housing perimeter wall 303 , with the retainer 305 simply affixed to the lid 302 and provided with an outlet for passage of treated fluid either to the outflow chamber 111 or some other fluid transfer means. When in position in the socket 230 , the housing 301 extends into the containment chamber 112 , thereby acting to block floating contaminants from reaching the retainer 305 . However, if there is no housing perimeter wall 303 , such floating contaminants will be retained by the retainer 305 . For purposes of this description, the housing perimeter wall 303 may effectively be the retainer perimeter wall 306 when only up flow of the fluid is desired.
[0040] The retainer perimeter wall 306 and the floor 307 define an interior retainer space 319 into which fluid to be treated passes. The interior retainer space 319 is in fluid communication with the outlet 114 of the tank 110 . The retainer perimeter wall 306 of the retainer 305 preferably includes an upper retainer wall flange 311 for affixing the perimeter wall 306 to the housing lid 302 . For upflow of fluid into the retainer 305 , the floor 307 is porous. For radial flow into the retainer, the retainer perimeter wall 306 is porous. In particular, in order to maximize fluid flow conditions, the retainer perimeter wall 306 is porous and is spaced from the interior of the housing perimeter wall 303 to create a space for fluid to enter the housing around the perimeter of the retainer 305 prior to entering it through the retainer perimeter wall 306 . If upflow and radial flow are desired, the retainer perimeter wall 306 and the floor 307 are both porous. The porous interior conduit 308 is only required if one or more filter media are employed to remove contaminants. When in use, the porous interior conduit 308 of the retainer 305 includes a conduit mounting flange 312 for affixing the porous interior conduit 308 to the housing lid 302 preferably approximately centered in relative position to the discharge port 309 of the housing lid 302 . Thus, in this embodiment of the filter unit 300 , the retainer perimeter wall 306 and the interior conduit 308 are not connected together but are instead separately connected to the housing lid 302 . The retainer perimeter wall 306 , the floor 307 , and the interior conduit 308 may be fabricated of metallic or nonmetallic material. When made porous, they may be made as perforated, corrugated, or pleated screening elements, or other configuration as selected by the user.
[0041] With continuing reference to FIGS. 5-11 , the interior of the housing perimeter wall 303 preferably includes a means for releasably retaining thereto a rotatable release rod 316 that extends through a housing lid hole 315 of the housing lid 302 . The means for releasably retaining may be a retaining clip (not shown) to which the release rod 316 may be clipped and allowed to rotate therein. The rotatable release rod 316 terminates at a first end thereof with a release handle 317 adjacent to the housing lid 302 , and at an opposing second end thereof in a retention leg 318 . The retention leg 318 is designed to fix the retainer floor 307 in a first position when the filter unit 300 is operational, and in a second position when the filter unit 300 is undergoing maintenance. The retention leg 318 may be rotated between the first and second positions by rotating the release handle 317 .
[0042] As noted, the space defined by the retainer perimeter wall 306 , the optional interior conduit 308 if used, and the retainer floor 307 defines the interior retainer space 319 within which one or more filtering media 320 may be located. The one or more filter media may include perlite, zeolite, granular activated carbon, peat, or other suitable filter media selectable as a function of the contaminants to be removed. The filtering media 320 are preferably selected for their effectiveness in removing entrained and/or dissolved matter from the fluid to be treated, but that allow the fluid to pass from the outside of the retainer 305 to the interior of the interior conduit 308 at specified flow conditions. Combinations of different filter media may be employed based on porosity, contaminant affinity, and the like. Such combinations may be mixed or layered, either vertically or horizontally. The porosity of the retainer perimeter wall 306 , the retainer floor 307 , and the interior conduit 308 must also be designed with both objectives in mind. In some instances, tightly packed filter media and/or relatively small pore sizes for the retainer 305 may be required or desired, whereas in other instances, loosely packed and/or large pore sizes for the retainer 305 may be required. It is to be noted that the retainer 305 may be used without any filter media 320 in those situations where it acts as a gross filtering device for separating relatively large particulates from the fluid prior to entering the outflow chamber 111 (or other form of outlet arrangement). In an arrangement in which there are no filter media 320 used, the interior conduit 308 is not required and the retainer 305 simply includes the retainer perimeter wall 306 and the retainer floor 307 . In an arrangement in which the filter media 320 are used in an up flow only system, a top screen may be used to block the filter media 320 from escaping into an exit space 360 prior to discharge, wherein the top screen and exit space 360 effectively act as an interior conduit.
[0043] An important aspect of the design of the retainer 305 for the purpose of maintaining the filter unit 300 as well as the system 100 is the arrangement of the retainer floor 307 . As shown in FIG. 5 , the retainer floor 307 is preferably a hinged structure and more preferably, a center-hinged structure. The retainer floor 307 includes a pivot shaft 321 , a first media retention plate 322 hingedly connected to the pivot shaft 321 , and a second media retention plate 323 hingedly attached to the pivot shaft 321 . Each of media retention plates 322 and 323 includes a perforated or porous body 325 and an optional outer flange 326 . The media retention plates 322 and 323 are selected and designed to provide structural support for any filter media to be retained by the retainer 305 , and to withstand the hydrostatic pressure to be experienced when the filter unit 300 is in use. The pivot shaft 321 pivots and is retained in openings 328 of the housing perimeter wall 303 . The retainer floor 307 may be fabricated of metallic or nonmetallic material. In an arrangement where there is no housing 301 but only retainer 305 , the media retention plates 322 and 323 may be retained in place by inserting the pivot shaft 321 into opposing holes of the retainer perimeter wall 306 . In that arrangement, the release rods 316 and the release handles 317 may be employed to releasably retain the media retention plates 322 and 323 in place until the filter media are to be released. Further, if there are no filter media 320 to be used, the hinged media retention plates 322 and 323 are unnecessary and the retainer floor 307 may be releasably or permanently affixed to the retainer perimeter wall 306 .
[0044] In operation, the system 100 enables the removal of undesirable matter from the fluid stream during the fluid's passage from the inlet conduit 120 to the outlet conduit 130 . Untreated fluid 330 entering the containment chamber 112 fills that containment chamber 112 and reaches the underside of the filter unit 300 during which time floating and non-floating contaminants are separated from the pretreated fluid reaching the underside of the filter unit 300 . This produces hydrostatic pressure on the filter unit 300 , thereby forcing the pretreated fluid into the retainer 305 . Preferably, floating and non-floating contaminants of relatively large size remain trapped in the containment chamber 112 by the housing 301 , the retainer perimeter wall 306 , the standpipe 220 or any combination of one or more thereof. As shown in FIGS. 3 and 8 , the pretreated fluid 330 enters the housing 301 through the retainer floor 307 . As hydrostatic pressure increases on the filter unit 300 with the filling of the containment chamber 112 , the pretreated fluid 330 moves into radial flow space 340 between the housing perimeter wall 303 and the retainer perimeter wall 306 . The pretreated fluid 330 enters space 319 by way of both the retainer perimeter wall 306 via radial flow space 340 and directly through the perforated body 325 of the retainer floor 307 . If there are no filter media 320 in space 319 , the fluid-under-treatment 350 passes directly through the space 319 before exiting the discharge port 309 into the outflow chamber 111 . It is anticipated that entrained relatively larger particulates will be trapped by either or both of the retainer perimeter wall 306 and the retainer floor 307 . If there are filter media 320 in space 319 , the fluid-under-treatment 350 dwells in space 319 for trapping entrained, suspended, and/or dissolved contaminants before passing through interior conduit 308 into exit space 360 and exiting the discharge port 309 into the outflow chamber 111 . When the pretreated fluid 330 in the containment chamber 112 recedes, contaminants trapped on the exterior of the retainer 305 and/or the housing 301 are more likely to drop back into the containment chamber 112 rather than remain caked on. This enhances the chance of the filter unit 300 remaining sufficiently clear to conduct subsequent filtering operations without the need to halt the fluid transfer process for filter unit 300 maintenance.
[0045] As illustrated in FIGS. 12-15 , the design of the system 100 of the present invention enables effective treatment of a fluid as well as ease of maintenance of the system 100 itself. The process of maintaining the system 100 when the filter media 320 are in use includes the step of releasing either or both of retainer media retention plates 322 and 323 to allow the filter media 320 to fall into the containment chamber 112 . That releasing step may be accomplished by rotating the release handles 317 to the second position to allow the hinged media retention plates 322 and 323 to pivot about the pivot shaft 321 . If no filter media are used, this step may be omitted and, in fact, hinged media retention plates 322 and 323 are not required as there is no need to remove filter media 320 therefrom. In the next step, pretreated fluid, trapped contaminants, and any released filter media are removed from the containment chamber 112 using removal means, such as vacuum means, to draw out the pretreated fluid, trapped contaminants, and any released filter media. This removal may be achieved by inserting the removal means into the manhole 116 and through the standpipe 220 , or port 210 if there is no standpipe 220 . Either while undertaking the removal step or thereafter, the one or more filter units 300 retained to the confinement deck 200 in filter sockets 230 may be removed by releasing filter unit clamps 240 , shown in FIGS. 1 and 12 , fixed against the housing lid 302 (or by other means of connection to the confinement deck) and removing the filter units 300 from the confinement deck 200 , preferably using lifting handles 310 . The filter units 300 in situ may be accessed via access hatch 115 . This method of removing the filter media 230 from the retainer 305 prior to removing the filter unit 300 substantially reduces the weight of the filter unit 300 to be maintained, thereby allowing such removal without using assistive mechanical equipment, such as a crane.
[0046] Upon removal of the one or more filter units 300 from the confinement deck 200 , the same or additional removal means may be used to remove untreated fluid and/or filter media from the containment chamber 112 . That additional removal step may be achieved by inserting the removal means into the access hatch 115 and through the one or more sockets 230 to access substantially all of the interior of the containment chamber 112 . As shown in FIG. 15 , the removed filter unit 300 may be inverted such that it rests on housing lid 302 . A new batch of filter media may be inserted into space 319 via either or both of open media retention plates 322 and 323 . The door(s) 322 and/or 323 may then be closed by rotating the release handles to the first position to clamp the door(s) 322 and/or 323 into the retained position(s). The filled and closed filter unit(s) may then be re-installed in the confinement deck 200 , the access hatch 115 closed, and the system 100 made available for treating the fluid.
[0047] An additional optional step of the filter method of the present invention involves draining down the fluid within the containment chamber 112 to keep the filter media 320 relatively dry under low or no flow conditions in the containment chamber 112 . For that step, a containment chamber outlet 400 is positioned in the containment chamber 112 as shown in FIGS. 16A and 16B . The containment chamber outlet 400 also acts as the outlet for the outflow chamber 111 via outlet port 401 that provides fluid communication from the outflow chamber 111 to the containment chamber outlet 400 through confinement deck 200 , effectively replacing outlet conduit 130 . An optional containment chamber downspout 402 may be included in that arrangement to trap floating particulates while allowing fluid to pass from the containment chamber 112 to the outlet 400 . Flow control means such as perforations 403 of the downspout 402 enable regulation of the flow of fluid out of the filter unit(s) 300 when flow into the containment chamber 112 subsides. In operation, the system of FIGS. 16A and 16B allows pretreated fluid to flow into the containment chamber 112 as previously described. The standpipe 220 also allows for pretreated fluid under relatively higher flow conditions to bypass the fluid unit(s) 300 , also as previously described. However, the outlet 400 in the containment chamber 112 positioned below the underside of the confinement deck 200 ensures that the standing fluid surface in the containment chamber 112 is below the bottom of the filter media 320 . If there is a housing 301 , the outlet 400 is preferably positioned so that the standing fluid surface is just below the bottom of the filter media 320 but just above the bottom of the housing 301 . This arrangement keeps previously separated floatables confined in the containment chamber 112 and away from the filter media 320 . Treated fluid passing through the filter unit(s) 300 exit the discharge 309 , passes along the upper side of the confinement deck 200 , and then drops down into the outlet port 401 to the containment chamber outlet 400 for discharge.
[0048] Another alternative arrangement of the system 100 ″ shown in FIG. 17 includes a pre-treatment forebay 500 to isolate the tank inlet conduit 120 from the containment chamber 112 ″ when the outlet conduit 130 cannot be positioned above the inlet conduit 120 , or when confinement of gross pollutants away from the filter units 300 is desired. In that situation, the forebay 500 is partially spaced from the containment chamber 112 ″ by a baffle 501 , and completely isolated from the outflow chamber 111 ″ by tank wall 502 . A forebay outlet conduit 503 provides the passageway for fluid entering the forebay 500 to enter the containment chamber 112 ″ via intermediate space 504 that forms part of the containment chamber 112 ″ when the fluid reaches and exceeds the standing fluid level 505 . The inlet of the forebay outlet conduit 503 is submerged and sealed to the baffle 501 such that floatables are retained in the forebay 500 . Under very high flow conditions, the fluid rises to the level of the top of the baffle 501 and drops over it into the intermediate space 504 without reaching the outflow chamber 111 ″. The baffle 501 also retains floating particulates, at least until the fluid flow rate causes the fluid level in the forebay 500 to exceed the top of the baffle. From there, the untreated fluid is subject to the same filtering process previously described. It is preferred for this arrangement that a forebay manhole 506 be provided directly over the forebay 500 to allow for removal of excess contaminants without directly reaching the containment chamber 112 ″. Although not shown, the tank 110 ″ of system 100 ″ may include a standpipe for bypass, also as previously described.
[0049] An alternative arrangement of the filter units 300 ′ with respect to a modified confinement deck 200 ′ is shown in FIGS. 18A and 18B as part of tank 600 . The filter units 300 ′ are positioned substantially in the outlet chamber 111 rather than substantially in the containment chamber 112 . Each of the filter units 300 ′ is in fluid communication with pretreated fluid of the containment chamber 112 through a filter port 601 . Each filter port 601 is preferably sealed such that pretreated fluid only enters the filter unit 300 ′ therethrough. The filter units 300 ′ include modified housings 301 ′ including a housing perimeter 306 ′ and a housing floor 307 ′. The housing floor 307 ′ includes a port 350 in fluid communication with the confinement deck port 601 that is configured to ensure that the pretreated fluid entering the filter units 300 ′ is forced to pass into filter area 320 for either or both of upward and radial flow. The filtering of the fluid upon entering the filter unit 300 ′ is achieved in the manner previously described with respect to filter unit 300 . The alternative arrangement of tank 600 enables the placement of more filter units 300 ′ in a defined area, it limits wetting of the filter media when the fluid subsides, and the sealing of the filter units 300 ′ with respect to the confinement deck 200 ′ may be easier to achieve. The filter units 300 ′ may include a filter outlet extension 360 to assist in drawing treated fluid out of the filter units 300 ′.
[0050] It is to be understood that the above-described steps are intended to represent primary aspects of the invention and that additional steps may be implemented. Further, the order of the steps illustrated as part of the process is not limited to the order described herein, as the steps may be performed in other orders, and one or more steps may be performed in series or in parallel to one or more other steps, or parts thereof. Additionally, in an alternative embodiment of the filter unit 300 , the retainer 305 is the only component of the filter unit 300 that is removable, whereas there is either no housing 301 and the retainer 305 is affixed directly to the confinement deck 200 , or the housing 301 is permanently affixed to the confinement deck 200 .
[0051] While the present invention has been described with particular reference to certain embodiments of the separation system, it is to be understood that it includes all reasonable equivalents thereof as defined by the following appended claims.
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A system and related method for separating floating and nonfloating particulate and entrained, suspended, and/or dissolved contaminants from a fluid. The system includes a tank with a lower chamber spaced from an outlet or upper chamber by a confinement deck. The deck includes one or more sockets for receiving one or more filter units for fluid treatment. In addition, the lower chamber of the tank acts as a pretreatment sump to remove floating and nonfloating particulates, thereby reducing the load on the filter units. The filter units are configured for radial and/or upward flow of the fluid from the lower chamber. The filter units may include one or more filter media through which the fluid pass prior to exiting the tank. The filter units include a removable screening retainer for retaining the filter media and/or to screen relatively large contaminants. The filter unit may be removed for ease of tank maintenance and replacement of filter media. The system allows a method of contaminated fluid treatment under varying flow conditions by directing the fluid radially and/or upwardly through the retainer. Establishing both types of flow through the filter unit improves filtering and extends filter life without compromising desired flow through rates.
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RELATED APPLICATIONS
The present invention was first described in and claims the benefit of U.S. Provisional Patent No. 61/548,392 filed Oct. 18, 2011, the entire disclosures of which are incorporated herein by reference.
FIELD OF THE INVENTION
The present invention relates generally to a storage container for a bicycle where the bicycle is secured to a track assembly affixed to an enclosure.
BACKGROUND OF THE INVENTION
The invention described herein pertains to a bicycle storage container and more particularly a plurality of modular storage units. Traditional bike racks provide a single static structure for securing a plurality of bicycles through the use of chains and/or locks. With advancements in bicycle construction such as quick-release tires, the use of a traditional bike rack often fails to provide adequate protection. It is difficult to lock both tires and a frame to a traditional rack through the use of a single chain or bike lock. When a bicyclist fails to lock their bike and tires to a rack, they all too often return to a stolen frame or wheels. Additionally, a traditional bike rack fails to provide any protection from the elements.
U.S. Pat. No. 4,506,786 to Alvin E. Buchanan et al. discloses a bicycle container having a substantially rectangular frame with an interior space for receiving a bicycle. The container has a track for guiding and securing a bicycles wheels during use. While the container provides additional security and protection from the elements as compared to a traditional bike rack, the open front and rear faces allow access to the bike from both thieves and the elements.
Another attempt at providing increased bicycle protection is disclosed in U.S. Pat. No. 6,505,637 to Stephen C. Voorhees. This patent describes a bicycle housing pivotally attached to a support frame. The housing is lowered over top of a bicycle and locked to the frame opposite the pivot point. This prevents the housing from being lifted and protects the bike from un-authorized access. The construction of this device does not allow for modular storage or an aesthetically pleasing arrangement of housings.
Although the various devices observed may fulfill their individual, particular objectives, each device suffers from one (1) or more disadvantage or deficiency related to design or function. Whether taken singly, or in combination, none of the observed devices disclose the specific arrangement and construction of the instant invention.
SUMMARY OF THE INVENTION
The inventor has recognized the deficiencies in the art pertaining to bicycle storage containers Furthermore, the inventor has observed that there is a need for secure public bicycle storage providing housing for a plurality of bicycle arranged in an efficient and aesthetically pleasing manner.
The inventor has addressed at least one (1) of the problems observed in the art by developing novel bicycle housing. It is a feature and aspect of the present invention to provide a bicycle storage container having a shell, first side panel, second side panel, rear panel and door. The door is affixed to a side panel through the use of hinges, and is secured in a closed position through use of a lock assembly and padlock. The rear panel is fastened to the side panels through use of first fasteners.
It is another aspect of the invention to provide a weather-resistant, translucent and elliptical-shaped rear panel and door. Additionally provided are weather-resistant, translucent arcuate-shaped side panels. When not in use the rear panel and door are removed and the side panels are pushed together, creating a flattened state for storage and transport. Furthermore, the side panels have reinforced frame portions providing increased rigidity and secure attachment points for the rear panel and door. The door and rear panel have corresponding flanged edge portions for mating with the reinforced frame of the side panels. Additionally, attached to an exterior portion of the side panels is a tether anchor for securing a first container to a second container.
It is yet another aspect of the invention to provide a track assembly for securing a bicycle in a vertical orientation. The track assembly includes a movable track, a pull handle, a stationary track, a first tire stop, a second tire stop and a plurality of rollers. Both the stationary track and the movable track have a “V”-shape, with the stationary track having a plurality of rollers mounted to an upper surface. The movable track is laterally attached to the stationary track through use of a retaining channel, and slides in a forward or rearward direction on the rollers. The first tire stop is affixed to the movable track and the second tire stop is affixed to the stationary track, with each receiving a rear and front bicycle tire respectively therein. The pull handle is affixed to the movable track and used as a grip for sliding the movable track.
It is a further aspect of the invention to provide at least one (1) light attached to an interior surface of each side panel. In a preferred embodiment, the lights are LED lamp units having an integral solar cell which charges an internal battery. An on/off switch is provided for user control when attempting to place or remove a bicycle during low light conditions.
It is still yet another aspect of the invention to provide a method for forming a modular arrangement of bicycle storage containers.
Furthermore, the described features and advantages of the disclosure may be combined in various manners and embodiments as one skilled in the relevant art will recognize. The disclosure can be practiced without one (1) or more of the features and advantages described in a particular embodiment.
Further advantages of the present disclosure will become apparent from a consideration of the drawing and ensuing description.
BRIEF DESCRIPTION OF THE DRAWINGS
The advantages and features of the present invention will become better understood with reference to the following more detailed description and claims taken in conjunction with the accompanying drawings, in which like elements are identified with like symbols, and in which:
FIG. 1 is a cutaway environmental view of a bicycle storage container 10 depicting an in-use state, according to a preferred embodiment of the present invention;
FIG. 2 is a perspective view of a plurality of bicycle storage containers 10 , according to the preferred embodiment of the present invention;
FIG. 3 is a side view of a bike track assembly portion 30 , according to the preferred embodiment of the present invention; and,
FIG. 4 is a section view of a bike track assembly portion 30 taken along section line A-A (see FIG. 3 ), according to the preferred embodiment of the present invention.
DESCRIPTIVE KEY
10 bicycle storage container
20 shell
20 a first side panel
20 b second side panel
20 c rear panel
21 door
22 lock assembly
23 hinge
24 tether anchor
25 padlock
27 light
28 flanged edge
29 frame
29 a first fastener
30 bike track assembly
31 movable track
31 a retaining channel
32 pull handle
33 stationary track
33 a first tire stop
33 b second tire stop
34 a roller
34 b roller axle
34 c second fastener
100 bicycle
101 tire
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The best mode for carrying out the invention is presented in terms of its preferred embodiment, herein depicted within FIGS. 1 through 4 . However, the invention is not limited to the described embodiment and a person skilled in the art will appreciate that many other embodiments of the invention are possible without deviating from the basic concept of the invention, and that any such work around will also fall under scope of this invention. It is envisioned that other styles and configurations of the present invention can be easily incorporated into the teachings of the present invention, and only one particular configuration shall be shown and described for purposes of clarity and disclosure and not by way of limitation of scope.
The terms “a” and “an” herein do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced items.
The present invention describes a bicycle storage container (herein referred to as an “apparatus”) 10 being offered to solve one (1) or more of the aforementioned problems and fulfill one (1) or more of the aforementioned needs. The apparatus 10 provides secure storage and protection for a bicycle 100 . The apparatus 10 is particularly adapted for modular use in an urban environment. The apparatus 10 is designed to accommodate a range of bicycle sizes. The apparatus 10 can be collapsed, transported, and a plurality of the apparatuses 10 may be attached to form an attractive structure.
Referring now to FIG. 1 , a cutaway environmental view of the apparatus 10 depicting an in-use state, is disclosed. The apparatus 10 provides a durable, aesthetic and space-saving enclosure having a pointed elliptical cross sectional shape (i.e. vesica piscis), and being sized to receive a full range of bicycle 100 models and sizes. The apparatus 10 includes a shell 20 made using a lightweight semi-rigid translucent material such as fiberglass sheet, plastic sheet, or the like, being weather resistant and suitable for use in various locations. The shell 20 is to be preferably made using recycled materials. The shell 20 provides a four-part assembly comprising a first side panel 20 a , a second side panel 20 b , a rear panel 20 c at a distal end, and a hinged door 21 at a proximal end, thereby forming a hollow container. When in use, the pointed elliptical-shape of the rear panel 20 c and hinged door 21 portions support the arcuate shape of the side panels 20 a , 20 b enabling the shell 20 to hold its shape. The rear panel 20 c and door 21 each comprise similarly-shaped elliptical panels that contain the open area between the side panels 20 a 20 b.
When in an empty state, one (1) or more shells 20 may be collapsed and stacked in a flattened state for purposes of storage and transport, if desired, by removing the first fasteners 29 a , door 21 , and rear panel 20 c portions of each shell 20 and pressing the side panels 20 a , 20 b together upon a flat surface.
The side panels 20 a , 20 b further comprise reinforced frame portions 29 along perimeter edges envisioned to be folded-over doubly-thick portions which provide increased rigidity along top, bottom, rear, and front edges. Said reinforced frame portions 29 enable secure attachment of the door 21 and rear panel 20 c portions. However, it is understood that the reinforced frame 29 may also utilize metal strips being fastened along said edge portions of the side panels 20 a , 20 b for increased strength with equal benefit, and as such should not be interpreted as a limiting factor of the apparatus 10 . The reinforced frame 29 provides strength and rigidity to maintain the curved shape of the shell 20 .
In a corresponding manner, the door 21 and rear panel 20 c portions comprise flanged edge portions 28 formed at right angles so as to provide mating surfaces being orientated in a parallel manner to the aforementioned frame portions 29 . One (1) flanged edge portion 28 of the door 21 is connected to a proximal frame portion 29 of the first side panel 20 a via a vertical axial-type hinge 23 being fastened thereto using a plurality of first fasteners 29 a such as rivets. The hinge 23 enables the door 21 to be swung open in order to access the inside of the shell 20 . The door 21 also includes a lock assembly 22 being located opposite the hinge 23 which enables a user to lock the door portion 21 of the apparatus 10 such that a bicycle 100 inside the shell 20 cannot be accessed by unauthorized users. The lock assembly 20 preferably comprises a hasp device designed to utilize a removably attached padlock 25 ; however, it is understood that other locking means such as those incorporating an integral padlock, a deadbolt mechanism, or an electronic locking mechanism may be used with equal benefit, and as such should not be interpreted as a limiting factor of the apparatus 10 .
The flanged edge portions 28 of the rear panel 20 c are fastened to respective frame portions 29 of both side panels 20 a , 20 b using a plurality of first fasteners 29 a to seal the rear opening of the shell 20 .
Each side panel 20 a , 20 b preferably includes at least one (1) light 27 being affixed to an interior surface. The lights 27 provide illumination to a user when attempting to place or remove a bicycle 100 from the apparatus 10 during low light conditions. The lights 27 are envisioned to comprise adhesively-attached self-contained LED lamp units which preferably comprise an integral solar cell which charges an internal battery, and an on/off switch.
A lower interior portion of the shell 20 includes an adjustable bike track assembly 30 that provides a means to secure a bicycle 100 in a vertical orientation within the apparatus 10 and to easily and quickly load or remove the bicycle 100 from the apparatus 10 (see FIGS. 3 and 4 ).
Referring now to FIG. 2 , a perspective view of a plurality of apparatuses 10 , is disclosed. The apparatus 10 is designed to be modular in installation and arrangement such that a plurality of the apparatus 100 may be attached and situated compactly together in a single location forming a row as well being stacked vertically. Each shell 20 includes one (1) or more tether anchors 24 being preferably adhesively bonded to exterior surfaces of the shell 20 . Each tether anchor 24 may be removably attached to a tether anchor portion 24 of an adjacent apparatus 10 or other fastening appendage on a nearby object. Each tether anchor 24 preferably comprises a ring or hook-shaped fastening bracket; however other designs may be utilized such as metal plates with threaded holes that enable direct hardware fastening to an adjacent tether anchor 24 . In a preferred embodiment, each shell 20 has a tether anchor 24 located at a central position on both side panels 20 a , 20 b . It is further envisioned that additional tether anchors 24 may be installed along a bottom edge of the side panels 20 a , 20 b to provide a means for anchoring the apparatus 10 to a ground surface, or along a top edge to anchor the apparatus 10 to other apparatuses 10 being stacked above.
Referring now to FIGS. 3 and 4 , side and section views of a bike track assembly portion 30 of the apparatus 10 , are disclosed. The bike track assembly 30 includes a movable track 31 , a pull handle 32 , a stationary track 33 , a first tire stop 33 a affixed to the movable track 31 , a second tire stop 33 b affixed to the stationary track 33 , and a plurality of rollers 34 a . The bike track assembly 30 is to be made using lightweight materials such as aluminum where possible to help minimize the weight of the apparatus 10 . The stationary track 33 comprises a piece of “V”-shaped aluminum angle being fastened to a lower interior edge of each side panel 20 a , 20 b using a plurality of second fasteners 34 c such as rivets, screws, or the like. The stationary track 33 is oriented such that the open top of the “V”-shape faces upwardly. The movable track 31 comprises a “V”-shaped structure having integral retaining channel portions 31 a along each outer edge enabling the movable track 31 to slide along the top surface of the stationary track 33 . Smooth motioning of the movable track 31 upon the stationary track 33 is facilitated by a plurality of rollers 34 a being stationarily-mounted to upper surfaces of the stationary track 33 along opposing outer edges which contact an inner surface of the retaining channels 31 a . Said retaining channel portions 31 a wrap around and captivate outer edge portions of the stationary track 33 , thereby acting to laterally attach the movable track 31 to the stationary track 33 . Thus, the rollers 34 a provide low-friction motioning of the movable track 31 in forward or rearward directions along the stationary track 33 . The rollers 34 a preferably comprise low-profile neoprene wheels being rotatingly mounted to the stationary track 33 via perpendicular linear roller axle portions 34 b.
The first tire stop 33 a and second tire stop 33 b each comprise mirror-image rigid “U”-shaped structures being particularly sized so as to receive respective rear and front bicycle tires 101 within. The first tire stop 33 a and second tire stop 33 b are permanently affixed at relative diverging angles to respective movable 31 and stationary 33 track portions via welding or equivalent means. While the bicycle 100 is situated atop the bike track assembly 30 , said tire stops 33 a , 33 b captivate the tire portions 101 of the bicycle 100 as the movable track 31 slides inwardly, thereby holding the bicycle 100 in a stable upright position.
The pull handle 32 comprises an ergonomic gripping means integrated upon a front end of the movable track 31 . The pull handle 32 provides a simple means for a user to motion the movable track 31 inwardly or outwardly from the shell 20 when the door 21 is opened. The movable track 31 can be pulled completely out from the shell 20 such that the user can easily place a front tire portion 101 of the bicycle 100 against the second tire stop portion 33 b of the stationary track 33 . The user would then use the pull handle 32 to push the movable track 31 onto the stationary track 33 until the first tire stop 33 a abuts against the rear tire portion 101 of the bicycle 100 prior to closing the door 21 and securing it using the lock assembly 22 .
It is envisioned that other styles and configurations of the present invention can be easily incorporated into the teachings of the present invention, and only one particular configuration shall be shown and described for purposes of clarity and disclosure and not by way of limitation of scope.
The preferred embodiment of the present invention can be utilized by the common user in a simple and effortless manner with little or no training. After initial purchase or acquisition of the apparatus 10 , it would be installed and utilized as indicated in FIGS. 1 and 2 .
The method of assembling and utilizing the apparatus 10 may be achieved by performing the following steps: procuring the apparatus 10 in a disassembled and collapsed state; transporting the apparatus 10 to a desired area; attaching the flanged edges 28 and frame portions 29 of the side panels 20 a , 20 b and rear panel 20 c together using first fasteners 29 a to form the shell 20 ; attaching the hinge 23 to a proximal edge of the frame portion 29 of the first side panel 20 a using the first fasteners 29 a ; attaching the bike track assembly 30 to lower inner surfaces of the side panels 20 a , 20 b using the second fasteners 34 c ; and, adhesively attaching the lights 27 to inner surfaces of the side panels 20 a , 20 b at desired locations, if not previously installed. The apparatus 10 is now ready to receive a bicycle 100 .
The method of utilizing the apparatus 10 to contain a bicycle 100 may be achieved by performing the following steps: turning on the lights 27 if installing the bicycle 100 during low-light conditions; gripping the pull handle 32 and pulling the movable track 31 outwardly from the shell 20 ; placing a bicycle 100 onto the stationary track 33 such that either tire portion 110 contacts the second tire stop 33 b ; using the pull handle 32 to push the retaining channel portions 31 a of the movable track 31 inwardly onto the roller portions 34 a of the stationary track 33 until the first tire stop 33 a contacts the opposing tire 101 of the bicycle 100 ; turning the light 27 off; closing the door 21 ; and, installing and locking the padlock portion 25 of the locking assembly 22 such that the bicycle 100 will be secure and protected within the shell 20 until such time the user is ready to obtain the bicycle 100 from the apparatus 10 for subsequent use.
The apparatus 10 may be fastened to adjacent apparatuses 10 , ground surfaces, or any other desired object by utilizing common tethering hardware and fasteners to fasten the tether anchors 24 to those objects.
The apparatus 10 is intended to provide various benefits to a user over other methods of bicycle parking methods in an urban environment. The apparatus 10 can be readily transported to a desired location and assembled with minimal effort.
A plurality of the apparatus 100 may be attached and situated compactly together in a single location forming a row as well being stacked vertically. The shape of each shell 20 is designed to accommodate slight variations in grade between adjacent apparatuses 10 while enabling multi-level vertical arrangements and gently curving horizontal arrangements.
The apparatus 10 facilitates ease of loading and security for a bicycle 100 . The apparatus 10 provides a valuable aesthetic presence when installed. The construction of the apparatus 10 promotes minimal energy and material waste both during manufacture and during use by comprising recycled materials and low operating energy requirements, and by providing a durable, reusable, reconfigurable, transportable construction.
When in an empty state, one (1) or more apparatuses 10 may be disassembled, collapsed, and stacked in a flattened state for purposes of compact storage and economical transportation by removing the first fasteners 29 a holding the door 21 and rear panel 20 c portions to the side panels 20 a , 20 b , and pressing the side panels 20 a , 20 b together upon a flat surface.
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 and method of use to the precise forms disclosed. Obviously many modifications and variations are possible in light of the above teaching. The embodiment was chosen and described in order to best explain the principles of the invention and its practical application, and 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 understood that various omissions or substitutions of equivalents are contemplated as circumstance may suggest or render expedient, but is intended to cover the application or implementation without departing from the spirit or scope of the claims of the present invention.
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A modular bicycle storage system designed primarily for use in urban environments includes a plurality of enclosures formed from a weatherproof fiberglass or plastic sheeting. The enclosure is accessed by a door that can be secured with a lock further includes lighting for nighttime use. A plurality of enclosures can be fastened and arranged in a modular fashion, both vertically and horizontally. The arrangement forms a pattern which is both space efficient and aesthetically pleasing. The enclosures also provide features which enable tethering to a ground surface if desired.
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FIELD OF INVENTION
The present invention relates to a process of the conversion of heat energy into mechanical energy by means of changing volume, pressure and temperature of the work medium, primarily gas in number of steps, and simultaneously relates to an apparatus for performing the process.
BACKGROUND TO THE INVENTION
There are known concepts of the conversion of heat energy into mechanical energy, where temperature and pressure is changed in the workspace with alternately changing volume. As the volume decreases, temperature and pressure increase both due to this volume change and primarily, in the last stage, due to the volume decreasing, or optionally, in the first stage due to the volume reincreasing, by the additional supply of heat energy either from the exterior, or from the heat generation (e.g. combustion) inside the workspace. As the volume reincreases, the pressure (originated from the previous workspace volume decreasing), after loss deduction, performs the work needed for consecutive volume decreasing. While the pressure, originated from the additional heat energy supply, after the loss deduction, performs the resulting mechanical work. At the permanently closed work space concept, the work medium temperature (due to the additional heat energy supply) would be, at the end of the operating cycle, greater than the temperature at the beginning of the previous volume increasing. So that, during an exterior heat supply, the medium temperature would reach the temperature, where the heat is supplied from the exterior and the temperature difference and also volume of the supplied heat would be, without a view to the losses, zero. The heat supply, developed in the medium, would stop due to the lack of oxygen, at the permanently closed workspace. It is therefore necessary to open the workspace for the used medium exhaust and the fresh medium supply for a certain time, namely both at the beginning of the volume decreasing, or before it and at the end of the volume increasing, or after it. The power cycle of the pressure and temperature variations, during the volume increasing and decreasing, proceeds in two stages. If there are other two stages added to the previous ones (i.e. volume increasing for the used medium supply and volume decreasing for the used medium exhaust) then there is the four-cycle process of the conversion of heat energy into mechanical energy implemented. If the medium supply and exhaust take place at the beginning of the first stage, or respectively at the end of the second stage, then the two-cycle process is implemented. All of these processes take place according to the known state of art in one workspace, exceptionally divided into two parts.
SUMMARY OF THE INVENTION
According to the present invention, work medium is sucked to the conversion of heat energy into mechanical energy by means of pressure and temperature change of the work medium into the first stage chamber simultaneously with the volume increasing of this stage chamber, whereby it transfers into the second stage chamber during the first stage chamber volume decreasing, whereby it transfers (during the second stage chamber volume decreasing) through the third stage chamber, simultaneously with the fourth stage chamber heat supply and simultaneously with this fourth stage chamber volume increasing, whereby it transfers from the fourth stage chamber (during its stage chamber volume decreasing) into the fifth stage chamber, where it is permitted to expand. The concept according to the present invention is described by the transfer of work medium through the third stage chamber simultaneously with the second stage chamber decreasing, simultaneously with warming, into the fifth stage chamber, or can be described by cooling during the transfer of the medium through the first stage chamber into the second one. Another aspect of the present invention is that the work medium is transferred, simultaneously with its cooling, from the fifth stage chamber into the first stage chamber simultaneously with this first stage chamber volume increasing. The concept can be, according to the present invention, modified so that the work medium is transferred from the fifth stage chamber, simultaneously with its volume decreasing, into the third stage chamber and is used for the warming process, or that the fifth stage chamber is joined with the first stage chamber and simultaneously with decreasing of the volume of this joined stage chamber is work medium (optionally with the simultaneous cooling) transferred directly into the second stage chamber, simultaneously with increasing the volumes of this second stage chamber. The apparatus for a multistage chamber conversion of heat energy into mechanical energy by means of changing volume, pressure and temperature of the work medium has the third stage chamber in form of a workspace with an invariable volume, while the other stage chambers are arranged as workspaces with variable volume (particularly as piston machines with the revolving piston) and are functionally, in a way of the work medium transfer, arranged one behind the other, partly before the third stage chamber and partly behind the third stage chamber. The apparatus for performing the present invention is further adapted in a way, so that the largest volume of the first stage chamber is larger then the largest volume of the second stage chamber, while the largest volume of the fifth stage chamber is larger than the largest volume of the fourth stage chamber, while the largest volume of the fifth stage chamber is larger than the largest volume of the first stage chamber or equal to the largest volume of the first stage chamber. The apparatus, according to the present invention, can be furthermore arranged, so that the fifth stage chamber concurrently forms the first one. According to another aspect of the present invention, the third stage chamber is created as a combustion chamber and/or a heat exchanger. The present invention is furthermore expediently adapted so that the fifth stage chamber is equipped by the inlet valve. According to this aspect of the present invention, the cooler is inserted between the first stage chamber and the second stage chamber, and also between the fifth stage chamber and the first stage chamber and also between the joined stage chamber and the second stage chamber.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention is readily understood from the Drawings, in which:
FIG. 1 shows an apparatus of the present invention;
FIG. 2 shows a version with the cooler between the first stage chamber and the second stage chamber and also between the fifth stage chamber and the first stage chamber in accordance with the present invention; and
FIG. 3 shows a concept with the first stage chamber joined together with the fifth stage chamber and a concept with the cooler between the fifth stage chamber and the second stage chamber in accordance with the present invention.
DETAILED DESCRIPTION
Work medium is brought into the first stage chamber 1 during the first stage chamber volume increasing, as in FIG. 1 , whereby it is, during the first stage chamber 1 volume decreasing, it is transferred into the stage chamber 2 , simultaneously with its volume increasing. It is then, during the second stage chamber 2 volume decreasing, transferred into the third stage chamber 3 . While transferring through the third stage chamber 3 , heat is supplied into work medium either from inside, by combustion of the fuel in the working medium, or from outside by the third stage chamber heating e.g. by exterior combustion. Work medium is transferred from the third stage chamber 3 into the fourth stage chamber 4 , whose volume simultaneously increases, whereon it is, from the fourth stage chamber 4 , concurrently with its volume decreasing, transferred into the fifth stage chamber 5 . In this fifth stage chamber 5 , the work medium is allowed to expand within its volume increasing. Work medium is after its expansion, concurrently with the fifth stage chamber 5 volume decreasing, either conducted outside, or inside back into the first stage chamber 1 . When using air as a work medium and exterior combustion as a process of the heat supply into the third stage chamber, it is convenient to use expanded, but hot, air for the outside combustion. The present invention therefore presents five-cycle thermo dynamical cycle. It can be convenient, in some cases, to avoid the fourth stage chamber 4 and to transfer work medium directly into the fifth stage chamber and allow it to expand in this stage chamber. It is convenient, when work medium is cooled inside the interstage cooler 6 , during its transfer from the first stage chamber 1 into the second stage chamber 2 (see Picture 2). In the closed cycle, where the work medium is transferred from the fifth stage chamber 5 back into the first stage chamber 1 , it is convenient to insert other interstage cooler 7 between the fifth and the first stage chamber. It is also convenient, in some cases, according to the other invention concept, to join the fifth and the first stage chamber into a joined stage chamber 51 and to transfer (during this joined stage chamber volume re-decreasing) work medium, expanded during the joined stage chamber 51 volume increasing, into the second stage chamber 2 , simultaneously with this second stage chamber increasing, optionally through the joined interstage cooler 76 . The basic five-stroke cycle is, in this case, adapted into the three-stoke cycles.
The apparatus, as described above, performing the conversion of heat energy into mechanical energy is according to the invention, arranged in a way, so that the third stage chamber 3 is formed by, at least, one workspace with an invariable volume, while the other stage chambers 1 , 2 , 4 , 5 , 51 are created as workspaces with the variable volumes. It is convenient to create all the stage chambers, excluding the third one, as piston machines with the revolving piston. The volume of the space defined by each surface joining the cusps edges of the piston and by the adjacent inside surface of the cylinder increases and decreases in a cyclic process of rotation of the piston in the cylinder. Here, the largest volume of the first stage chamber 1 is larger than the largest volume of the second stage chamber 2 , and furthermore, the largest volume of the fifth stage chamber 5 is larger or equal than the largest volume of the fourth stage chamber 4 and the largest volume of the stage chamber 5 is larger than the largest volume of the stage chamber 1 . The largest volume of the joined stage chamber 51 is larger than the largest volume of the stage chamber 4 and also larger than the largest volume of the second stage chamber 2 . The third stage chamber 3 is created as a combustion chamber and/or as a heat exchanger. Work medium is firstly supplied (e.g. by sucking) into the increasing volume of the first stage chamber 1 . After reaching maximum, the volume of this stage chamber begins to decrease and work medium is exhausted into the increasing volume of the second stage chamber 2 . Because the largest volume of the second stage chamber 2 is many times smaller than the largest volume of the first stage chamber 1 , the state of work medium changes so that, after its shift from the first stage chamber 1 into the second stage chamber 2 , this medium has higher pressure and also higher temperature. If an undue temperature increase is not desirable, it is possible to insert an interstage cooler 6 between both of the stage chambers according to the FIG. 2 . When the volume again decreases in the second stage chamber 2 , work medium is transferred from it through the third stage (chamber 3 into the fourth stage chamber 4 , while increasing its volume. Heat is supplied into work medium in the third stage chamber 3 either by outside warming, where the stage chamber is made as a heat exchanger, or by inside combustion similarly as in the turbine's combustion chambers, but under considerably higher pressure. Because the largest volume of the fourth stage chamber 4 is generally equal to the largest volume of the second stage chamber 2 , work medium has in the fourth stage chamber 4 , after warming in the third stage chamber, in the final state, higher pressure and also higher temperature contrary to the initial state in the second stage chamber 2 . Work medium expands from decreasing volume of the fourth stage chamber 4 into increasing volume of the fifth stage chamber 5 , where it performs work. It is also possible to adapt this apparatus according to the present invention, so that the largest volume of the fourth stage chamber 4 is larger than the largest volume of the second stage chamber 2 , so that the partial isobaric to isothermal expansion between both of the stage chambers will occur and the process according to the present invention will reach Carnot's cycle concept. In an extreme case, it is possible to completely avoid the fourth stage chamber and to let work medium expand from the second stage chamber 2 , during warming in the third stage chamber 3 , into the fifth stage chamber 5 . The third stage chamber has a nonzero volume so that, if there is no heat supplied, the partial expansion occurs at the beginning of the work medium transfer and after transferring through the third stage chamber, work medium will have lower pressure and also lower temperature in the fourth stage chamber then in the second stage chamber. However, due to this lower pressure, the fourth stage chamber takes proportionally lower weighted quantity of work medium from the third stage chamber than it is supplied into the third stage chamber from the second stage chamber and the residual quantity generates, or optionally increases, the residual pressure in the third stage chamber. According to the size of the third stage chamber, in this manner also without heat supply, the pressure in the third stage chamber very quickly rises, so that expansion, within the work medium transfer from the second stage chamber through the third stage chamber, does not occur and it is possible to supply heat under the pressure given by compression of work medium from the first stage chamber into the second stage chamber. It is therefore possible to dimension the third stage chamber both as a combustion chamber with a small external area, so that needles heat leak does not occur, and as a heat exchanger with a large area, so that the largest heat quantity may be fed into it. In order to supply the largest possible heat quantity in the third stage chamber and to decrease the work expended during the compression stage of the cycle, it is, if possible, needed to decrease temperature during the transfer from the first stage chamber into the second one. It is, according to the present invention, enabled by inserting the interstage cooler 6 between the first stage chamber 1 and the second stage chamber 2 . At the closed cycle, where work medium is transferred from the fifth stage chamber 5 back into the first stage chamber 1 , it is appropriate to insert an innerstage cooler 7 between these two stage chambers. At the configuration according to the invention, it is possible to choose, independently upon the compression ratio, magnitude of the expansion ratio, so that it is possible to let expand the compressed and heated work medium to the pressure of the surrounding environment, whereby a good cycle efficiency is reached. At the given expansion ratio, the pressure at the end of the expansion is given by magnitude of the pressure at its beginning and this pressure, at the end of the expansion, can therefore, at the smaller heat supply, drop under the surrounding environment pressure. If this phenomenon is not desirable, it is possible to incorporate other inventive aspects i.e. additional work medium sucking through the inlet valve 8 at the end of the expansion. The power cycle, realized according to the present invention and apparatus, is therefore five-stroke cycles. At certain expansion ratio magnitude in the fifth stage chamber 5 (i.e. the ratio between the largest volumes of the fifth and fourth stage chambers), not only the pressure at the end of the expansion, but also the temperature drops to the value of the surrounding environment. It is therefore possible at the enclosed cycle and at the outside work medium warming, which take place in the third stage chamber 3 , according to the other invention character, to join the fifth stage chamber 5 with the first stage chamber 1 according to FIG. 3 and to transfer work medium after expansion advantageously from the joined stage chamber 51 through the interstage cooler 76 into the second stage chamber 2 concurrently with its compression. In this case, it is also desirable to equip the joined stage chamber 51 by the inlet valve 8 . It is therefore possible, in some cases, within the invention, to adapt the five-stroke cycle to the three-stroke cycle.
The present invention is, both according to the design examples mentioned previously and in comparison to the other known heat engines, more convenient especially by its possibility to allow higher working pressure and temperature then turbine engines, longer warming time of the compressed work medium and lower pressure and temperature at the end of the expansion then so far know piston engines. Higher cycle efficiency, lower emissions of the carbon and nitrogen oxides, lower noise in the case of work medium warming by external or internal combustion is the outcome of the present invention. It is also possible to use the present invention for the conversion of solar energy into mechanical energy.
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The invention relates to a method for converting heat energy into mechanical energy by modifying the volume, pressure and temperature of a working medium, wherein the working medium in the first state ( 1 ) is suctioned and the volume of said first stage ( 1 ) is increased, whereupon it is converted into a second stage ( 2 ) when the volume of the first stage ( 1 ) is reduced and the volume of the second stage is increased, whereupon the working medium is converted into a fourth stage ( 4 ) via a third stage ( 3 ) wherein the volume of the second stage ( 2 ) is reduced, heat is also supplied and the volume of the fourth stage ( 4 ) is increased, whereupon the working medium is converted into a fifth stage ( 5 ) from the fourth stage ( 4 ) wherein the volume thereof is reduced and in the fifth stage ( 5 ) the volume of said fifth stage is expanded. The inventive method discloses a thermodynamic cycle process comprising five cycles. The invention also relates to a device for carrying out said method.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority to and benefit of Chinese Patent Application No. 201320089712.6, entitled “SYSTEM AND METHOD FOR REDUCING BACK PRESSURE IN A GAS TURBINE SYSTEM”, filed Feb. 15, 2013, which is herein incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] The subject matter disclosed herein relates to gas turbine systems and, more specifically, a system for reducing back pressure on the turbine.
[0003] Gas turbine engine systems benefit from improved efficiency. Gas turbine designs minimize inefficiencies in order to extract as much work as possible from a combustible fuel. Specifically, the gas turbine system uses the combustible fuel to create hot, pressurized exhaust gases that flow through a turbine. The turbine uses the momentum of the exhaust gases to create rotational energy for use by a load (e.g., a generator). As the exhaust gases exit the turbine into an exhaust section, they may create undesirable back pressure. The back pressure may reduce the gas turbine system's efficiency, causing the system to use more energy to move the exhaust gases out of the turbine.
BRIEF DESCRIPTION OF THE INVENTION
[0004] Certain embodiments commensurate in scope with the originally claimed invention are summarized below. These embodiments are not intended to limit the scope of the claimed invention, but rather these embodiments are intended only to provide a brief summary of possible forms of the invention. Indeed, the invention may encompass a variety of forms that may be similar to or different from the embodiments set forth below.
[0005] In a first embodiment, a system, including an exhaust duct configured to flow an exhaust gas, and an air injection system coupled to the exhaust duct, wherein the air injection system comprises a first air injector configured to inject air into the exhaust duct to assist flow of the exhaust gas through the exhaust duct.
[0006] In a second embodiment, a system including, a controller having instructions to control air flow through an air injection system into an exhaust duct to reduce back pressure associated with flow of the exhaust gas through the exhaust duct.
[0007] In a third embodiment, a method including, receiving the air flow from a compressor of a gas turbine engine, routing the air flow through the air injection system into the exhaust duct downstream of a turbine of the gas turbine engine, and reducing the back pressure with the air flow.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] These and other features, aspects, and advantages of the present invention will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein:
[0009] FIG. 1 is a schematic of a gas turbine system using an air injection system;
[0010] FIG. 2 is a cross-sectional view of an exhaust duct along line 2 - 2 in FIG. 1 that illustrates an air injector stage with rakes;
[0011] FIG. 3 is a cross-sectional view of the exhaust duct along line 2 - 2 in FIG. 1 that illustrates an air injector stage with rakes;
[0012] FIG. 4 is a cross-sectional perspective view of the exhaust duct along line 4 - 4 in FIG. 1 that illustrates an air injector stage with air injector nozzles;
[0013] FIG. 5 is a cross-sectional perspective view of the exhaust duct along line 4 - 4 in FIG. 1 that illustrates an air injector stage with air blades;
[0014] FIG. 6 is a cross-sectional perspective view of the exhaust duct along line 6 - 6 in FIG. 1 that illustrates an air injector stage with air injector nozzles; and
[0015] FIG. 7 is a cross-sectional perspective view of the exhaust duct 18 along line 7 - 7 in FIG. 1 that illustrates the air injector stage with air injector nozzles and air blades.
DETAILED DESCRIPTION OF THE INVENTION
[0016] One or more specific embodiments of the present invention will be described below. In an effort to provide a concise description of these embodiments, all features of an actual implementation may not be described in the specification. It should be appreciated that in the development of any such actual implementation, as in any engineering or design project, numerous implementation-specific decisions must be made to achieve the developers' specific goals, such as compliance with system-related and business-related constraints, which may vary from one implementation to another. Moreover, it should be appreciated that such a development effort might be complex and time consuming, but would nevertheless be a routine undertaking of design, fabrication, and manufacture for those of ordinary skill having the benefit of this disclosure.
[0017] When introducing elements of various embodiments of the present invention, the articles “a,” “an,” “the,” and “said” are intended to mean that there are one or more of the elements. The terms “comprising,” “including,” and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements.
[0018] The present disclosure is generally directed towards a gas turbine system with an air injection system that reduces back pressure on a gas turbine. Specifically, the air injection system helps move back-pressure-causing-exhaust gases away from the gas turbine engine. This improves efficiency by reducing the work used by the gas turbine engine to expel exhaust gases. In certain embodiments, the air injection system includes multiple air injector stages that move the exhaust gas away from the gas turbine engine. Each injector stage may include one or more air injectors. The air injectors may include air blades or air injector nozzles. The injectors or air blades are designed to minimize air blockage and maximize air energization. In operation, the air injectors and air nozzles entrain surrounding and/or upstream air that is then energized with a small amount of compressed air. In this manner, the air injectors and air blades can move large volumes of air at high velocities. These air blades and nozzles may be modified in various ways to include changing their shape; the angle at which they inject air; sizes; quantity; and spacing between the duct and neighboring air injectors. Furthermore, the air injectors may interact in different ways with the exhaust duct. For example, some air injectors may project into the exhaust duct while others are flush or recessed with exhaust duct walls.
[0019] FIG. 1 is a schematic of a gas turbine system 10 using an air injection system 12 . The gas turbine system 10 includes the air injection system 12 , a gas turbine 14 , a load 16 , and exhaust duct work 17 with an exhaust stack 18 . The air injection system 12 may advantageously improve the efficiency of the gas turbine system 10 . Specifically, the air injection system 12 may move excess compressed air from the gas turbine 14 to the exhaust duct 17 (including the exhaust stack 18 ) to reduce back pressure on the gas turbine 14 . The air injector system 12 may include one or more air injector stages or modules 11 that are mountable in or part of the exhaust duct work 17 , each having one or more air injectors 13 . Each injector 13 injects air to help flow the exhaust gases in a downstream direction to reduce back pressure.
[0020] The gas turbine engine 14 includes a compressor 20 , combustor 22 , fuel nozzle 24 , and turbine 26 . In operation, the compressor 20 draws air into the gas turbine 14 and compresses it for combustion. As illustrated, the compressor includes multiple rotors or compression stages 28 , 30 , and 32 each having a plurality of compressor blades. While only three rotors or stages are shown, a compressor 20 may include additional rotors or stages (e.g., 1, 2, 3, 4, 5, 6, 10, or more). Each stage 28 , 30 , and 32 uses the blades to progressively compress the air to a greater pressure. After passing through the compressor 20 , the air enters the combustor 22 . In the combustor 22 , the air combines and combusts with fuel from the fuel nozzle 24 . The combustion of the air and fuel creates hot pressurized combustion gas that then travel through the turbine 26 .
[0021] The turbine 26 , like the compressor 20 , includes several rotors or turbine stages 34 , 36 , and 38 , each having a plurality of turbine blades. While only three rotors or stages are shown, a turbine 26 may include additional rotors or stages (e.g., 1, 2, 3, 4, 5, 6, 10, or more). The movement of the combustion gases through the turbine 26 , causes the turbine blades and rotors to rotate. The rotation of the rotors or turbine stages 34 , 36 , and 38 cause shaft 40 to rotate, which then drives a load 16 (e.g., a generator). As the hot and fast moving combustion gases pass sequentially through the turbine stages 34 , 36 , and 38 , the gases restricts exhaust gas 42 due to the stations walls 19 , turns and general flow restriction, thereby collecting back pressure on the flow of exhaust gases 42 progressively expand, cool, and slow before entering the exhaust stack 18 as slower moving exhaust gas 42 . The exhaust duct 17 generally conforms or the flow of exhaust gas 42 , and generally slows the flow of traveling through the turbine 26 . The back pressure causes the gas turbine 14 to work harder and burn more fuel to counter the back pressure. Advantageously, the gas turbine system 10 may include an air injection system 12 that reduces the back pressure and increases efficiency. In particular, the air injectors system 12 is configured to energize or add momentum to the flow of exhaust gas to counter the effects of the flow restriction.
[0022] The air injection system 12 includes a controller 44 ; air injector modules or stages 46 , 48 , 50 , and 52 ; compressed air supply 54 ; pressure collecting valve assembly 56 ; pressure releasing valve assembly 58 ; and sensor 59 . Advantageously, the air injection system 12 may use compressed air from the gas turbine 14 to reduce the back pressure caused by the exhaust gas 42 . As explained above, the compressor 20 compresses air for combustion in the combustor 22 . The compressor 20 may create more pressurized air than the gas turbine 14 can use during combustion. Instead of wasting this excess pressurized air, the air injection system 12 uses the pressurized air in the air injector stages 46 , 48 , 50 , and 52 to reduce back pressure.
[0023] The air injection system 12 uses the valve assemblies 56 and 58 to control the flow of the compressed air from the compressor 20 into the air injector stages 46 , 48 , 50 , and 52 . The controller 44 includes a processor 45 , memory 47 , and instructions stored on the memory 47 executable by the processor 45 . The controller 44 operates with and receives data from the sensor 59 (e.g., exhaust gas velocity, pressure in exhaust duct 17 ). The controller then processes this data with the processor 45 and executes instructions stored in the memory 47 . While only one sensor 59 is illustrated other embodiments may include multiple sensors measuring properties at different locations in the exhaust duct 17 . In operation the controller 44 executes instructions to open and close the valves 60 , 62 , and 64 in the valve assembly 56 to selectively flow excess pressurized air from respective compressor stages 28 , 30 , and 32 into the compressed air supply 54 . While only three valves are illustrated, more valves in different configurations are possible. For example, the valve assembly 56 may include (1, 2, 3, 4, 5, 10, 15 or more valves). In some embodiments, each valve may control pressurized air release from a respective compression stage in the compressor 20 . In other embodiments, a single valve may control pressurized air release from a single stage, all stages, or some of the stages. In still other embodiments, valves may only connect to some of the stages (e.g., the stages with the most pressure or suitable pressure for the exhaust duct 17 ).
[0024] The compressed air supply 54 may include an air distribution manifold, storage tank, conduits, or any combination thereof. In certain embodiments, the supply 54 may simply represent, or include the source of compressed air, i.e., the compressor 20 itself. The valve assembly 56 receives the compressed air from the supply 54 and routes it to the air injector stages 46 , 48 , 50 , and 52 . The valve assembly 58 includes valves 66 , 68 , 70 , and 72 . Each valve corresponds to a respective air injector stage 46 , 48 , 50 , and 52 . In other embodiments there may be more air injector stages (e.g., 1, 2, 3, 4, 6, 8, 14, or more) and a corresponding number of valves (e.g., 1, 2, 3, 4, 6, 8, 14, or more). In still other embodiments, there may be fewer valves than the number of air injector stages (e.g., one valve for all of the air injectors). In operation, the controller 44 executes instructions to open and close valves 66 , 68 , 70 , and 72 to provide compressed air into the respective air injector stages 46 , 48 , 50 , and 52 . The air injector stages 46 , 48 , 50 , and 52 then direct the compressed air into air injectors 13 . The air injectors 13 use the compressed air to increase the speed or momentum of the exhaust gas 42 as it travels though the exhaust duct 17 (including exhaust stack 18 ), reducing back pressure on the gas turbine 14 . The controller 44 executes instructions to selectively control the valves to adjust the quantity flow rate, and distribution among the various stages and injectors 13 . For example, the controller 44 may execute instructions to progressively increase exhaust gas speed between the stages 46 , 48 , 50 , and 52 by increasing the amount of compressed air in each stage. In other embodiments, the controller 44 may execute instructions to increase the speed of the exhaust gas 42 in the stage closest to the turbine 26 (e.g., stage 46 ) and then progressively reduce compressed air injection into the later stages 48 , 50 , and 52 . In each configuration the injectors 13 in each stage or module 11 helps to energize the exhaust flow to counteract the flow restriction as the exhaust gas 42 travels through the exhaust duct. Furthermore, each stage or module 11 may energize/interact with the flow in different ways. For example, the stages or modules 11 may have air injectors 13 that protrude into the flow, are flush with the exhaust duct 17 , or are angled with respect to the flow. By projecting into the flow the air injector 13 may more effectively energize the center of the flow. In contrast, the injectors 13 that are flush with the exhaust duct 17 may more effectively energize the outer portions of the flow. Furthermore, the angle of the air injectors 13 with respect to the flow may more effectively energize the flow in a direction out of the exhaust duct 17 . Thus depending on the embodiment a stage or module 11 may adjust how the air injector(s) 13 interact with the flow (i.e., energize the flow center, flow edges, or the direction of flow movement).
[0025] FIG. 2 is a cross-sectional view of the exhaust duct 17 along line 2 - 2 in FIG. 1 , illustrating an embodiment of the air injector stage 46 with rakes 90 , 92 , and 94 . While only three rakes are shown, there may be more rakes depending on the embodiment (e.g., 1, 2, 3, 4, 5, 10, 15, or more). As illustrated, the exhaust duct 17 is rectangular with four side walls 96 , 98 , 100 , and 102 . In other embodiments, the exhaust duct 17 may be circular, square, oval, hexagonal, etc. In the present embodiment, the rakes 90 , 92 , and 94 are between the side walls 96 and 98 and spaced apart by distances 104 , 106 , 108 , and 110 . The distances 104 , 106 , 108 , and 110 may change, depending on the embodiment, to achieve particular flow characteristics. For example, the distances 104 and 110 may be small in order to place the rakes 90 and 94 near the side walls 100 and 102 . In other embodiments, the rakes 90 , 92 , and 94 may be spaced closer together. The rakes 90 , 92 , and 94 may also have different orientations to include vertical orientations between the walls 100 and 102 . In still other embodiments, the rakes may be oriented diagonally between the walls 96 , 98 , 100 , and 102 .
[0026] The rakes 90 , 92 , and 94 include one or more air injectors 13 , e.g., air injector nozzles 112 . Each rake 90 , 92 , and 94 may include one or more nozzles 112 (e.g., 1, 2, 3, 4, 5, 10, 25, or more). In some embodiments, the number of nozzles 112 may differ between rakes 90 , 92 , and 94 . For example, rake 94 may have twelve nozzles 112 while rakes 90 and 92 have four each. The nozzles 112 may also differ in shape and size with respect to each other. Shapes may include circular, chevron, rectangular, square, half-moon, and ellipse, among others. In other embodiments, the nozzles 112 may progressively change in size across the rake to improve flow velocity characteristics of the exhaust gas between the side walls 96 , 98 , 100 , and 102 of the exhaust duct 17 . For example, smaller nozzles 112 that emit pressurized air at a high velocity may be closer to the sides of the exhaust duct 17 where the flow may be slowest, while lower pressure nozzles 112 are near the center of the exhaust duct 17 . In still other embodiments, the spacing and sizes of the nozzles 112 may be equal. This may improve exhaust gas 42 flow through the exhaust duct 17 . Moreover, there are many possible combinations using the variables of nozzle size, nozzle shape, nozzle number, nozzle spacing, and rake spacing.
[0027] FIG. 3 is a cross-sectional view of the exhaust duct 17 along line 2 - 2 in FIG. 1 , illustrating the air injector stage 46 with rakes 140 , 142 , and 144 . The rakes 140 , 142 , and 144 include air blade slots 146 , 148 , 150 , and 152 . The air blades 146 , 148 , and 150 function like the air nozzles 112 in FIG. 2 , and provide air to energize or push exhaust gases 42 through the exhaust duct 17 . Furthermore, the air blades 146 may more uniformly energize the flow. In the present embodiment, the rakes 140 , 142 , and 144 extend between the side walls 100 and 102 in a vertical orientation. The rakes 140 , 142 , and 144 may change orientation (e.g., horizontal, diagonal), and change distances 154 , 156 , 158 , and 160 between each other and the side walls 96 , 98 , 100 , and 102 , depending on the embodiment. Furthermore, the rakes 140 , 142 , and 144 may include more than one air blade. As illustrated rake 140 includes two air blades 150 and 152 , while rakes 142 and 144 have one air blade 146 and 148 , respectively. Different embodiments may include more air blades in each rake (e.g., 1, 2, 3, 4, 5, 6, or more), or different numbers of rakes (e.g., 1, 2, 3, 4, 5, 6, or more). For example, rake 140 may have two blades while rake 144 has five and rake 142 has three. Finally, the shape of the air blade may differ (e.g., straight, wave-like, zigzag, etc.). For example, the blade 148 forms a wave-like slot, while the remaining blades 146 , 150 , and 152 form a straight rectangular slot.
[0028] FIG. 4 is a cross-sectional view of the exhaust duct 17 along line 4 - 4 in FIG. 1 , illustrating the air injector stage 48 with air injector nozzles 180 . As illustrated, the nozzles 180 are flush with the side walls 96 , 98 , 100 , and 102 . Accordingly, the air injector nozzles 180 may impact the portions of the flow closest to the side walls 96 , 98 , 100 , and 102 . The air injector stage 48 may form various configurations with the air nozzles 180 using the variables of shape, angle, size, quantity, and spacing. For example, the side walls 96 , 98 , 100 , and 102 may have the same or different numbers (e.g., 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10) of nozzles 180 . For example, side wall 96 may have three nozzles 180 , while the remaining walls 98 , 100 , and 102 have six, seven, and four nozzles 180 , respectively). Each of these nozzles 180 may form a variety of shapes, such as circular, chevron, rectangular, square, half-moon, and ellipse among others. Furthermore, the air injector stage 48 may place differently shaped nozzles 180 at different locations (e.g., on some or all of the side walls 96 , 98 , 100 , and 102 ).
[0029] The air nozzles 180 may also form an angle 182 with respect to the side walls 96 , 98 , 100 , and 102 in the direction of the exhaust gas flow. The angle of the air nozzles 180 may change how they energize the flow (i.e., smaller angles may energize flow in a direction parallel to the exhaust duct 17 while a large angle will increasingly energize the flow in a direction perpendicular to the exhaust duct 17 ). The angle 182 may be any angle between approximately 0 and 90 degrees (e.g., approximately 10-30, 20-70, 45-65 degrees). For example, the angle 182 may be approximately 18, 20, or 30 degrees. In some embodiments, the air nozzles 180 on the side wall 96 may form an angle of approximately 90 degrees, while the air nozzles 180 on side wall 100 are at approximately 45 degrees. In still other embodiments, each of the air nozzles 180 may form an angle 182 that differs from the others.
[0030] As discussed above, the air nozzles 180 may form different sizes and be spaced differently with respect to each other. As illustrated, the side wall 102 includes different sizes of air nozzles 180 . The different sizes of the air nozzles 180 may increase or decrease air flow in portions of the air injector stage that optimize the flow of the exhaust gas 42 . The air nozzles 180 on the side wall 102 are spaced apart by distances 184 , 186 , 188 , 190 , and 192 . The spacing between the air nozzles 180 may change the profile of the exhaust gas 42 flow through the air injector stage 48 . For example, the air injectors 180 may provide greater air flow near the side walls 96 and 98 by decreasing the distances 184 , 186 , 190 , and 192 and increasing the distance 188 , thereby providing greater energization of the exhaust gas 42 flow along the side walls 96 and 98 . In other embodiments, the opposite may occur by decreasing distance 188 and increasing distances 184 , 186 , 190 , and 192 .
[0031] FIG. 5 is a cross-sectional perspective view of the exhaust duct 17 along line 4 - 4 in FIG. 1 , illustrating the air injector stage 48 with air blades 210 . The blades 210 like the nozzles in FIG. 4 move exhaust gas 42 through the exhaust duct 17 . The air blades 210 like the nozzles in FIG. 4 are flush with the exhaust duct 17 and will therefore impact the portions of the flow closest to the side walls 96 , 98 , 100 , and 102 . The air blades 210 may form various configurations by changing the shape, angle, and quantity. The air blades 210 may form different shapes, including wave-like, zigzag, and straight rectangular slots. The air blades 210 may project from side walls 96 , 98 , 100 , and 102 . This angle 212 may be any angle between approximately 0 and 90 degrees (e.g., approximately 10-30, 20-70, or 45-65 degrees). For example, the angle 212 may be approximately 10, 20, or 30 degrees. In certain embodiments, one of the air blades 210 may have an angle 212 of approximately 90 degrees with the side wall 96 , while the other air blades 210 have an angle 212 of approximately 30 degrees with respective side walls 98 , 100 , and 102 . In still other embodiments, each of the air blades 210 may form an angle 212 that differs from the others. Furthermore, each side wall 96 , 98 , 100 , and 102 may include more than one air blade 210 or some walls may have no air blades 210 .
[0032] FIG. 6 is a cross-sectional perspective view of the exhaust duct 17 along line 6 - 6 in FIG. 1 , illustrating the air injector stage 50 with air injector nozzles 240 . As illustrated, the nozzles 240 project from the side walls 96 , 98 , 100 , and 102 . In other embodiments, air blades instead of the nozzles 240 may project from the side walls 96 , 98 , 100 , and 102 . By projecting into the flow the air nozzles 240 (or air blades) may more effectively energize the center of the flow.
[0033] The air injector stage 50 may form various configurations with the air nozzles 240 using the variables of shapes, angles, sizing, quantity, and spacing. For example, the side walls 96 , 98 , 100 , and 102 may have the same or different numbers (e.g., 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10) of nozzles 240 on each wall. For example, side wall 96 may have three nozzles 240 , while the remaining walls 98 , 100 , and 102 have four, five, and six nozzles 240 respectively. In some embodiments, some walls may exclude nozzles 240 . Each of these nozzles 240 may form a variety of shapes to include circular, chevron, rectangular, square, half-moon, and ellipse shaped nozzles, among others. Furthermore, the air injector stage 50 may place differently shaped nozzles 240 at different locations (e.g., on different side walls 96 , 98 , 100 , and 102 ).
[0034] The air nozzles 240 may also form an angle 242 with respect to the side walls 96 , 98 , 100 , and 102 in the downstream direction of the exhaust gas flow. The angle of the air nozzles 240 may change how they energize the flow (i.e., smaller angles may energize flow in a direction parallel to the exhaust duct 17 while a large angle will increasingly energize the flow in a direction perpendicular to the exhaust duct 17 ). The angle 242 may be any angle between approximately 0 and 90 degrees (e.g., approximately 10-30, 20-70, or 45-65 degrees). For example, each nozzle 240 may have an angle 242 of approximately 10, 20, or 30 degrees. In some embodiments, the air nozzles 240 that connect to side wall 96 may form an angle of approximately 90 degrees, while the air nozzles 240 that connect to side wall 98 are at approximately 45 degrees. In still other embodiments, each of the air nozzles 240 may form an angle 242 that differs from the others.
[0035] As discussed above, the air injector stage 50 may change spacing and sizing between nozzles 240 . The different sizing of air nozzles 240 may increase or decrease air flow in portions of the air injector stage 50 to optimize the flow of the exhaust gas 42 . The air nozzles 240 may also change spacing with respect to each other. For example, the nozzles 240 are spaced from one another by distances 244 , 246 , 248 , and 250 . The spacing between the air nozzles 240 , like the size of the air nozzles 240 , may change how the exhaust gas 42 accelerates through the air injector stage 50 . For example, changing the distances 244 , 246 , 248 , and 250 may move the nozzles 240 closer to side walls 96 and 98 , accelerating the exhaust gas near the opposite edges of side wall 102 . In other embodiments, the opposite may occur by decreasing distances 244 , 246 , 248 , and 250 the nozzles 240 may accelerate the exhaust gas 42 flow near the exhaust duct 18 center.
[0036] FIG. 7 is a cross-sectional perspective view of the exhaust duct 18 along line 7 - 7 in FIG. 1 , illustrating the air injector stage 52 with air injector nozzles 270 and 280 and air blades 300 and 310 . The embodiment shown in FIG. 7 combines the different air nozzles and air blades from the previous embodiments in FIGS. 2-6 into the air injector stage 52 . Specifically, the air injector stage 52 includes nozzles 270 that are flush with the wall 96 , nozzles 280 that project from the side wall 98 into the duct 17 , air blade 300 that projects from the wall 102 into the duct 17 , and the air blade 310 that is flush with the wall 100 . While FIG. 7 illustrates one possible configuration, many others are possible. For example, some walls may include combinations of air blades and air nozzles that are flush recessed, or projecting relative to the exhaust duct 17 . In still other embodiments, different walls may combine projecting air nozzles 280 with flush nozzles 270 on all the walls 96 , 98 , 100 , and 102 , or an embodiment that combines projecting air blades 300 and flush air blades 310 . Furthermore, the air injector stage 52 may further modify the air nozzles 270 and 280 and air blades 300 and 310 in FIG. 7 using the variables discussed above in FIGS. 2-6 , including changing shapes, angle 312 , sizing, quantity, and spacing.
[0037] Technical effects of the invention include the ability to reduce back pressure on a gas turbine system using excess compressed air from the compressor. Specifically, the disclosed embodiments reduce back pressure on a gas turbine engine with air injector stages along an exhaust duct. The air injector stages include air injectors that use the excess compressed air to accelerate the exhaust gases out of the system. In this manner, the system reduces back pressure on the gas turbine engine improving its efficiency.
[0038] This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.
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In a first embodiment, a system, including an exhaust duct configured to flow an exhaust gas, and an air injection system coupled to the exhaust duct, wherein the air injection system comprises a first air injector configured to inject air into the exhaust duct to assist flow of the exhaust gas through the exhaust duct.
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BACKGROUND OF INVENTION
[0001] In the process of electrophotographic printing, a photoconductive surface has an electrostatic latent image recorded therein. Toner particles are attracted from carrier granules to the latent image to develop the latent image. Thereafter, the toner image is transferred from the photoconductive surface to a sheet and fused thereto.
[0002] Typically, toner may be produced by melt-mixing the soft polymer and pigment whereby the pigment is dispersed in the polymer. The polymer having the colorant dispersed therein is then pulverized. Recently in U.S. Pat. No. 5,227,460 (Mahabadi et al.), incorporated herein by reference, a low melt toner resin with minimum fix temperature and wide fusing latitude containing a linear portion and a cross-linked portion containing high density cross-linked microgel particles, but substantially no low density cross linked polymer was disclosed. A method of manufacturing that toner and its resin was disclosed in U.S. Pat. No. 5,376,494 (Mahabadi et al.), incorporated herein by reference. The method of fabricating the low fix temperature toner resins includes a reactive melt mixing process wherein polymer resins are cross-linked at high temperature and high shear. The resins are particularly suitable for high speed fusing, show excellent offset resistance and wide fusing latitude and superior vinyl offset properties.
[0003] The base resin and pigment are melt mixed together typically in an extruder, which is a part of an extruding system. The soft polymer and pigment are translated and mixed in an auger within a cavity of the extruder.
[0004] The polyester base resins of the present invention are typically in the form of soft polymers. These base resins have an extremely low melting temperature. The melting temperature of these polyester based toners are about 90° C. A typical extruder is maintained at high temperature by jacket heaters on the extruder body. On top of this, as the base resin is extruded in an extruder, a significant amount of heat is generated which is result of high shear energy of the extruding. The heat from the extruding process raises the temperature of both the body of the extruder and the screw within the extruder. The entire extruder is at an elevated temperature above ambient. The polymer base resin is added to the extruder through a feed opening in the inlet end of the extruder.
[0005] When utilizing the low melt polymer based resins, the heat from the screws and body of the extruder tend to melt the base resin at the open feed barrel at which the resin is added to the extruder. The premature melting of the toner affects the productivity of the extruder. If the premature melting is severe enough, the extruder must be shut down and cleaned of the melted extruder before the process may continue.
[0006] Furthermore, the use of a commercially available extruder to manufacture the polyester base resins requires that the input area of feed barrel be redesigned to have a shape between the screws of the extruder and the body of the extruder which has increased clearance in order to optimize conveying base resin into the extruder. The requirement for increased clearance between the body and the screws when utilizing the polyester based resin, necessitates that the feed barrel of the extruder be changed from a standard feed barrel to a specially designed feed barrel when manufacturing such resin. This process is very time and labor intensive and results in a loss of productivity.
[0007] The following disclosures may be of note:
[0008] U.S. Pat. No. 5,145,762 (Grushkin) discloses a process for the preparation of toner compositions. The process comprises melt blending toner resin particles, magnetic particles, wax, and charge additives. The process further comprises adding a coupling component to the aforementioned mixture, injecting water therein, and cooling.
[0009] U.S. Pat. No. 4,973,439 (Chang et al.) discloses an apparatus for obtaining toner particles with improved dispersion of additive components therein comprised of a toner extrusion device containing therein a blending chamber, a mixing screw, a heater, a toner supply, and an injector for injecting additive components including charge control agents into the extrusion device enabling a decrease in the melting temperature of the toner resin particles contained therein.
[0010] In U.S. Pat. No. 4,894,308 (Mahabadi et al.), a process for preparing an electrophotographic toner is disclosed, which comprises premixing and extruding a pigment, a charge control additive and a resin. The pigment and the charge control additive may be premixed prior to being added to the extruder with the resin; alternatively, the pigment and charge control additive may be premixed by adding them to the extruder via an upstream supply means and extruding them, and subsequently adding the resin to the extruder via a downstream supply means.
[0011] In U.S. Pat. No. 3,778,287 (Stansfield et al.) dispersions of inorganic pigments, lakes or toners in organic liquids containing polyesters dissolved therein having acid values up to 100 derived from certain hydroxy-containing, saturated or unsaturated aliphatic carboxylic acids are described. While liquid colorants offer the distinct advantage of being more readily incorporated into the medium to be colored than dry pigments, their commercial significance is seriously limited due to the problems of handling and storing potentially hazardous liquid chemicals. Thus, from an economic and safety standpoint, it is desirable to have the colorants in a dry, storage stable form which is readily dispersible in a wide variety of coating media without detriment to any of the desirable properties of coating produced therefrom.
[0012] U.S. Pat. No. 5,227,460 (Mahabadi et al.) discloses a low melt toner resin with minimum fix temperature and wide fusing latitude containing a linear portion and a cross-linked portion containing high density cross-linked microgel particles, but substantially no low density cross linked polymer.
[0013] U.S. Pat. No. 5,376,494 (Mahabadi et al.) discloses a method of fabricating low fix temperature toner resins by a reactive melt mixing process wherein polymer resins are cross-linked at high temperature and high shear. The resins are particularly suitable for high speed fusing, show excellent offset resistance and wide fusing latitude and superior vinyl offset properties.
[0014] U.S. Pat. No. 5,468,586 (Proper et al.) discloses an apparatus for the preparation of a mixture of toner resin and a liquid colorant. The apparatus includes a toner extruder having the resin being conveyed therethrough and a colorant feeder for adding the colorant to the toner resin in the toner extruder to form the toner mixture. The color of the extrudate is measured, compared to a standard and the amount of colorant added is modified accordingly.
[0015] U.S. Pat. Nos. 5,650,484 and 5,750,909 (Hawkins et al.) disclose apparatus for the preparation of a mixture of toner resin and initiator, to form a toner resin or toner mixture including cross-linked microgel particles is provided. The apparatus includes a toner extruder having the resin being conveyed therethrough and an adder for adding the initiator to the toner resin in the toner extruder to form the toner resin or mixture. The apparatus also includes a measurer for measuring the cross-linked microgel particles in the toner mixture substantially immediately after mixing in the toner extruder and transmitting a signal indicative of the quantity of cross-linked microgel particles in the toner resin or mixture. The apparatus also includes a controller for controlling the addition rate of initiator in response to the signals from the measurer.
[0016] U.S. Pat. No. 5,686,219 (Higuchi) discloses a Toner Extruder Feed Port Insert that overcomes many of the problems associated with the prior art. The insert provides cooling to the extruder feed port, reducing premature melt of the resin. However, toner resin can still melt prematurely, fusing on the crest of a screw element and forming clumps of fused material that can cause material backup.
SUMMARY OF THE INVENTION
[0017] In embodiments, a lead in gap is provided at the feed port end of a toner extruder used for the preparation of a toner resin extrudate from a resin. The lead-in gap can collect prematurely melted resin, allowing the screws to carry the melt away with a lower incidence of clumping. Embodiments also provide enhanced cooling capability on one or both of a downwardly traveling screw feed port wall and downstream feed port wall. This extra cooling of the walls reduces adhesion of the fused resin on the cooled surfaces. The greater the temperature difference between the walls and the fused base resin, the less likely the fused base resin will be to adhere on the walls.
[0018] Embodiments can include a housing defining a housing aperture and a resin inlet opening in the housing. The extruder can also include a conveyor for conveying the resin through the housing aperture. The extruder further includes a member adjacent the resin inlet opening for inhibiting the heat transfer from the housing and/or the conveyor to the resin at the opening. The flow of resin adjacent the opening is thus improved.
[0019] In additional embodiments, there is provided a method for preparing a toner resin. The method includes conveying the base resin to an aperture in the housing of a toner extruder, the housing surrounding a conveyor, inhibiting the heat transfer from the extruder to the base resin at the aperture, adding chemical initiator to a toner extruder, mixing the base resin and the chemical initiator within the extruder to form the mixed resin, and conveying the mixed resin within the extruder to an extruding die.
BRIEF DESCRIPTION OF DRAWINGS
[0020] Embodiments will be described herein with reference to the following Figures in which like reference numerals denote like elements and wherein:
[0021] [0021]FIG. 1 is a schematic perspective view of a toner extruder feed port with a toner extruder feed port insert according to embodiments.
[0022] [0022]FIG. 2 is a schematic elevational view of the toner extruder according to embodiments.
[0023] [0023]FIG. 3 is a schematic elevational view of a toner manufacturing system including a micronization system and the toner extruder of embodiments.
[0024] [0024]FIG. 4 is a schematic perspective view of the toner extruder feed port of FIG. 1.
[0025] [0025]FIG. 5 is a schematic perspective view of a toner extruder feed port insert of FIG. 1.
[0026] [0026]FIG. 6 is a schematic of embodiments with no lead-in gap.
[0027] [0027]FIG. 7 is a schematic of embodiments with no lead-in gap and illustrating backup of prematurely melted resin.
[0028] [0028]FIG. 8 is a schematic of embodiments with a lead-in gap.
[0029] [0029]FIG. 9 is a schematic of embodiments with no lead-in gap and illustrating reduction of backup of prematurely melted resin by the presence of the lead-in gap.
DETAILED DESCRIPTION
[0030] According to embodiments, the toner created by the subject process comprises a resin and preferably a charge control additive and other known additives and, some times, very fine toners for reclaim purpose. The manufacture of black toners will be discussed henceforth. It should be readily apparent that the manufacture of colored toner may likewise include the process of the embodiments described as well as variations within the capabilities of one of skill in the art.
[0031] In a process of an embodiment, polyester resins with associated additives are fed to a melt mixing apparatus. Dispensing and mixing of additives are carried out at high temperature and high shear to produce a toner in extrudate form for the next process.
[0032] Referring first to FIG. 2, a toner preparing apparatus 20 in the form of an extruding system is shown. The toner preparing apparatus 20 include an extruder 22 for mixing prepared resin mix with additives including very fine toner 26 and converting the prepared resin mix into a liquid form having a portion of the toner. Generally, any extruder, such as a single or twin screw extruder, suitable for preparing electrophotographic toners, may be employed for the melt mixing of prepared resin mix 26 . For example, a Werner & Pfleiderer ZSK-58SC extruder is well-suited for melt-mixing the prepared resin mix 26 .
[0033] The prepared resin mix is stored adjacent the extruder 22 in a dry resin feeder hopper 62 . The extruder 22 typically includes a body 28 which defines a centrally located aperture 30 therethrough. A feed and mixing mechanism 36 is located in the aperture 30 . Preferably the feed mechanism is in the form of a screw rotatably located in the aperture 30 . The screw 36 rotates within aperture 30 about its axis. The extruder 22 for simplicity is described with a single screw, but many commercial extruders include twin screws, parallel to each other and closely spaced from each other. As the prepared resin mix is mixed, an extrudate 110 is formed which contains the additives evenly distributed within the raw resin. The screw 36 within the extruder 22 is preferably turned at the predetermined rate which allows the molten resin to achieve the desired melt-mixing and temperatures. The extrudate continues to pass through the extruder 22 to a die plate 120 located at an outlet 122 of the extruder 22 . The die plate 120 includes a large rectangular aperture 124 through which the extrudate 110 exits the extruder 22 . The aperture 124 is chosen of suitable size to provide flow sufficient to provide for a commercially acceptable process.
[0034] The extrudate 110 from the extruder 22 is cooled and squeezed to form a thin, preferably 1 to 2 mm, sheet by a pair of squeeze rolls 126 to form a thin sheet 111 . This thin sheet 111 is further cooled by belt 127 , preferably by double water cooled metal belts, prior to crushing the sheet 111 with a rotary pin breaker 128 or other suitable means.
[0035] After the resin has been cooled and crushed, resin particles are reduced in size by any suitable method including those known in the art. An important property of toners is brittleness which causes the resin to fracture when impacted. This allows rapid particle size reduction in attritors, other media mills, or even jet mills used to make dry toner particles. It should be appreciated that the particle size reduction may possibly include the use of a pulverizer (not shown). The pulverizer may be a hammer mill such as, for example, an Alpine® hammer mill or FitzMill® rotary mill. The hammer reduces the toner particles to a size of about 300 microns to about 3 mm.
[0036] Referring now to FIG. 3, a micronization system 134 is shown in use with the toner preparing apparatus 20 to form a toner manufacturing system 135 . The micronization system 134 serves to reduce the particle size of milled particles or material 130 into toner particles of an appropriate size, such as four to ten microns. The micronization system 134 is connected to the toner preparing apparatus 20 to form a toner manufacturing system 135 .
[0037] As earlier stated, an important property of toners is brittleness, which causes the resin to fracture when impacted. This allows rapid particle size reduction in aerators, other media mills, or even jet mills to make dry toner particles.
[0038] The micronization system 134 includes a micronizer 136 which provides for the rapid particle size reduction of the particles 130 into toner particles. Preferably, the micronizer is a jet-type micronizer such as a jet mill. Jet mills containing a milling section into which water vapor jets or air jets are blown at high speeds and the solid matter to be micronized is brought in across an injector by a propellant. Compressed air or water vapor is usually used as the propellant in this process. The introduction of the solid matter into the injector usually occurs across a feeding hopper or entry chute.
[0039] For example, the micronizer 136 may be a Sturtvant 36 inch jet mill having a feed pressure of about 115 psig and a grinding air pressure of about 120 psig may be used in the preparation of the toner resin particles. The nozzles of this jet mill are arranged around the perimeter of a ring. Feed material is introduced by a pneumatic delivery device and transported to the injector nozzles. The particles collide with one another and are attrited. These particles stay in the grinding zone by centrifugal force until they are small enough to be carried and collected by a cyclone separator. A further size classification may be performed by an air classifier.
[0040] Preferably, however, the micronizer 136 is in the form of an AFG-800 grinder. The AFG-800 grinder is a fluidized air mill made by AFG (Alpine Fliebbertt-Gegenstrahlmuhle). The micronizer 136 includes a feed chamber 138 and a grind chamber 140 . A pipe or tube 142 connects the rotary mill 128 with the feed chamber 138 . The pipe 142 is made of any suitable durable material which is not interactive with the toner composition, such as stainless steel. The milled material 130 are propelled toward the feed chamber 138 by any suitable means such as by augers (not shown) or by blowers (not shown). The milled material 130 accumulated in the feed chamber 138 are extracted from the feed chamber 138 by a screw 144 located in a tube or pipe 146 interconnecting the feed chamber 138 with the grind chamber 140 . The screw 144 and the pipe 146 are made of any suitable durable material which is not chemically interactive with the toner, such as stainless steel. The milled material 130 enter lower portion 150 of the grind chamber 140 .
[0041] A pressurized fluid, preferably in the form of compressed air is added to the grind chamber 140 in a lower central portion 152 of the grind chamber 140 . The compressed air is supplied by any suitable compressed air source 154 , such as an air compressor. Compressed air conduit 156 interconnects the compressed air source with a ring 162 located around the grind chamber 140 . Extending inwardly from the ring 162 are a series of inwardly pointing nozzles (not shown) through which the compressed air enters the grind chamber 140 . The compressed air causes the particles 130 to accelerate rapidly inwardly within the grind chamber 140 .
[0042] In an upper portion 178 of the grind chamber 140 a series of rotating classifier wheels (not shown) set the toner air mixture into rapid rotation. The classifier wheels (not shown) include fins (not shown) along the periphery of the classifier wheels. The wheels cause the larger particles, milled material 130 , to be propelled to inner periphery 184 of the grind chamber 140 and to return to the lower portion 150 of the grind chamber 140 . The milled material 130 impact each other and the components of the micronizer 136 and thereby micronize the toner into micronized toner 188 . The micronized toner 188 , on the other hand, is permitted to move upwardly within the grind chamber 140 into manifold 186 .
[0043] A long connecting pipe 190 is connected on one end thereof to manifold 186 and on the other end thereof to a product cyclone 192 . The long connecting pipe 190 serves to provide a conduit between the grind chamber 140 and the product cyclone 192 for the micronized toner 188 . The long connecting pipe 190 may be of any suitable durable material, such as stainless steel.
[0044] The product cyclone 192 is designed to separate particles from the air stream in which they are carried. The product cyclone 192 may be any suitable commercially available cyclone manufactured for this purpose and may, for example, include a (quad) cyclone which consists of four cyclones combined. Within the product cyclone 192 , the micronized toner 188 circulates in a spinning manner about inner periphery 194 of the cyclone 192 . The larger micronized toner 188 has a greater mass and is thereby propelled to the inner periphery 194 of the cyclone 192 , falling into lower portion 196 of the product cyclone 192 . Air and very small dust particles 200 having a lesser mass and a particle size of, perhaps, less than 1 microns are drawn upwardly through upper opening 202 of the cyclone 192 into dust collector 204 . The micronized toner 188 collects in the lower portion 196 of the cyclone 192 and is extracted therefrom.
[0045] According to the present invention and referring to FIG. 1, a toner extruder feed port insert 210 is shown in position ready for assembly into toner extruder feed port 212 . The toner extruder feed port 212 is in the form of a housing aperture within feed barrel 214 of extruder 22 . The feed barrel 214 represents one section or portion of the body 28 of the extruder 22 . While the invention may be practiced with extruders 22 having only a singular screw 36 , preferably, the extruder 22 includes a twin screws 216 and 220 . The first and second screws 216 and 220 , respectively, are located proximate each other. Preferably, the first screw 216 has a first screw axis 222 which is parallel to second screw axis 224 of the second screw.
[0046] The feed barrel 214 includes a feed barrel body or housing 230 which defines the housing aperture or port 212 . The feed barrel housing 230 includes a lower portion 232 which closely conforms with the screws 216 and 220 as well as an upper portion 234 which includes the central opening or port 212 . The upper portion 234 of the feed barrel housing 230 may have any suitable shape, for example, as shown in FIG. 1, the upper portion 234 has a generally rectangular shape with four vertically extending walls which define the upper portion 234 . These four walls include a downstream wall 236 located in the direction of flow 240 of the extrudate 110 . Opposed to the downstream wall 236 is an upstream wall 242 . Located normal to the walls 236 and 242 are downwardly traveling screw wall 244 and upwardly traveling screw wall 246 .
[0047] In prior art extruders, the entire feed barrel 214 would require removal when converting from conventional toner to polyester based resin toner. This is because the clearance between the screws 216 and 220 and the feed barrel 214 need to be altered or increased at initial meeting clearances when using the polyester based resin.
[0048] Heat from the extruding process propagates from the extrudate 110 to the body 28 of the extruder in a first direction 250 opposite a second direction 252 of flow of the extrudate 110 . Since the heat propagates in the first direction 250 , wall 236 of the feed barrel 214 receives the most heat.
[0049] Furthermore, the intensive melt-mixing utilizes very high shear energy which results into heat. This heat is conducted throughout the screws 36 including the portion of screws 216 and 220 in the feed port 214 . Applicants have found that it is at the downstream wall 236 and side wall 244 where the base resin 24 is most likely to melt and the most of scrapping of melted resin occur and cause damage to the extruder as well as to reduce its productivity and require downtime. The base resin 24 is most likely to melt at crests of the two screws 216 and 220 ; it is at downstream wall 236 and side wall 244 where the melted resin on the crests is scraped and form lumps. These lumps can keep growing and could eventually fill the feed port cavity, causing major machine downtime. Since the second screw 220 rotates in direction of arrow 254 , the base resin 24 is urged between the screw 220 and the downwardly traveling screw wall 244 . Between the downstream wall 236 and the two screws 216 and 220 , the base resin 24 is also likely to melt.
[0050] Referring again to FIG. 1, toner extruder feed port insert 210 is shown. The insert 210 serves three main purposes. The first of these purposes is to isolate the heat from the extrusion process from the base resin 24 . This isolation of the heat of the screws and the extruder from the base resin 24 serves to reduce the likelihood of the base resin melting and the associated problems therewith. The second of these benefits is enhanced cooling of the two vertical walls 264 , which greatly reduces adhesion the melted resin to the cooled surfaces. The melted resin is repelled by the walls and pushed back into the remaining resin, keeping the wall surfaces clear from melted resin. The third purpose of the insert is establishing the greater clearance between the screws 216 and 220 and both walls 264 of the insert 210 that is required for the polyester base resin 24 .
[0051] While the insert 210 may have any suitable shape, preferably the insert 210 includes a top ring or rim 260 which when assembled into the feed barrel 214 rests upon upper face 262 of the feed barrel 214 . Extending downward from the top rim 260 are vertical walls 264 which separate the feed barrel housing 230 from the base resin 24 . It should be appreciated that the invention may be practiced with as few as a single vertical wall 264 , but preferably includes an insert downstream wall 266 as well as an downwardly traveling screw insert wall 270 . Downstream wall 266 and downwardly traveling screw insert wall 270 are included in that they correspond with downstream wall 236 and downwardly traveling screw wall 244 of the feed barrel 214 , respectively. The heat from walls 236 and 244 are thus isolated from the base resin 24 by the walls 266 and 270 .
[0052] Since the insert 210 serves to isolate the heat from the extruder 22 and keep the surfaces of the two vertical walls 264 and the base resin 24 cold, it is preferable that the insert 210 be ineffective in transferring heat from the housing 230 of the feed barrel 214 .
[0053] There are several ways of curing the ineffective heat transfer desired between the insert 210 and the feed barrel 214 . First, a water cooling may be practiced by running a fluid 275 through the walls of the insert 264 . The passage of the fluid 275 is to be a number of conduits 306 drilled throughout both walls 264 . The cooling fluid 275 may be utility water supply, however, circulating chilled water is preferred.
[0054] Furthermore, pads 272 may be placed on outer surface 274 of the walls 270 and 266 to assure the spacing between the walls 266 and 270 and the feed barrel 214 . In fact, these pads may be made of an insulative material to improve the heat insulating properties even further.
[0055] The insert 210 may be made of any suitable durable material which is chemically non-reactive with the base resin 24 . While the invention may be practiced with an insert 210 made of steel or other somewhat conductive material, preferably, the insert 210 is made of an somewhat thermally non-conductive material, such as an insulative material, for example, a ceramic or a carbon graphic material, or a suitable plastic material.
[0056] Referring now to FIG. 4, the feed barrel 214 is shown in greater detail. The first screw 216 as well as the second screw 220 rotate within aperture 30 along axis 222 and 224 , respectively. First screw 216 has a periphery 276 defined by radius R S1 , while second screw 220 has a periphery 278 defined by radius R S2 . The aperture 30 is defined by radius R B1 at the first screw 216 and by radius R B2 at the second screw 220 . Radius R S1 and R S2 , are typically identical and are slightly smaller than radius R B2 and R B1 .
[0057] The walls of the feed barrel 214 have any suitable width capable of withstanding the pressures, temperatures, and other environment factors of the extruder 22 but typically have a thickness T of approximately one inch. The walls of the feed barrel define the housing aperture 212 which has a length L 1 and a width W 1 .
[0058] Referring now to FIG. 5, the insert 210 is shown in greater detail. The insert 210 includes the top rim 260 as well as downwardly traveling screw insert wall 270 and downstream insert wall 266 which extend vertically downward from the top rim 260 . It should be appreciated that a third and fourth wall may be added to the insert and still remain within the scope of the invention. The applicant, however, has found that a third or fourth wall (not shown) are not required for the effective implementation of the invention.
[0059] Referring again to FIG. 5, insert 210 is shown. To accommodate the polyester base resin which has a lower melt temperature than standard resins, the gap between the barrel and the screws need to be increased. This is accomplished with the use of the insert 210 . For the use of the low melt base resin 24 , the distance between at upstream end of the first screw downstream wall bore 280 and the first screw 216 as well as the distance between the second screw downstream wall bore 282 and the second screw 220 is more than the corresponding distance at the downstream end of the bores. Furthermore, the distance between the entering end of the downwardly traveling screw insert wall 284 and the second screw 220 is more than that distance at the other end of the downwardly traveling screw insert wall 284 and the second screw 220 .
[0060] Because of the intense heat of the extruding process, the extruder 22 (see FIG. 2) may generate sufficient heat that when the low melt base resin toner 24 contacts the screws 216 and 220 (see FIG. 4), the base resin 24 may melt even with the use of the insert 210 . The applicant has found by providing surface 284 with clearances between the surface 284 and the screw 220 , which clearance is increased in the direction opposite to the direction of rotation of the screws 36 , the prematurely melted base resin 24 will be conveyed away by the screws 36 and not be scrapped along the periphery 278 of the screw 220 . The applicant has also found that by providing surfaces 280 and 282 with clearances between the surfaces 280 and 282 , and the screws 216 and 220 , which clearances are decreased in the direction of flow of the extrudate 110 , the prematurely melted base resin 24 will be conveyed away by the screws 36 and not be scrapped along the peripheries 276 and 278 of the screws 216 and 220 , respectively.
[0061] Increasing the clearance of the insert 210 to the screws 36 may be accomplished in any suitable way. For example, again referring to FIG. 5, the first screw downstream wall bore 280 may be defined by radius R i1. The radius R i1 extends from axis 290 of the insert 210 . Axis 290 is parallel and concentric with the axis 222 of the screw 216 when the insert 210 is assembled into the feed barrel 214 . Radius R i1 is slightly larger than radius R S1 of the first screw 216 at first end 292 of bore 280 . The radius R i1 decreases steadily in the direction of material flow 301 such that the radius R i1 at second end 293 of bore 280 is slightly smaller than the radius R i1 at first end 292 , typically 2 to 3 mm.
[0062] Second screw downstream wall bore 282 is defined by radius R i2 which extends from axis 298 of insert 210 . Axis 298 is parallel and concentric with second screw axis 224 of the second screw 220 when the insert 210 is assembled into the feed barrel 214 . The radius R i2 is slightly larger than radius R S2 of the second screw 220 at the entering end 295 of the bore 282 . Radius R i2 decreases steadily in the direction of material flow 301 . At second end 297 of the bore 282 , the radius R i2 is slightly smaller than the radius R i2 at the entering end 295 .
[0063] Downwardly traveling screw insert wall surface 284 is defined by radius R i3 which extends from axis 298 of insert 210 . The radius R i3 increases steadily in size in the direction of arrow 294 which is opposite arrow 296 of the screws 36 . Radius R i3 a t position 300 is slightly larger than radius R S2 of the second screw 220 while radius R i3 at position 302 is significantly larger than radius R S2 of the second screw 22 and slightly larger than radius R i3 at position 302 .
[0064] As seen, for example, in FIG. 5, the cooling feature 304 includes a chamber 306 within the insert 210 is shown. The chamber 306 may be in the form of a conduit. The conduit 306 may be positioned anywhere within the insert, and may, for example, extend around the top rim 260 of the insert 210 . An inlet 310 as well as an outlet 312 are operatively connected to the conduit 306 . A cooling source 314 is connected to the inlet 310 as well as to the outlet 312 . It should be appreciated that the cooling feature 304 may be accomplished by an external conduit (not shown) attached to the insert 210 as well as by an internal conduit within the insert 310 .
[0065] It should be appreciated that the bores 280 and 282 may, like wall surface 284 , have a profile that provides for a decrease in clearance between the screws 36 and the insert 210 in the direction of rotation 296 of the screws 36 .
[0066] The fluid 275 is circulated through the conduit 306 of the cooling feature. The fluid 275 may be air or, preferably, water or ethylene glycol. The cooling source may be tap water or a tank of fluid. The fluid may be propelled through the conduit in any suitable fashion, for example, by a pump (not shown). The cooling feature 304 serves to remove the heat from the insert 210 making it more effective.
[0067] The feed port insert described above isolates the extruder heat from the resin to reduce the melting of resin at the feed port. This reduction of heat of the resin reduces melting of the resin at the feed port insert and the associated problems with melted toner at the feed port. However, even this arrangement can suffer premature melting of the toner resin 24 on the screws, resulting in lump formation.
[0068] As another approach to overcome premature resin melt, referring to FIGS. 8 and 9 in particular, embodiments can include a lead-in gap 300 that accepts prematurely melted resin on the screws. Where the resin might ordinarily accumulate, cool, and form lumps, the lead-in gap smoothes and eventually squeezes the excess material to the sides of the screws to await take-up. In embodiments, the lead-in gap 300 is located near the point at which resin enters the conveyor. While the lead-in gap could be used in conjunction with the insert disclosed above, the combination is not required.
[0069] An advantageous variation of the lead-in gap 300 can be variable in size and shape. For example, the portion of the inner surface of the housing could be movable to allow the gap 300 to grow or shrink as required for particular rates of flow of base resin into the conveyor. A more simple approach could include a slidable section of the housing wall that would slide longitudinally to expose more or less of the lead-in gap 300 as required.
[0070] While the invention has been described with reference to the structures and embodiments disclosed herein, it is not confined to the details set forth, and encompasses such modifications or changes as may come within the purpose of the invention.
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A toner extruder for the preparation of a toner resin extrudate from a resin is provided. The extruder includes a housing defining a housing aperture and a resin inlet opening in the housing. The extruder also includes a conveyor for conveying the resin through the housing aperture. A lead-in gap at the resin inlet opening collects prematurely melted base resin and holds it for take-up by the conveyor, thus preventing fusing of the resin on the conveyor and avoiding clumping. The extruder can further include a member adjacent the resin inlet opening for inhibiting the heat transfer from the housing and/or the conveyor to the resin at the opening. The flow of resin adjacent the opening is thus improved.
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BACKGROUND OF THE INVENTION
The present invention relates to a triaxial contact assembly having an intermediate contact within an outer contact and an inner contact within the intermediate contact, the inner and intermediate and outer contacts being isolated from one another by means of inner and outer insulators respectively.
A triaxial contact assembly includes three electrical contacts, inner, intermediate and outer, isolated from one another by inner and outer insulators. Taking into account additional components needed to retain the finished assembly on the cable, triaxial contact assemblies suitable for terminating screened, twisted wire pairs have generally included at least seven components.
Examples of such contact assemblies are known from published European patent applications Nos. 0190843 and 0067727 and from United Kingdom application No. 2085676. The latter two documents describe assemblies having ten loose components each; that of application 0190843 has nine such components.
In assembling such contact arrangements onto the cable, some twelve to fifteen separate operations must be carried out, the most difficult of which has been found to be the feeding of an already mounted inner contact, together with the bared multi-cored wire into the intermediate contact while hampered by a loose spacer (that is the disc-like member which spaces the ferrule, which retains the assembly on the cable, from the inner components of the contact assembly).
SUMMARY OF THE INVENTION
The contact assembly of the invention is characterised in that at least one of the insulators is fixed to one of the contacts. Preferably, a spacer member for spacing the inner or intermediate contact from a ferrule onto which the outer contact is crimped to secure the assembly to a cable, is fixed to the intermediate contact. Preferably, the inner and intermediate contacts are provided with retaining means interengageable to secure them together; the retaining means being deformable to allow the inner contact to be inserted into the intermediate contact so as to interengage the retaining means but acting to oppose disengagement thereof. At least one of the contacts may be provided with a bore for receiving an end of a wire; there being adjacent the inlet end of said bore a conical guide surface for guiding the wire into the bore.
BRIEF DESCRIPTION OF THE DRAWINGS
A contact assembly in accordance with the invention will now be described in detail, by way of example, with reference to the drawings in which:
FIG. 1 is an exploded view showing the four components of a pin contact assembly in accordance with the invention;
FIG. 2 is a sectional view of the contact assembly of FIG. 1; and
FIG. 3 is a sectional view of a socket contact assembly for use with the pin contact assembly of FIG. 2.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The triaxial contact assembly 10 shown in FIGS. 1 and 2 comprises three contact members, an inner contact member 12, an intermediate contact member 14 and an outer contact member 16. In use, the three are disposed concentrically, one within the other. The fourth component of the assembly shown in FIG. 1 is a ferrule 18 onto which is crimped the outer contact member 16 to retain the contact assembly in place on the cable.
The inner contact member 12 is a conventional pin, or male, contact typically formed by machining from bar stock. It is provided, towards the rear, with a projecting conical lip 13.
The intermediate contact member 14 includes a hollow tubular intermediate contact 20 which has a forward portion 22 of smaller diameter than its rearward part 24 so that, at the junction of the forward and rearward parts 22 and 24 a radially-extending annular lip 26 is formed. The intermediate contact 20 has two through bores 28 and 30 formed in it. The bore 28 is offset from the central axis of the contact assembly and extends only through the rearward part 24 of the intermediate contact 20. In use, the bore 28 receives the end of one of the multi-core wires of the twisted wire pair.
The other bore 30 is centred on the axis of the contact assembly 10 and extends through both the forward and rearward parts 22 and 24 of the intermediate contact 20. The bore 30 has three parts. At its forward end where, when fully assembled, it surrounds the inner contact member 12, it is of relatively large diameter. At its rearmost end it is also of relatively large diameter, but in its middle region it is of smaller diameter so that an outwardly extending annular lip 32 is formed close to the rearward end of the bore 30.
The intermediate contact member 14 also includes the inner insulator 34 which, in use, serves to isolate the inner and intermediate contacts 12 and 20 from one another.
The inner insulator 34 is generally tubular and of external diameter such that it fits closely in the narrower middle region of the bore 30. At its forward end it has an inturned annular lip 36 and at its rearward end it has an outwardly extending annular flange 38. The insulator 34 is inserted into the bore 30 of the intermediate contact 20 until the annular flange 38 at the rearward end of the insulator 34 bears against the annular lip 32 at the rearward end of the bore 30 in the intermediate contact 20. In this position, the end surface of the insulator 34 is flush with the radially-extending end surface of the intermedate contact 20.
The insulator 34 is held in place in the intermediate contact 20 by the third part of the intermediate contact member 14, the spacer 40.
The spacer 40, is generally disc-shaped and is of diameter greater than the intermediate contact 20. At its forward end, it is extended to form a sleeve 42 which, in use, surrounds the rearward end portion of the intermediate contact 20. The sleeve 42 has an inwardly directed lip 44 at its forward end which is received in an annular groove 46 which runs around the periphery of the intermediate contact 20. Alignment of the bores 48 and 50 with the bores 28 and 30 is ensured by the provision of a flat key face 63, which is machined onto the rearward part 24 of the intermediate contact 14 and which co-operates with a corresponding flat key face 64 formed on the interior of the sleeve part 42 of the spacer 40.
The spacer 40 also has two through bores 48 and 50 formed in it which are, in use, aligned with the bores 28 and 30 formed in the intermediate contact member 20.
The intermediate contact member 14 is assembled by pushing the inner insulator 34 into the bore 30 of the intermediate contact 20 and then snapping the spacer 40 onto the rearward end of the contact 20 to hold the insulator in place. Once assembled, the intermediate contact member 14 can be handled as a single, integral unit as the three parts are held firmly together with no play between them.
The outer contact member 16 consists of two parts, the outer contact or body 52 and the outer insulator 54. Both parts are generally tubular and fit one within the other.
The outer insulator 54 has a forward part of internal cross-section such that the forward part of the intermediate contact 20 fits closely within it. The rearward part of the insulator 54 is of larger diameter, and is, in fact, of the same diameter as the forwardly-projecting sleeve 42 of the spacer 40. In use, the forward end of the sleeve 42 bears against the rearward edge of the outer insulator 54 thus forming a continuous insulating sleeve between the intermediate and outer contacts 14 and 16. The insulator 54 also has an outwardly-projecting retaining lip 58 formed at its forward end.
The outer body 52 has an internal bore whose diameter increases stepwise towards the rear of the contact assembly 10. At its forward end, the outer body 52 fits closely around both the forward and rearward parts of the outer insulator 54. At its rearward end the outer body 52 is of sufficiently large internal diameter to receive the spacer 40 and ferrule 18.
At its forward edge, the outer body 52 is formed with an annular recess 60 which co-operates with the retaining lip 58 on the outer insulator 54. The insulator 54 is snapped into place, the engagement of the retaining lip 58 in the recess 60 then serving to hold the outer body 52 and insulator 54 together so that they can be handled as a single unit.
The contact assembly 10 is assembled onto a screened twisted wire pair cable 62 as follows.
The ferrule 18 is slid onto the end of the cable 62. The outer sheath of the cable 62 is then stripped from the end portion of the cable and the screen, which is formed of braided copper wire, combed out and folded back over the outer sheath and ferrule 18. Once any fillers have been removed from the stripped portion of the cable, the inner contact 12 can be crimped, in a conventional manner, onto a suitably stripped end portion of one of the pair of twisted wires.
The end of the second wire is then stripped for insertion into the intermediate contact member 14.
It is the next stage of the assembly which is particularly difficult in existing contact assemblies. However, two features of the assembly shown in the drawings help to make this stage of the procedure easier.
The bore 48 formed in the spacer 40 has an inwardly directed conical surface 65 at its end adjacent the intermediate contact 20. The conical surface in the bore 48 helps to guide any stray strands of the second multi-core wire into the bore 28 formed in the rearward portion of the intermediate contact 20.
The internal diameter of the bore 50 at its forward end is slightly reduced to act as a deformable retaining lip 67. The inner contact 12 is provided with a rear conical lip 13 which acts as a barb or tang. As the inner contact 12 is inserted through the spacer 40 into the bore 30 of the intermediate contact 20, the lip 67 deforms. Once in place, the inner contact cannot, however, be withdrawn due to the engagement of the tang 13 with the edges of the lip 67 of the bore 50 of the spacer 40.
These two features, taking in combination with the fixed spacer 40 make insertion of the inner contact 12 and second wire into the intermediate contact member 14 relatively easy and all that remains to secure the intermediate contact member to the cable 62 is to crimp the periphery of the bore 28 onto the second wire, while pushing the wire firmly into the bore. The flat key surface 63 on the intermediate contact 14 is used to locate and align the crimping tool.
Using a suitable tool, the ferrule 18 is then pushed along the cable 62 until it butts up against the rear of the spacer 40 with the combed-out braided screen turned back over it. The now combined inner and intermediate contact members 12 and 14 are then inserted into the central opening of the outer contact member 16. Movement of the assembled inner and intermediate contact members 12 and 14 into the central bore of the outer contact member 16 is limited by the abutment of the outwardly-projecting lip 26 on the intermediate contact 20 against an inwardly directed shoulder 66 formed on the interior of the outer insulator 54. The portion of the outer body 52 which overlies the ferrule 18 is then crimped onto the ferrule 18 trapping the screen in the process and onto the cable to secure the whole contact assembly 10 in place.
It will be seen from the description above that assembly of the triaxial contact arrangement shown in the drawings is easier and quicker than that of existing assemblies whist being simple and relatively inexpensive to manufacture and retaining the sequential termination of wires by conventional crimping methods.
Although only the pin contact assembly 10 shown in FIG. 2 has been described in detail it will readily be appreciated that a socket contact assembly of the type shown in FIG. 3 can easily be constructed in accordance with the invention. It will also be understood that, whilst the assembly shown in the drawings has only a single group of contacts, the invention is also applicable to a multi-way contact, that is, a connector arrangement in which a plurality of inner and intermediate contact members are disposed in a common outer connector member or shell.
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A triaxial contact assembly for terminating a screened twisted pair of wires comprises three contact members (12,14,16) and a ferrule (18). The inner contact (12) is of conventional construction but the intermediate contact member (14) consists of an intermediate contact (20) to which are secured the inner insulator (34) and a spacer member (40). The outer insulator (54) is fixed to the outer contact (52). The number of separate components required to be assembled by the operator is thus reduced and assembly made quicker and easier.
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CROSS REFERENCE TO RELATED APPLICATION
Priority is claimed from U.S. provisional application Ser. No. 60/113,503, filed Dec. 21, 1998.
GOVERNMENTAL RIGHTS
The subject matter disclosed and claimed herein was developed under Department of Defense Contract No. DLA900-93-D-0011/0038. The government has certain rights in the invention.
BACKGROUND OF THE INVENTION
The invention relates to isolation pods and particularly to a collapsible low cost pod for isolating a person previously exposed to a chemical or biological hazard from a safe environment, or in the alternative, for isolating an unexposed person from a hazardous environment for medical transport.
The threat to health from biological and chemical contaminants has, if anything, increased over the last several years. The popular press is full of accounts of potential biological attacks which might either be privately or state sponsored. Chemical terrorist attacks have already occurred in various areas of the world and certain governments have engaged in chemical attacks against enemies and even members of their own society. While the risks from chemical attacks are believed to be substantial, in the future the threat of biological attack may continue to increase and may become more significant than chemical attacks.
Apparatus are currently available for transporting victims of natural biological hazards. Such victims may include persons who have been infected with Ebola or Marburg virus, anthrax or the like. One such system is the so-called Vickers box which comprises a relatively self-contained unit having an external frame with a biological hazard barrier comprising sheet polyvinyl chloride sheet suspended therefrom. The frame has a foot rest or step. A lower substantially oval loading port provides access to the interior through which a patient may be carried to rest on a stretcher-like structure. The barrier has a ventilation tube entering its foot end. Glove ports are formed on the sides of the frame thereof. A pass-through port extends through the barrier near where the calves of a patient would normally rest. There are pairs of glove ports on each side of the unit. Intravenous bags and the like may be suspended from the frame of the unit. An intravenous line may extend through a port in the side of the unit. The Vickers box weighs over 200 pounds unloaded. In addition, the Vickers box is not disposable and is very expensive. It typically costs $20,000 to $30,000. When assembled the Vickers frames are bulky and the unit is simply not adapted for storage in large numbers for use in the event of a biological emergency. In addition it cannot be transported in all types of military evac vehicles.
Another approach has been taken in U.S. Pat. No. 5,626,151 to Linden. Linden discloses a transportable life support system including a base 2, a stretcher 3, and a rigid cover 4. The base may be constructed from a fiber reinforced resin composite. Medical equipment is housed within the base including a ventilator 11, an oxygen source 12 such as an oxygen tank or oxygen generator, a suction unit 13 and an environmental control unit 14. A high volume intravenous pump 23, a pulse oximetry sensor 24 a blood pressure sensor 25 and electrocardiography sensor all are relatively bulky and may or may not be needed for the treatment for the particular patient depending upon whether the patient had merely been exposed or has been infected. The environmental control unit includes means for providing contaminant-free air to the unit including at least one filter 14 B, which may be a typical nuclear-biological-chemical type filter. The problem with such a unit is that it appears to be relatively bulky because of the built-in components in the base of the unit and the unit may not quickly and easily be stored in a compact configuration and may represent overkill for a variety of hazards.
What is needed then is an inexpensive easily transportable compact biological isolation system for use in isolating victims in a chemical or bioterror event.
SUMMARY OF THE INVENTION
A collapsible personnel isolation apparatus for isolating an individual who may have been exposed or has been infected with a biological agent or may have been exposed with a chemical agent embodies the present invention and is particularly well adapted for compact storage. The collapsible personnel isolation system embodying the present invention may include a pod, a suit or a flexible wrap. The system is inexpensive, may be completely disposed by burning or the like, and provides facilities for a variety of medical interventions without the necessity that expensive treatment equipment be associated therewith.
The system includes a flexible base, which may be made from polyvinyl chloride material and which is tear resistant. Specifically the base includes an outer sheet and an inner sheet. Each of the inner and outer sheets has first and second polyvinyl chloride outer layers with an intermediate nylon mesh layer positioned between. A nylon webbing formed in the shape of a ladder includes a pair of upright or runner elements extending longitudinally on opposite sides of the base for providing support when the base is carried. The nylon webbing is positioned between the inner and outer sheets. This prevents the base from tearing and provides support to handholds in the base. Lateral or central spine type support is provided by five nylon web strips connecting the two longitudinal strips.
Rectangular handholds are formed adjacent to the elongated nylon uprights for grasping by persons carrying the patient. If the patient is being carried by stretcher, grommets formed in the walls of the sheets accept hooks, cords or other tension members. The tension members wrap the base material around a stretcher, in particular a decontamination stretcher, for transport of the patient.
A clear 20 mil thick PVC material extends upwardly from the base into an over area and terminates at each side at a zipper half. The zipper halves are completely separable so that the apparatus may be opened in a clamshell arrangement and a patient may be laid therein. This is particularly important with patients infected by hemorrhagic fevers such as Ebola or Marburg. Such patients may resist handling. Attempts to place the patient into a prior art isolation system, such as a Vickers box, where there is a relatively small port of entry can be difficult without contaminating the handlers. It may be appreciated that contamination of the environment and other persons must be avoided in order to prevent the spread of these types of virulent viruses.
Accordingly, the present invention, as embodied in the apparatus, is easily closed around the patient without panicking the patient and without unwarranted spread of virus during the process.
The PVC material has a plurality of flexible, nylon ribs or stays positioned in sleeves to provide support. The stays are used to hold the transparent PVC shell away from the patient to allow the patient to be manipulated and to reduce the patient's sense of from being enclosed within the pod. Multiple pairs of glove box ports are provided in the sides of the walls of the unit and at the head end to allow physicians, nurses or other medical professionals to treat the patient within the apparatus without exposing themselves to the infected patient.
A pass-through port is provided for transferring materials in a one way fashion from the outside to the interior of the pod without exposing others. A plurality of small outwardly extending access ports are provided through which may be extended electrocardiographic leads, a suction pump line, infusion lines from a intravenous infusion pump or the like. A larger port is provided for extending a ventilator tube from the outside to a patient to provide ventilation through an airway extending into the patient's trachea. A single glove box port is positioned at the head end of the apparatus to allow a physician or other care giver to intubate the patient.
A plurality of internal storage pouches are provided within the apparatus. The pouches may be preloaded with a variety of supplies such as first aid or medical kits including gauze, tape, various antibiotics, analgesics and the like. The supplies are made available for rapid administration to a patient, particularly a patient who might be in extremis. A pair of patient straps are provided which extend from side to side on the interior of the base to anchor the patient with respect to the base of the pod. While not intended to restrain the patient, they help to maintain the base of the apparatus in contact with the patient so that the upper clear walls of the apparatus are spaced away from the patient and not in contact with him or her.
A blower and filter are provided which may be connected either to the head end or the foot end of the pod. The blower may provide positive pressure to the pod in the event that the patient is uncontaminated and the immediate environment around the patient is contaminated. That is relatively clear air from within the pod would be exhausted to a hot environment. The blower also may be connected to the opposite and of the pod and run in the other direction to provide negative pressure within the pod which is the more usual configuration. This configuration is used when the patient is hot or contaminated and the environment is relatively or completely uncontaminated. This prevents the release of contaminants including pathogens to the environment. Air is drawn in through one of the ports and is exhausted through a filter system at the blower which prevents the pathogens from being released into the environment. The blower, however, when operated in either mode, provides air to the patient so that the patient may breath. The blower may be energized by lithium batteries or D-cell batteries and may have a life for one set of batteries of up to fifteen hours of service time. This is enough time to transport the patient from a casualty site to a hot handling facility.
A drain port is also provided at the foot end of the pod in an end wall thereof. Any liquid which may be present or form within the apparatus due to decontamination or release of contaminated fluids from the patient may be drained out of the apparatus while the patient is isolated inside. Such patient-generated fluids would likely be biologically contaminated. Fluid removal is done simply by elevating the head end of the pod with respect to the foot end and allowing the fluid to travel out by gravity. A patient for instance who might be contaminated with a biological contaminant can be decontaminated within the pod with a rinse such as water or some other liquid decontaminant which may comprise a decontaminant solution.
The blower and filter assembly may be optionally supported by a stand having a sleeve-type clamp. The clamp may be attached to a handle of a decontamination stretcher for convenient support. It allows anchoring the blower and filter assembly substantially fixed with respect to an air inlet at the head end of the apparatus adjacent the head of the patient when the apparatus is to be operated in positive pressure mode. The blower and filter may also be similarly mounted at the front end of the stretcher for operation of the apparatus in the negative pressure mode.
It may also be appreciated that coverings are provided for the port holes for each of the glove box arms so that any glove box arms remaining sealed need not later be decontaminated.
A number of the ports connected to the walls include flexible diaphragms which are opened when connected to the blower and filter assembly and closed when unconnected to maintain isolation between the interior of the apparatus and the surrounding environment.
It is a principal aspect of the invention to provide a portable, inexpensive and easily stored isolation system for isolating a patient from an environment for preventing the transport biological and chemical agents between the environment and the person.
Other aspects and advantages of this invention will become apparent to one of ordinary skill in the art upon a perusal of the following specification and claims in like of the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of an isolation apparatus, specifically an isolation pod, embodying the present invention, having plastic tube stays, having a person lying therein, and being supported by a mobile intensive care rescue facility;
FIG. 2 is a perspective view of the isolation apparatus shown in FIG. 1 but having nylon rod stays and being mounted upon a decontamination stretcher;
FIG. 3 is a perspective view of the opposite side of the isolation pod shown in FIG. 2 showing details of a zipper closure and a ventilation system.
FIG. 4 is an end perspective view of the isolation pod shown in FIG. 2 showing details of the region in which a patient's feet would rest and showing details of a portion of a glove box assembly;
FIG. 5 is a further view of the glove box assembly shown in FIG. 4;
FIG. 6 is a partial perspective view of a portion of the isolation pod shown in FIG. 2 showing details of its attachment to the decontamination stretcher;
FIG. 7 is a partial perspective view of the isolation pod shown in FIG. 2 showing a pair of clamped-off ports extending from a lower portion thereof and showing details of a handhold;
FIG. 8 is a partial perspective view of the isolation pod shown in FIG. 2 and showing a zipper-type sealed opening for a glove arm for manipulation of a patient or instruments within the isolation pod;
FIG. 9 is a partial perspective view of the isolation pod shown in FIG. 2 showing a transfer port together with a glove port arm;
FIG. 10 is a partial perspective view of the isolation pod shown in FIG. 2 showing details of multiple glove pairs therein and multiple access ports;
FIG. 11 is partial perspective view of the isolation pod shown in FIG. 2 showing the transfer assembly together with one of the glove box assemblies;
FIG. 12 is a partial side view of the isolation pod shown in FIG. 2 showing the relation between the zippers, the ports and the gloves of the glove box;
FIG. 13 is a partial perspective view of the isolation pod shown in FIG. 2 showing a ventilation system and its attachment in ventilating communication to an upper portion of the isolation pod;
FIG. 14 is an end perspective view of the isolation pod shown in FIG. 2 showing a head end of isolation pod having a single port for use in manually intubating a patient within the isolation pod;
FIG. 15 is a perspective view of the isolation pod shown in FIG. 2 in an open configuration;
FIG. 16 is another perspective view of the isolation pod shown in FIG. 2 shown in the open configuration;
FIGS. 17-19 are perspective views of an alternative embodiment of the isolation pod having a centerline zipper closure; and
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings and especially to FIGS. 1 and 2, a collapsible personnel isolation apparatus embodying the present invention is shown therein and generally identified by reference numeral 10 . The collapsible isolation apparatus 10 is an isolation pod and includes a flexible base 12 and a transparent cover 14 . The transparent cover comprises a transparent flexible polyvinyl chloride wall having a thickness of 20 mils or 0.020 inch. The transparent cover 14 has a plurality of internal supports or stays 16 . The stays may be plastic tubes, as shown in FIG. 1 or nylon rods, as shown in FIG. 2 . The stays 16 extend through portions of the cover 14 and support it with respect to the base 12 to prevent the cover 14 from collapsing onto a patient who may be placed therein. A closure 20 comprising a zipper extends partially along a back wall 22 , completely along a pair of side walls 24 and 26 and a front wall 28 . The zipper 20 is a 132-134 inches long gas seal zipper and may be obtained from YKK of Japan. The zipper 20 holds the pod closed and causes the stays to be compressionally curved into arches to support the wall 14 . It also provides a clamshell opening configuration defining a bottom 30 and a top 32 . The bottom 30 includes the base 12 and a portion of the transparent cover 14 . The top 32 includes the remainder of the transparent enclosure 14 . The pod 10 is collapsible into a very small volume and may be stored in a duffle bag. It may be rapidly deployed and is self-supporting.
The clamshell opening configuration allows a patient to be easily placed within the interior of the pod type apparatus providing secure isolation of the patient from the environment and vice-versa. In order to prevent the patient from damaging the pod 10 after having been enclosed therein by enclosing the bottom 30 to the top 32 by way of the zipper a pair of anchoring belts 40 and 42 are provided and are attached to the base. Belt 40 includes a first half 44 and a second half 46 . The belt 42 includes a first half 48 and a second half 50 , as shown in FIGS. 15 and 16. In addition, the base 12 is provided with a capped drain 54 from which fluids may be drained from the interior of the pod 10 such fluids may be decontamination fluids or fluid materials generated by the patient themself.
The material of the flexible base is constructed of an outer sheet and an inner sheet. Each of the sheets has first and second polyvinyl chloride outer bags with an intermdant nylon mesh layer. A nylon webbing formed in the shape of a ladder includes a pair of uprights or runner elements extending longitudinally on opposite sides of the base 12 for providing support when the base 12 is carried. Lateral or central spaced-type support is provided by five nylon straps connecting the uprights to each other.
The base 12 has formed therein a plurality of rectangular handholds 56 which may be used to pick up the pod 10 without any supporting structure underneath in order to transport the patient. The base 12 has a plurality of grommets 58 formed therein. The grommets 60 are provided to be connectable with elastic tension members 60 having elastic members 62 and 64 hooks for engaging the grommets 58 , as may best be seen in FIG. 6 . This allows overlapping base edge portions 70 and 72 to be wrapped around a stretcher 74 to attach the pod 10 securely to the stretcher 74 for transport.
As set forth above, in order to support the upper portion or top 32 of the pod 10 the plurality of internal supports, stays or ribs has been provided. Each of those stays or ribs is confined within a sleeve 80 comprising a strip 82 . The strip 82 and top 32 along the outside of the pod 10 define a stay-receiving channel having an entryway formed in the bottom thereof. In alternative embodiments the strips 82 may be attached by heat sealing as opposed to being sown.
In addition the pod 10 includes a plurality of ports including a plurality of small ports for the introduction of EKG apparatus lines, intravenous lines defibrillator lines, suction lines and the like. The ports are positioned in the lower half or bottom of the pod 10 so that the leads may stay connected to the patient whether the pod 10 is open or closed. The small ports 88 are closed with port clips 90 at the ends thereof. In the alternative, when lines are extending through the ports 88 they may be held closed with tape to avoid the communication of contaminants between the inside of the pod and the environment. The ports 88 are typically tapered and may be sown or heat sealed as two halves. The ports 88 are tapered to provide a varying diameter cross-section for receiving a variety of connections thereto.
An enlarged ventilation port 100 is also provided for receiving a ventilator tube 102 for a respirator. The ventilator tube 102 may be connected to an device for forming an airway to the patient's respiratory system.
A pass-through port 110 comprising a double-bagged air lock, is provided with a the top including a large ring 112 with an elastic band 114 surrounding it to engage at least one of a plurality of bags 116 extending into the interior of the opening. The pass-through port 110 may be used to pass plastic bags containing objects through one at a time without breaching the containment of the pod 10 . The pass-through port 110 may be optionally covered with a soft plastic top 118 to prevent material from falling inside one of the bags before it is transferred into the interior of the pod 10 .
A plurality of drain ports are providing including a drain port 130 and a drain port 132 through which liquids may be drained by gravity by tilting the pod 10 with the patient inside.
In addition, a pair of air stream or general diaphragm or check-valve type ventilator ports 140 and 142 are provided. The ports only provide communication when they are connected to a fitting which opens the internal check valve. One of which is connected to a ventilator 144 having a pair of filters 146 and 148 . The ventilator is supported by a PVC tubing support 149 that engages an arm of the stretcher. Ventilation air is carried from the head end port 142 to the tail end port 140 . If it is desired to provide positive pressure to the interim of the pod 10 the ventilator 144 is attached to the head end port 142 to provide positive pressure. If it is desired to provide a negative pressure environment in the interior of the pod 10 the ventilator 144 is connected to the port 140 through which it draws air entering the head end port 142 . Thus, the interior of the pod 10 may be run either above ambient pressure or below ambient pressure. When run above ambient pressure the pod 10 is configured for use with a contaminated environment and a uncontaminated patient within the pod. When the pod 10 is run below atmospheric pressure air drawn out of the pod is filtered in the filters 148 and 144 before being released to the environment so that a contaminated patient may not spread contamination.
In order to obtain access to the patient sealed in the pod 10 a plurality of glove ports 200 are provided. The glove ports 200 are primarily arranged in pairs with a first pair of glove ports 200 on the front wall, a second pair of glove ports 202 on the front wall, two pairs of glove ports on the back and a single glove port 210 at the head end for access to the patient for incubating the patient when necessary. Each of the glove ports 200 of the glove port pairs includes a glove 220 , which may be a substantially unisex latex glove. The glove 220 is connected to a PVC sleeve 222 extending to a glove port opening 224 . In addition, the glove port openings 224 have zipper-type closures 226 associated therewith. The closure 226 has a first flap 228 and second flap 230 with a sealing line 232 similar to an overlapping interlock plastic seal formed thereon. The closure 226 prevents material from falling into the open glove arm during transportation or the like. The glove ports 220 may be used to manipulate the patient within the pod 10 without breaking the barrier and releasing contaminants from the pod 10 into the environment or allowing the contaminants from the environment to reach the patient.
A further embodiment of the present invention is shown in FIGS. 17-19 wherein a pod 300 includes a left transparent PVC pod half 302 and a right transparent PVC pod half 304 joined by a zipper 306 at a center line. The pod 300 includes a plurality of belts 308 for securing the patient to a relatively thick PVC base 310 and includes a plurality of ports 312 having clamps 314 associated therewith for admission of suction lines, defibrillator lines, infusion lines, IV lines, EKG lines and the like. A ventilator port 330 is provided at one end. The pod 300 includes handholds 340 formed in the base thereof. A plurality of stays 350 comprising substantially flat Lexon plastic strips are positioned in sleeves 352 for supporting the pod. The stays are arranged in the stay halves 354 and 356 which provide a tent-like structure.
The pod 300 works in substantially the same fashion as the pod 10 . It includes a plurality of glove box ports 370 for the admission of the hands and forearms of a doctor or a nurse treating the patient. The glove box ports 370 terminate in gloves 384 connected to PVC sleeves 386 which are attached to an opening 388 . Drain plugs 390 are provided for draining materials from within the pod 300 . A ventilator 400 , which is substantially identical to the ventilator 142 is positioned on a ventilator support 402 and connected to a check valve port 404 for ventilation of the interior of the pod 300 .
A further alternative pod 500 may be positioned on a stretcher 502 and includes a base 504 with an upper portion 506 and a right transparent half 510 and a left transparent half 512 joined by a zipper closure 514 . A plurality of glove box ports 520 , 522 and 524 are provided for treating the patient. Each of the glove box ports has an opening 530 with a PVC sleeve 532 attached thereto and a latex glove 534 . The pod 500 includes a plurality of internal supports or stays 550 comprising flattened ribs which are positioned in sleeves in the walls of the bag to support the bag above the patient. The system includes a head-end glove port 600 and an attachment 602 to which a ventilator 604 may be coupled. The pod may be secured to a stretcher by elastic cords 620 and may accommodate a patient 622 therein.
The present invention may also be incorporated into wraps for civilian use in scenarios involving a limited number of pods for contaminated patients such as might be present in a chemical incident or for persons who would need to have medical attention administered through the wrap. In addition, suits may be provided including a power respirator hood that creates negative pressure within the hood and including rib or other supports for supporting the suit in particular the hood away from the person when the suit is being run in a negative pressure mode to prevent the suit from collapsing around the person.
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 collapsible personnel isolation apparatus for preventing unwanted contaminations of hazardous biological and chemical materials including a base. A cover connects to the base by way of a zipper. A plurality of glove box ports are provided to allow rapid and convenient treatment of the patient.
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This is a division of application Ser. No. 07/175,178 filed Mar. 30, 1988.
BACKGROUND OF THE INVENTION
A. Field of Invention
The present invention relates to an improved process for producing phenyl- or substituted-phenylalkanolamine compounds having pharmacologic activity and to novel intermediates useful in the process, and more particularly relates to a process for directly obtaining the desired (+)- or (-) enantiomer in essentially 100% ee (enantiomeric excess) without the need for tedious resolutions.
Many biologically active compounds and medicinals are synthesized as racemic mixtures. However, commonly, only one of the optical isomers has the desired properties, while the other may possess only very weak or a different, undesired pharmacological activity, or at worst, is toxic. This problem is best illustrated by the problems associated with Thalidomide which was unfortunately marketed as a racemic mixture of the toxic isomer, responsible for the well-publicized birth defects, as well as the active optical isomer which was free from the teratological side effects. The Thalidomide tragedy could have been avoided had there been a simple, economical process available for separating the isomers. Since then, the pharmaceutical industry has employed tedious and expensive resolution processes to insure that only the desired optical isomer is present in the finished formulation. It is therefore highly desirable for the pharmaceutical industry to be able to obtain one enantiomer in a simple, direct, less costly process.
Many pharmaceutically active compounds are phenyl- or substituted-phenylalkanolamines having the basic structure ##STR1## wherein n is 1 or 2, R 1 is hydrogen, acetoxy, phenyl or substituted phenyl and R 2 is lower alkyl, phenyl or substituted phenyl.
Typical drugs of this kind include Isoproternol, Colterol, phenylephrine, Bitolerol, Dipeverfrin, and the major new anti-depressent agents, Tomoxetine, Fluoxetine and Nisoxetine.
Tomoxetine, [[R]-(-)-N-methyl- -(2-methylphenoxy)-benzenepropamine hydrochloride, Eli Lilly, and Company, LY 139603] is a new drug currently undergoing investigation as an antidepressant (R. L. Zerbe et al., J. Pharmacol. Exp. Ther. 1985, 232, 139). The (-)- optical isomer has been shown to be nine times more potent than the (+)- isomer. Unlike chemical tricyclic antidepressants such as imipramine, (-)-Tomoxetine has been shown to inhibit specifically norepinephrine uptake in humans at dosages which are clinically well tolerated and to be a relatively weak ligand for α-1, α-2 and β-adrenergic receptors. The latter receptors are generally regarded as responsible for undersirable side-effects associated with antidepressants.
The patent literature preparation of (-)-Tomoxetine involves a long and tedious procedure culminating in a highly inefficient resolution (20%) of the racemic mixture. See Molly et al. U.S. Pat. No. 4,018,895 and Foster et al. Eur. Patent No. 0052492. Clearly, an enantiomeric preparation of (-)-Tomoxetine is needed. The best procedure to date provides an overall yield of the (-)- isomer of 14% and an optical purity of only 88% ee. The present invention provides a simple synthesis of both (-)-Tomoxetine, (+)-Tomoxetine in essentially 100% ee, as well as both optically pure enantiomers of the cognant compounds, Fluoxetine and Nisoxetine.
In general, many of these valuable drugs in addition to the Lilly antidepressants discussed above are synthesized via the Mannich reaction to produce the amino substituted arylalkyl ketone. Reduction of the ketone gives the alcohol. The mixture of enantiomeric arylalkanolamines are then resolved in a generally tedious, costly inefficient process.
Thus, there exists a need for a more efficient, cost effective, simple process for directly obtaining the desired isomer of Tomoxetine and other arylalkanolamine pharmaceutical agents in essentially 100% enantiomeric excess. The present invention provides such a process as well as valuable intermediates useful in such process.
B. Prior Art
Recently, it was discovered that diisopinocamphylchloroborane, hereafter Ipc 2 BCl, derived from either (+)- or (-)-alpha-pinene is capable of reducing arylalkyl ketones to the corresponding alcohols in a highly enantioselective fashion. (Brown et al., J. Org. Chem. 1985, 50, 5446. See also Herbert C. Brown copending U.S. patent application Ser. No. 902,175 filed Aug. 29, 1986). The alcohols so obtained were simple compounds, containing no other functionality, and as such were end-products in themselves. However, for the construction of more complex molecules, often required of biologically active compounds, additional functionalities that can be further transformed are desirable. The halides are a particularly appealing functional group.
Chiral haloalcohols have been prepared in variable enantiomeric excess with a reagent developed by Itsuno et al. (J. Chem. Soc. Perkin Trans. I. 1985, 2615). In addition to inconsistant optical yields, the nature of the reagent remains in doubt. Soai et al. (J. Chem. Soc. Chem. Comm. 1986, 1018) have demonstrated that a chirally modified lithium borohydride can reduce beta-halogenoketones in 81-87% ee. More consistent results have been obtained for asymmetric reduction of 2-haloacetophenones with neat Alpine-Borane (Brown et al., J. Org. Chem. 1985, 50, 1384).
In my copending application Ser. No. 902,175, filed Aug. 29, 1986, I disclosed that diisopinocampheylhaloboranes (Ipc 2 BX) are exceptionally effective asymmetric reducing agents for simple phenylketones to the corresponding alcohol. The reagents Ipc 2 BX appear to be the most effective currently available for such asymmetric reductions, and one would expect that reduction of the arylalylketoamines should provide a direct route to the desired optically pure arylalkylaminoalcohols. Unfortunately, the presence of the amino groups prevents the desired reaction. Tertiary amines coordinate with Ipc 2 BX to prevent its use for reduction. Primary and secondary amines react to give the amino-substituted boron compounds RNHBIpc 2 +HX.
The present invention provides a solution to that problem by providing a method in which the Ipc 2 BX reagents are used to reduce a halo-substituted arylalkylketone. Treatment of the haloaralkylalcohol with the appropriate amine gives the desired optically pure arylalkylaminoalcohol.
The present invention also fulfulls the need for a simple, reliable method of preparing each enantiomer of structurally diverse, optically pure haloalcohols at will, which are intermediates in the preparation of optically pure phenoxyhalides which are useful as intermediates in the synthesis of the optically pure, desired enantiomer of a pharmaceutically active phenyl- or substituted-phenylalkanolamine.
SUMMARY OF THE INVENTION
In one embodiment, the present invention provides an improved, simple, cost effective method of directly producing either optical isomer of a pharmaceutically active arylalkanolamine represented by the formula ##STR2## wherein R 1 is phenyl or substituted phenyl, n is an integer from 0 to 10 and R 2 and R 3 each are hydrogen or lower alkyl, in essentially 100% ee without the need for resolution as well as novel optically active intermediates useful in said process.
Generally speaking, the process of this invention, comprises the steps of reducing a halo-substituted phenylalkylketone with optically pure (-)- or (+)- Ipc 2 BX to obtain the corresponding optically pure alcohol, and treating the alcohol with the appropriate amine to provide the desired optically pure (+)- or (-)-arylalkylaminoalcohol.
The following reaction scheme summarizes the process of the preferred embodiments of this invention. ##STR3##
While in the preferred embodiment, the process of this invention is employed in the synthesis of either optically pure isomer of Tomoxetine hydrochloride and related anti-depressants, Nisoxetine hydrochloride and Fluoxetine hydrochloride, it can be used to synthesize essentially any arylalkylaminoalcohol in optical purities of essentially 100% ee by simply adjusting the starting materials and the amine employed in the reaction, as will be readily apparent to one skilled in the art.
In another embodiment, the present invention provides novel haloalcohols of essentially 100% ee represented by the formula: ##STR4## wherein each R is the same or different member of the group consisting of fluoro, chloro, bromo or iodo.
As used herein, the term "essentially 100% ee" or "high state of optical purity" refers to an enantiomeric excess of >95%, as determined by any analytical technique, i.e. gas chromotography, proton magnetic resonance, etc., on the derivatized or underivatized alcohols.
The term "lower alkyl", as used herein, refers to straight or branched chain alkyl groups having from 1 to 8 carbon atoms, inclusive, i.e., methyl, ethyl, n-propyl, iso-propyl, n-butyl, iso-butyl, n-pentyl, 2-methylbutyl, 2,2-dimethylpropyl, n-hexyl, 2-methylpentyl, 2,2-dimethylbutyl, 2,3-dimethylbutyl, n-heptyl, 2-methylhexyl, 2,3-dimethylpentyl, 2,4-dimethylpentyl, n-octyl, 2-methylhexyl, 2,3-dimethylheptyl, and the like.
The term "substituted phenyl", as used herein, refers to a phenyl group represented by the formula: ##STR5## wherein R 1 and R 2 are the same or different members of the group consisting of hydrogen, loweralkyl or haloloweralkyl, with the limitation either R 1 or R 2 must be other than hydrogen.
The term "lower alkoxy" refers to an alkoxy group having from 1-8 carbon atoms, such as methoxy, ethoxy, propoxy, etc.
The term "halo lower alkyl" refers to a lower alkyl group as defined about containing from 1-4 halo substitutions, i.e., trifluoromethyl, 1,3-dichlorobutyl and the like.
The present invention also provides a method for converting 1,4-halohydrins of high optical purity to the corresponding tetrahydrofurans in which the optical purity of the alcohol is retained in the cyclized products of the following general structure in which one enantiomer is arbitrarily depicted. ##STR6## wherein R is halo (fluoro, chloro, bromo or iodo).
In addition, the present invention provides novel chiral 1,3-phenoxychlorides following general formula in which one enantiomer is arbitrarily drawn. ##STR7## wherein R is lower alkyl, haloloweralkyl or loweralkoxy. The 1,3-phenoxychlorides of this invention are intermediates in the preparation of the corresponding 1,3-phenoxyamines or their salts with complete retention of optical activity. The 1,3-phenoxyamines are represented by the formula ##STR8## wherein R 1 is phenoxy substituted with lower alkyl, haloloweralkyl or loweralkoxy, R 2 is hydrogen or lower alkyl and R 3 is hydrogen or loweralkyl, or a pharmaceutically acceptable salt thereof.
Representative 1,3-phenoxypropylamines include Tomoxetine, Nisoxetine and Fluoxetine.
In a preferred embodiment, the haloalcohols of this invention are prepared by reacting diisopinocampheylchloroborane, Ipc 2 BCl, with both ring and chain substituted haloaralkylketones to the corresponding haloalchols in excellent enantiomeric exess (95% or better). In most cases, simple recrystallization provides the pure enantiomers. The chiral haloalcohols of the present invention are highly versatile intermediates. They can be readily cyclized to oxiranes and 2-substituted tetrahydrofurans with retention of chirality. Using this methodology, the present invention provides an efficient, highly enantioselective synthesis of both optical isomers of the antidepreseent drugs Tomoxetine, Fluoxetine and Nisoetine, from the antipodal intermediates, (+)- or (-)-3-chloro-1-phenyl-1-propanol.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
The following examples further illustrate the present invention. Unless otherwise specified, all operations with organoboranes were performed under nitrogen. Melting points and boiling points are uncorrected. 13 C NMR spectra were obtained on a Varian FT-80A spectrometer (20.00 MHz) relative to TMS. GC analysis was done on a Hewlett-Packard 58902 gas chromatograph-mass spectrometer Model 4000. Optical rotations were recorded on a Rudolph Polarimeter Autopol III and were obtained at 23° C. unless otherwise specified. Reduction of ketones were carried out as described in the literature, by Chandrasekharan, J.; Ramachandran, P. V. and Brown, H. C., J. Org. Chem. 1985 50, 5446 and Brown, H. C.; Chandrasekharan, J.; Ramachandran, P. V., J. Am. Chem. Soc. 1988 110, 0000.
Tetrahydrofuran (Fisher), THF, was distilled from benzophenone ketyl and stored under nitrogen in an ampule. Diethyl ether (Mallincrodt), ethyl acetate (Mallincrodt), dichloromethane (Mallincrodt), pentane (Phillips), and hexane (Fisher) were used as received. Anhydrous ethereal hydrogen chloride was prepared from hydrochloric acid and sufuric acid using a Brown gasimeter. (Brown, H. C.; Kramer, G. W.; Levy, A. B.; Midland, M. M. "Organic Synthesis via Boranes, : Wiley-Interscience: N. Y., 1975). o-Cresol,-α, α, α-trifluoro-p-cresol, guaiacol, triphenylphosphine, diethylazodicarboxylate and aqueous methylamine were purchased from the Alrdich Chemical Company. Reactions were monitored where ever possible by TLC using Whatman precoated silica plates. Neutral alumina (J. T. Baker & Company, Column Chromatography) was used for column chromatography.
The enantiomeric excess, ee, of the haloalcohols was determined by conversion to the MTPA esters, followed by analysis on a Methyl Silicone column (50 m) or Supelcowax column (15 m). In all cases, racemic alcohols gave baseline separations and 1:1 ratios of integrated areas.
EXAMPLE 1
[S]-(-)-1-chloro-3-phenyl-3-propanol
A solution of 3-chloropropiophenone (8.93 g, 50 mmol in 25 ml THF) was added to (-) diisopinocampheylchloroborane (Ipc 2 BCl, 18.0 g, 56 mmole, in 25 ml THF at -24° C.). The reaction was complete within 7 hours after which all volatiles were removed under reduced pressure. The residue was dissolved in ether, and diethanolamine (2 equivalents) was added. The resulting suspension was stirred for two hours and filtered. The solid residue was washed with ether and the combined washings and filtrate were concentrated. Distillation furnished [S]-(-)-1-chloro-3-phenyl-3-propanol. Yield: 6.1 g, 72%; mp 56°-57° C.; [α] D 23 -25.25, c=7.05, CHCl 3 ; 97% ee.
EXAMPLE 2
[R]-(+)-1-Chloro-3-phenyl-2-propanol
[R]-(+)-1-Chloro-3-phenyl-2-propanol was prepared by the method of example 1 except that (+)-diisopinocampheylchloroborane was used. [α] D 23 +25.3, c=7.05, CHCl 3 ; 97% ee.
EXAMPLE 3-28
The following novel optically active haloalcohols were prepared following the methods of Examples 1 and 2 by reduction of the appropriate prochiral haloketone with (-)- or (+)- diisopinocampheylchloroborane:
______________________________________Example Compound______________________________________ 3 [S]-1-(2-bromophenyl)-1-ethanol 4 [R]-1-(2-bromophenyl)-1-ethanol 5 [S]-1-(4-bromophenyl)-1-ethanol 6 [R]-1-(4-bromophenyl)-1-ethanol 7 [S]-1-(4-chlorophenyl)-1-butanol 8 [R]-1-(4-chlorophenyl)-1-butanol 9 [S]-1-chloro-2-(2,4-dichlorophenyl)-2- ethanol10 [R]-1-chloro-2-(2,4-dichlorophenyl)-2- ethanol11 [S]-1-chloro-4-(4-bromophenyl)-4-butanol12 [R]-1-chloro-4-(4-bromophenyl)-4-butanol13 [S]-1-(3-fluorophenyl)-1-ethanol14 [R]-1-(3-fluorophenyl)-1-ethanol15 [S]-1-(4-fluorophenyl)-1-ethanol16 [R]-1-(4-fluorophenyl)-1-ethanol17 [S]-1-(2,4-difluorophenyl)-1-ethanol18 [R]-1-(2,4-difluorophenyl)-1-ethanol19 [S]-1-(2,5-difluorophenyl)-1-ethanol20 [R]-1-(2,5-difluorophenyl)-1-ethanol21 [S]-1-(2,6-difluorophenyl)-1-ethanol22 [R]-1-(2,6-difluorophenyl)-1-ethanol23 [S]-1-(3,4-difluorophenyl)-1-ethanol24 [R]-1-(3,4-difluorophenyl)-1-ethanol25 [S]-1-chloro-2-(4-fluorophenyl)-2- ethanol26 [R]-1-chloro-2-(4-fluorophenyl)-2- ethanol27 [S]-1-chloro-4-(4-fluorophenyl)-4-butanol28 [R]-1-chloro-4-(4-fluorophenyl)-4-butanol______________________________________
Table I summarizes the above representative novel optically active haloalcohols of the present invention which are represented by Formula I.
TABLE I______________________________________ ##STR9## (I)R.sub.2 R.sup.3 R.sup.4 R.sup.5 R.sup.6 R.sup.7 n % ee abs. config______________________________________Br H H H H H 1 99 SBr H H H H H 1 99 RH H Br H H H 1 97 SH H Br H H H 1 97 RH H H H H Cl 3 98 SH H H H H Cl 3 98 RCl H Cl H H Cl 1 95 SCl H Cl H H Cl 1 96 RH H Br H H Cl 3 98 SH H Br H H Cl 3 98 RH F H H H H 1 96 SH F H H H H 1 96 RH H F H H H 1 97 SH H F H H H 1 97 RF H F H H H 1 96 SF H F H H H 1 96 RF H H F H H 1 96 SF H H F H H 1 96 RF H H H F H 1 96 SF H H H F H 1 96 RH F F H H H 1 95 SH F F H H H 1 95 RH H F H H Cl 3 98 SH H F H H Cl 3 98 R______________________________________
In the above examples, the S isomer was obtained from (-)-Ipc 2 BCl and the R isomer was obtained from (+)-Ipc 2 BCl. All reductions were performed in THF at approximately 2M. The % ee was determined as the (+)-MTPA ester.
EXAMPLES 29-46
Following the process of Example 1, the following haloalcohols are prepared from the corresponding haloketone and either (-)- or (+)- diisopinocampheylchloroborane:
______________________________________Example Compound______________________________________29 [S]-(-) -1-iodo-3-phenyl-2-propanol30 [R]-(+)-1-iodo-3-phenyl-2-propanol31 [S]-1-(2-iodophenyl)-1-ethanol32 [R]-1-(2-iodophenyl)-1-ethanol33 [S]-1-(4-iodophenyl)-1-ethanol34 [R]-1-(4-iodophenyl)-1-ethanol35 [S]-1-(4-iodophenyl)-1-butanol36 [R]-1-(4-iodophenyl)-1-butanol37 [S]-1-iodo-2-(2,4-dichlorophenyl)-2- ethanol38 [R]-1-iodo-2-(2,4-dichlorophenyl)-2- ethanol39 [S]-1-iodo-4-(4-bromophenyl)-4-butanol40 [R]-1-iodo-4-(4-bromophenyl)-4-butanol41 [S]-1-(3-fluorophenyl)-1-pentanol42 [R]-1-(3-fluorophenyl)-1-pentanol43 [S]-1-(4-iodophenyl)-1-octanol44 [R]-1-(4-fluorophenyl)-3-propanol45 [S]-1-(2,4-difluorophenyl)-3-propanol46 [R]-1-(2,4-diiodo-1-hexanol______________________________________
The novel optically active tetrahydrofurans of the present invention are represented by Formula II ##STR10## wherein R is halo. The preparation of the optically active tetrahydrofurans of this invention are illustrated in Examples 47-50.
EXAMPLE 47
[S]-2-(4-bromophenyl)-tetrahydrofuran
A solution of [S]-1-chloro-4-(4-bromophenyl)-4-butanol (50 mmol) in THF (25 ml) was added to a cooled suspension (0° C.) of NaH (55 mmol) in THF (50 ml). After being stored for 2 h at 25C, the reaction mixture was quenched with water, brought to pH 6 with concentrated HCl, and extracted with ether (2×50 ml). The organic phase was dried over H 2 SO 4 , filtered and all volatiles removed under reduced pressure. The residue was distilled to provide the product in 75% yield, 98% ee as determined on a chiral capillary column of Ni(HFN-IR-Cam) 2 .
EXAMPLES 48-50
The following representative optically active 2-substituted tetrahydrofurans were prepared by the method of Example 47 from the corresponding optically active haloalcohol.
______________________________________Example Compound % ee______________________________________48 [S]-2-(4-fluorophenyl)-tetrahydrofuran 9849 [R]-2-(4-fluorophenyl)-tetrahydrofuran 9850 [R]-2-(4-bromophenyl)-tetrahydrofuran 98______________________________________
EXAMPLES 51-54
The following representative are also prepared following the method of Example 47: [S]-2-(4-iodophenyl)-tetrahydrofuran; [R]-2-(4-iodophenyl)-tetrahydrofuran; [S]-2-(4-chlorophenyl)-tetrahydrofuran; and [R]-2-(4-chlorophenyl)-tetrahydrofuran.
The 1,3-halohydrins of Formula I are converted to novel 1,3-phenoxyhalides represented by Formula III below which are important intermediates in the preparation of biologically active propylamines. The novel optically active 1,3-phenoxychlorides of the present invention are presented by the formula: ##STR11## wherein R is phenoxy substituted by lower alkyl, loweralkoxy or haloloweralkyl. The preparation of representative 1,3-phenoxychlorides is described in the following examples.
EXAMPLE 55
[R]-(-)-1-Chloro-3-phenyl-3-(2-methylphenoxy)propane
Triphenylphosphine (5.25 g, 20 mmol) and ethylazodicarboxylate (3.15 ml, 3.48 g, 20 mmol) were added to a solution of [S]-1-chloro-3-phenyl-3-propanol (3.4 g, 20 mmol) and o-cresol (2.06 ml, 2.16 mmol) in THF (50 ml). The mixture was stirred at room temperature overnight until the reaction was complete as determined by TLC. THF was removed under aspirator vacuum and the residue treated with pentane (3×50 ml). The combined pentane fractions were concentrated and the residue chromatographed on neutral alumina. Elution with pentane and removal of solvent afforded 3.6 g (70% yield) of the chloro ether as a thick liquid which was found to be 99% pure by gas chromatograph. Bp 180°-200° C./0.5 mm; [α] D 23 -21.7° (c 3.9, CHCl 3 ); 13 C-NMR: 150.67, 147.81, 128.76, 127.98, 125.32, 122.23, 120.96, 117.35, 112.71, 59.02, 56.02, 41.61. Mass spectrum (EI): 260/262 (1,M.sup. +), 224 (1, M + --HCl), 153 (21, M + --C 7 H 8 O), 91 (100, C 7 H 7 ). (CI): 261 (7.4, M + +H), 153/155 (100, M + +H--C 7 H 8 ).
EXAMPLE 56
[R]-(-)-Tomoxetine Hydrochloride
To the chloroether of Example 55 (2.6 g, 10 mmol) in a Paar "mini-reactor" was added aqueous methylamine (40%, 20 ml). Ethanol (10 ml) was added as a cosolvent and the solution heated at 130° C. for 3 hours. The solution was cooled to room temperature and the mixture was poured on water (150 ml) and extracted with ether. The ether extract was washed with water, brine and dried over MgSO 4 . HCl in EE (5 ml of 3.2M, 16 mmol) was added to the decanted solution
EXAMPLE 57
[S]-(+)-1-Chloro-3-phenyl-3-(2-methylphenoxy)propane
This chloroether was prepared following the method of Example 55, using [R]-3-chloro-1-phenylpropanol (3.4 g, 20 mmol), o-cresol (2.06 ml, 20 mmol), triphenylphosphine (5.25 g, 20 mmol) and diethylazodicarboxylate (3.15 ml, 20 mmol) in THF (50 ml). Workup yielded the title compound (3.5 g, 68%) as a thick liquid, bp 180°-200° C./0.5 mm; [α] D +21 .7 (c 3.9, CHCl 3 ); 13 C NMR and the mass spectra were identical to the [R]-(-)- isomer of Example 55.
EXAMPLE 58
[S]-(+)-Tomoxetine Hydrochloride
[S]-Tomoxetine hydrochloride was prepared using the same procedure as for the preparation of the [R]-(-)-isomer from the chloroether of Example 57 and excess aqueous methylamine in a "mini-reator" at 130° C. for 3 hours. Workup provided the optically pure [S]-(+)-isomer in 95% yield, [α] D 23 +42.9° (c 6, MeOH). All spectral data are identical to [R]-(-)-Tomoxetine hydrochloride. Anal. Calcd. for C 17 H 22 ClNO: C, 69.98; H, 7.55; Cl, 12.18; N, 4.9. Found: C, 69.1; H, 7.9; Cl, 12.29; N, 4.91.
EXAMPLE 59
[R]-(+)-1-Chloro-3-phenyl-3-(4-trifluoromethylphenoxy)propane
The title compound was prepared by the method of example 55 using [S]-3-chloro-1-phenylpropanol (2.57 g, 15 mmol), α, α, α-trifluorocresol (2.4 g, 15 mmol) in THF (40 ml) at room temperature. Workup provided the optically pure title compound as a thick liquid, bp 180°-200° C./0/5 mm. [α] D +2.3° (c 10, CHCl 3 ; 13 C NMR (CDCl 3 ): 140.50, 129.39, 128.66, 127.56, 127.38, 127.19, 127.01, 126.34, 116.45, 77.82, 41.69, 41.38. Mass spectrum (EI): 153/155 (45), 91 (100). (CI): 314/316, (1, M + ), 153/155 (100). Anal. Calcd. for C 16 H 14 ClNO: C, 61.05; H, 4.45; Cl, 11.29; F, 18.12. Found: C, 61.06; H, 4.51; Cl, 11.16; F, 18.22.
EXAMPLE 60
[R]-(-)-Fluoxetine Hydrochloride
[R]-(-)-Fluoxetine hydrochloride was prepared following the procedure of Example 56 for [R]-(-)-Tomoxetine hydrochloride utilizing [R]-(+)-1-chloro-3-phenyl-3-(trifluoromethylphenoxy)propane (Example 59) (1.57 g, 5 mmol) and excess aqueous methylamine in ethanol as cosolvent in a "mini-reactor" at 130° C. for 3 hours. Workup provided 1.55 g, 90% yield, of the recystallized, optically pure (CH 2 Cl 2 /EtOAc) [R]-(-)-Fluoxetine hydrochloride: mp 142°-143° C.; [α] D 22 +3.01° (c 5.3, MeOH); [α] D 22 -15.52° (c 7.15, CHCl 3 ); 13 C NMR (CDCl 3 ): 160.10, 139.46, 129.28, 128.66, 127.35, 127.16, 126.96, 126.77, 126.08, 116.26, 55.49, 46.32, 34.77, 33.13. Mass spectrum (EI): 44 (100, CH 2 NHMe). (CI): 310 (100, M + +H), 148 (12). Anal. calcd. for: C 17 H 19 ClF 3 NO: C, 59.05 ; H, 5.54; N, 4.05; F, 16.48; Cl, 10.25. Found: C, 59.02; H, 5.6; N, 4.13; F, 16.67; Cl, 10.5.
EXAMPLE 61
[S]-(-)-1-Chloro-3-phenyl-3-(4-trifluoromethylphenoxy)propane
The title chloro ether was prepared from [R]-(+)-3-chloro-1-phenylpropanol (2.56 g, 15 mmol), α, α, α-trifluoro-p-cresol (2.43 g, 15 mmol), triphenylphospine (3.93 g, 15 mmol) and diethylazodicarboxylate (2.36 ml, 15 mmol) in THF (40 ml) at room temperature. Workup provided the title compound as a thick liquid. Yield: 3.07 g, 65%, bp 180°-200° C./0.5 mm [α] D -2.2° (c 12.5, CHCl 3 ): 13 C NMR and mass spectrum were identical to those of the [R]-(-) isomer of Example 59.
EXAMPLE 62
[S]-(+)-Fluoxetine Hydrochloride
[S]-(+)-Fluoxetine hydrochloride was prepared following the method of Example 60 from the chloro ether of Example 61 (1.59 g, 5 mmol) and excess aqueous methylamine in ethanol as cosolvent in a "mini-reactor" at 130° C. for 3 hours. Workup provided 1.55 g (95%) of the recystallized (CH 2 Cl 2 /EtOAc) optically pure title compound, mp 142°-143° C.: [α] D 22 -3.04° (c 5.9, MeOH), [α] D 22 +15.83° (c CHCl 3 ); 13 C NMR (CDCl 3 ): 160.08, 139.44, 129.26, 128.64, 127.30, 127.12, 126.76, 116.25, 77.48, 46.32, 34.77, 33.14. Mass spectrum (EI): 44 (100, CH 2 NHMe). (CI): 310 (100, M + +H), 148 (12). Anal. calcd. for C 17 H 19 ClF 3 NO: C, 59.05; H, 5.54; N, 4.05; F, 16.48; Cl, 10.25. Found: C, 58.70 ; H, 5.58; N, 4.29; F, 16.38; Cl, 10.35.
EXAMPLE 63
[R]-(+)-1-chloro-3-phenyl-3-2-methoxyphenoxy)propane
The title chloroether was prepared by the method of Example 55 using [S]-(-)-3-chloro-1-phenylpropanol (1.71 g, 10 mmol), guaiacol (1.1 ml, 10 mmol), Ph 3 P (2.62 g, 10 mmol) and diethylazodicarboxylate (1.57 ml, 10 mmol) in THF (40 ml) at room temperature. Workup and chromatography with neutral alumina (hexane/ethyl acetate: 97.3) gave 1.7 g (62%) of the title compound as a thick liquid, bp 180°-200° C./0.5 mm. The liquid, upon cooling, solidified and was recrystallized from pentane, mp 59°-61° C. [α] D +40.96 (c 7.8, CHCl 3 ): 13 C NMR (CdCl 3 ): 150.67, 147.81, 141.28, 128.76, 127.98, 126.32, 122.23, 120.96, 117.35, 112.71, 79.02, 56.07, 41.61. Mass spectrum (EI): 276/278 (1, M + ), 240 (M + --HCl), 260/262 (M--CH 4 ), 91 (100), 124 (82). (CI): 277/279 (13.6, M + +H), 153/155 (100). Anal. calcd. for C 17 H 22 ClNO 2 : C, 69.44; H, 6.15; Cl, 12.84. Found: C, 69.67; H, 6.3; Cl, 12.65.
EXAMPLE 64
[R]-(+)-Nisoxetine hydrochloride
[R]-(+)-Nisoxetine hydrochloride was prepared from the chloroether of Example 63 (1.35 g, 5 mmol) and excess aqueous methylamine in ethanol (1 ml) in a "mini-reactor" at 130° C. for 3 hours. Workup gave 1.41 g ((91%) of recrystallized product (Ch 2 Cl 2 /EtOAc), mp 149°-150° C.; [α] D +51.88° (c 4.8, MeOH); 13 C NMR: 150, 140.18, 129.29, 129.07, 128.58, 126.14, 123.03, 121.32, 117.29, 112.23, 81.83, 56.44, 47.56, 34.20, 33.19. Mass spectrum (EI): 167, 44 (100), 148 (8). (CI): 272 (100, M + ). Anal. Calcd. for C 17 H 22 ClNO 2 : C, 66.34; H, 7.15; N, 4.55; Cl, 11.5. Found: C, 66.08; H, 5.2; N, 4.66; Cl, 11.59.
EXAMPLE 66
[S]-(-)-Chloro-3-phenyl-3-(2-methoxyphenoxy)propane
The title chloroether was prepared in a manner similar to Example 64. Yield: 1.64 g (60%). Mp 59°-61° C.; [α] D -41.6 (c 3, CHCl 3 ); 13 C NMR and mass spectrum were identical to the chloroether of example 64.
EXAMPLE 67
[S]-(-)-Nisoxetine Hydrochloride
[S]-(-)-Nisoxetine hydrochloride was prepared from [S]-(-)-chloro-3-phenyl-3-(2-methoxyphenoxy)propane by the method of Example 65 to yield 1.41 g (91%) of the optically pure product. Mp 149°-151° C.; [α] D -52° C. (c 5, MeOH). 13 C NMR and mass spectra were idential to that of the [R]-(+)-isomer.
The conversion of optically active 1,3-phenoxychlorides to the corresponding 1,3-phenoxyamines with complete retention of optical activity has been illustrated in the above representative examples. The process of this invention is applicable as a general method for the preparation of any (+) or (-) Tomoxetine, Fluoxetine or Nisoxetine analog in 100% optical purity. Referring to the following general formula for such derivatives: ##STR12## any substituent or substituents on the phenyl ring can be accomodated for reduction with Ipc 2 BCl. Any chain length is also compatible with the process of this invention.
The process of this invention is also broadly applicable to the preparation of the desired, optically pure isomer of any aryalkanolamine pharmaceutical agent.
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A process for producing the optically pure (+)- or (-)-isomer of a phenyl- or substituted-phenylalkanolamine compounds having pharmacologic activity without the need for resolution processes and novel intermediates useful in the process including optically pure haloalcohols are provided.
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BACKGROUND OF THE INVENTION
This invention relates to bridges for stringed instruments and, in particular, to saddles for guitars.
Stringed instruments employ bridges to transmit vibrations to the body of the instrument. For example, a guitar has a bridge mounted on the body of the guitar. The strings run over the bridge which is in contact with the body.
The bridges of electric guitars typically include a plurality of members known as "saddles". Normally there is one saddle for each string. The saddles are connected to the body of the guitar and each string passes over a saddle near the point of connection with the body of the guitar.
Conventionally these guitar saddles are made of metal, such as pressed steel, brass or stainless steel. Each string has a bend at the point of contact with the saddle. This bend has been thought to be the cause of string breakage. String breakage is a serious problem for musicians, particularly when it occurs during a performance or during an expensive recording session. The problem of string breakage has long existed and it has been thought to be an inherent problem with musical instruments with no satisfactory solution available.
Bridge saddles have been developed which have rollers at the point of contact with the string. The rollers are intended primarily as a tuning aid, by easing movement of the string over the bridge when the string is being tuned. However, these rollers have not caused an appreciable reduction in string breakage.
SUMMARY OF THE INVENTION
The invention provides a bridge for a stringed instrument having a string supporting portion comprising a composition having a first component and a second component. The first component is a rigid material and the second component is a lubricating material.
The string supporting portion may be, for example, a saddle for a guitar bridge.
The rigid material may be a plastic material such as a resin and the second component may comprise polytetrafluoroethylene, a silicone or graphite.
The composition may also include a third component comprising reinforcing fibers of, for example, aramid, carbon or glass fibers.
The use of a string supporting portion of the stated composition has provided a dramatic reduction in string breakage of guitars. It is believed that previous string breakage has been due in large measure to friction between the string supporting portion of the bridge and the string. Motion of the string from side to side apparently is a significant factor because the roller-type saddles have not alleviated string breakage. On the other hand, employing a composition with an integral lubricating material has considerably decreased the occurrence of string breakage when compared with conventional metal bridge saddles of the same type.
BRIEF DESCRIPTION OF THE DRAWING
The drawing is an isometric view of a fragment of a guitar body with a fragment of a bridge mounted thereon including one string and one saddle mounted on the bridge.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The drawing shows a fragment of a guitar bridge shown generally at 2 mounted on a fragment of a guitar body 4. The bridge includes an angle-shaped member 6, typically of metal, having a plurality of bridge saddles 8 juxtaposed thereon (only one of which is shown in the drawing). The guitar has a plurality of strings, only one of which, namely string 10, is shown in the drawing. Each saddle has an elongated aperture 12 therethrough with a notch 14 at one end for receiving the string 10. The string passes over front end 16 of the saddle and then over notch 14. The end of the string passes through aperture 12 and a corresponding aperture in member 6 and is fixedly connected to the body of the guitar in the conventional manner. The saddle 8 is secured to member 6 by a pair of Allan bolts 18 and 20 at the front end thereof and by an Allan bolt 22 at the back end thereof which passes through an aperture in flange 24 of member 6. A coil spring 28 is located between the flange 24 and the back of the saddle.
As described so far, the arrangement is conventional and is an example of one type of saddle only. It should be understood that the invention is equally applicable to guitar saddles of other types and, for that matter, to string supporting portions of other musical instruments.
Conventionally saddle 8 is made of metal, such as brass or stamped steel. However, the invention provides a saddle 8 having a body comprised of a composition including a first component and a second component. The first component is a rigid material selected to provide the strength required as well as appropriate sound transmission to the body of the guitar. The second component is a lubricating material selected to provide lubrication for the guitar string at the point of contact with the saddle. In the preferred embodiment there is also a third component to increase the strength and durability of the saddle.
In the preferred embodiment, the first component is a polyphenylene sulfide resin. The second component is polytetrafluoroethylene and the third component is glass fibers. A composition having a suitable combination of the first component, second component and third component is available from Phillips Chemical Co. under the trade mark RYTON. The preferred composition includes proportions by weight of 55 percent polyphenylene sulfide resin, 15 per cent polytetrafluoroethylene and 30 percent glass fibers. However, these proportions may be varied. The polytetrafluoroethylene is mixed homogeniously with the resin and the glass fibers are evenly distributed throughout the composition. The guitar saddles of the preferred embodiment are produced by molding this composition.
It is also believed that polycarbonate resins or acetal resins would be suitable although the latter may not have as good a tone as the preferred polyphenylene sulfide. Desirable properties of the resin or other plastic material are believed to be high tensile strength, high flexural modululus and high stiffness. Other possible substitutes for the first component include amino, polyamide-polyimide, polyester, polyimide thermoset, styrene-acrylonitrile or polyethersulfone resins or nylon.
As stated, the second component is chosen for its lubricant qualities and polytetrafluoroethylene is the preferred component. However, possible alternatives include silicones and graphite.
The composition of the preferred embodiment has glass fiber reinforcement. Alternatives are carbon fibers and aramid fibers. Unreinforced plastic compositions may be substituted.
It should also be understood that the lists of alternatives given above is not necessarily exhaustive. Furthermore, each component may comprise a mixture of two or more of the alternatives given above.
In the preferred embodiment, the entire body of the saddle is molded from the stated composition. Alternatively, only the portion of the saddle contacting the guitar string needs to be made from the lubricating composition. The body could be made of metal, for example, with an insert of the stated composition being fitted thereto for contacting the string.
As a further alternative, the saddle could have a body of metal with a coating of the stated composition at least where the saddle contacts the string.
In operation, the saddles according to the invention are simply fitted to the body of the guitar in a conventional manner after metal saddles are removed. Of course the saddles may also be installed on new guitars. An initial break in time of four to six hours may be required to create a film of lubrication as the strings move over the saddles.
In actual tests, guitar saddles according to the invention have appreciably reduced the rate of string breakage compared with conventional metal saddles. These tests included actual trials of the invention by skilled musicians and workbench tests wherein guitar strings were repetitively plucked by a member similar to a guitar pick. These tests related to compositions according to the preferred embodiment, although it is believed that string breakage would also be reduced employing the alternatives listed above.
Other embodiments of the invention will be apparent to the skilled in the art from a consideration of this specification or practice of the invention disclosed herein. It is intended that the specification and examples be considered as exemplary only with the true scope and spirit of the invention being indicated by the following claims.
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A bridge for a stringed instrument has a string supporting portion comprising a composition having a first component and a second component. The first component is a rigid material and the second component is a lubricating material. Preferably the first component is plastic and the second component is polytetrafluoroethylene, graphite or a silicone. The composition may also include a reinforcement comprising aramid, carbon or glass fibers or combinations thereof.
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CROSS REFERENCE TO PRIOR APPLICATIONS
[0001] This application is a U.S. National Phase application under 35 U.S.C.§371 of International Application No. PCT/EP2011/058410, filed on May 24, 2011 and which claims benefit to German Patent Application No. 10 2010 025 175.5, filed on Jun. 25, 2010. The International Application was published in German on Dec.29, 2011as WO 2011/160910 A1 under PCT Article 21(2).
FIELD
[0002] The present invention relates to a pressure-control valve comprising a housing accommodating a coil wound upon a coil carrier, an armature axially displaceable in a bearing, a core and a flux guiding means, and comprising a first connection bore for connection with a reservoir and a connection sleeve, the connection sleeve comprising a valve seat for a valve member of the armature.
BACKGROUND
[0003] Such pressure-control valves are used, in particular, in hydraulic actuators, in controls for automatic transmissions of motor vehicles, or in combination with a pressure or flow-rate controlled motor oil pump. These may be so-called on/off-valves or so-called modulator valves which are advantageous in that the flow rate can be controlled in an infinitely variable manner. An example of an infinitely variable pressure-control valve is described in DE 44 02 523 C2 where the armature of a pressure-control valve, known per se and operating according to the principle of proportionality, cooperates with a valve member which, put simply, is adapted to open and close a connection between a consumer port and a tank. The connection bore to the tank and the connection to the consumer are formed in a connection sleeve. In order to further enhance the damping properties of such a pressure-control valve, a branch includes a buffer damping means. Such a pressure-control valve is very complex and therefore expensive to manufacture and to assemble. The infinitely variable control is also exclusively effected through the electromagnetic drive which also requires high efforts with regard to control technology.
SUMMARY
[0004] An aspect of the present invention is to provide a pressure-control valve that is infinitely variable while requiring a low effort with regard to control, and which at the same time exhibits good damping properties. An additional aspect of the present invention is to provide a pressure-control valve which can be manufactured as economically and as simply as possible.
[0005] In an embodiment, the present invention provides a pressure-control valve which includes a housing, a coil carrier, a coil wound on the coil carrier, a first bearing, an armature comprising a valve member. The armature is configured to be axially displaced in the first bearing. A core. A flux guiding device. A connection sleeve comprises a valve seat for the valve member. A first connection bore is configured to be connected with a tank and with the connection sleeve. A second connection bore is configured to be connected with a consumer. An end of the connection sleeve distant from the core comprises a control bore with a control member supported therein. The armature and the control member are configured to be in a force-transmitting operative connection at least in an opening direction of the pressure-control valve. It is thereby possible to control, for example, the delivery rate or the oil pressure of a motor oil pump in a simple manner. For this purpose, for example, the first connection bore should be connected to a tank and the second connection bore should be connected to the consumer to be controlled. The control pressure prevails at the control member, the pressure and the magnetic force together acting against the spring force, both with regard to their direction and the sum of forces. In this manner, a simple oil pressure control of the consumer is provided, with the control member additionally being adapted to be used as an integrated damping means.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] The present invention is described in greater detail below on the basis of embodiments and of the drawing in which:
[0007] FIG. 1 illustrates a sectional view of an embodiment of a pressure control valve of the present invention, with the integration into an oil circuit being shown schematically for clarification of operation.
DETAILED DESCRIPTION
[0008] In an embodiment of the present invention, the housing can, for example, be built from a upper part and a lower part, wherein the lower part comprises the connection sleeve and the connection bores and is arranged in the upper part of the housing either positively or non-positively, wherein a bearing bush for the armature is provided in the portion of the lower part facing to the core and a bearing bushing for the control member is provided in the control bore of the connection bore. In this manner, a pressure-control valve that is particularly simple to produce and to assemble is provided.
[0009] By designing the control member as a piston element, it becomes possible to seal the connection to the consumer in a simple manner against the connection to the controlled variable. The fact that the valve member is cone-shaped provides for a tight, linear abutment of the valve member and the valve seat when the valve is in the closed state. A pressure-control valve that is particularly simple to assemble is realized by providing the armature and the control member as an integral structure, wherein the valve member and the control member are connected by a connection body of reduced diameter that is configured as a connection rod. The difference between the diameter of the bore of the valve seat and the diameter of the connection rod determines the flow area in front of the valve seat, with the forces from the control pressure acting on the valve seat and on the control member being in equilibrium in the closed state.
[0010] The interior can be supplied with atmospheric pressure in a simple manner by forming the first connection bore above the valve seat and by forming the second connection bore between the valve member and the control member. When the bearing bush for the armature is offset backward with respect to the first connection bore, an unimpeded flow is obtained between a consumer and the tank. The risk of oil leakage to the environment or the risk of a damage to the electromagnetic drive caused by pressure variations is very low due to the fact that the armature has a transversal groove, if it is a separate armature, or a transversal bore, in case of an integral control member/armature structure, and a longitudinal bore, such that atmospheric pressure prevails in the interior of the pressure-control valve above the armature.
[0011] In an embodiment of the present invention, the lower part can, for example, be bipartite, with the first part supporting the armature and having the first connection bore formed therein, and the second part being formed with the valve seat and the second connection bore as well as the connection sleeve with the control member. Due to the fact that the penetration depth of the second part into the first part is adjustable, such that the stroke of the armature is adjustable, a fine adjustment of the pressure-control valve is possible during assembly. This is possible in a particular manner, when the second part is pressed into the first part.
[0012] The core can further comprise a pin of non-magnetizable material that serves as a stop element for the armature and as a spring seat of a spring that resiliently supports the armature with respect to the core.
[0013] Further fine adjustment is made possible by the fact that the pin is arranged in the core in an adjustable manner.
[0014] The path of the magnetic field lines can be influenced by the fact that the end of the core averted from the armature has an adjustment bore in which an adjustment screw is provided. It is particularly advantageous here if the core has a substantially circumferential recess in the region of the adjustment bore on the side facing to the coil.
[0015] The following is a detailed description of the present invention with reference to an embodiment and to the accompanying drawing.
[0016] The pressure-control valve 1 comprises a housing 2 which is built substantially from an upper part 3 and a lower part 4 . The upper part 3 comprises an electromagnetic drive unit 5 acting upon an armature 7 arranged for axial displacement in a bearing/bearing bush 6 . The electromagnetic drive unit 5 substantially comprises a coil 8 , a core 9 and a flux guiding means 10 that is formed by a backiron 11 and a yoke 12 . The housing 2 , which is made of a plastic material, further comprises a plug 13 for connection with a control module known per se and not illustrated herein. The electromagnetic drive unit 5 acts on the armature 7 which has a valve member 14 at its end averted from the core 9 . In the present instance, the valve member 14 is connected with a control member 16 via a connection rod/valve rod 15 and is of conical shape so as to provide a linear abutment. In the present instance, the armature 7 , the valve member 14 , the connection rod 15 and the control member 16 are integral. A spring 17 biases the armature 7 to a closed position with respect to the core 9 . The spring 17 is guided by a pin 18 adapted to be arranged in an adjustable manner in the core 9 during assembly. At the same time, the pin 18 serves as an upper stop element for the armature 7 . Further, an adjustment screw 19 is provided that is arranged in an adjustment bore 20 and which allows for a fine adjustment of the electromagnetic drive unit 5 such that the path of the magnetic field lines can be influenced. In order to influence the number of magnetic field lines in the transition region to the armature 7 in a simple manner, a recess 21 is additionally provided to prevent a scattering of the magnetic field lines in the region of the adjustment screw 19 and thereby allow a linear fine adjustment during assembly.
[0017] In the shown embodiment, the lower part 4 is of bipartite structure, wherein, in the first part 23 , the bearing bush 6 for the armature 7 is offset backward with respect to a connection bore 24 . The term connection bore can also include a series of bores in the lower part 4 . The connection bore 24 leads to a non-illustrated tank in which atmospheric pressure p 0 prevails. A valve seat 25 is provided below the connection bore 24 which cooperates with the valve member 14 . Instead of giving the valve member 14 a conical shape, the valve seat 25 may be given a corresponding shape. By the fact that the bearing 6 for the armature 7 is provided in the first part 23 of the lower part 4 in a manner offset rearward with respect to the connection bore 24 , an unimpeded flow is provided when the pressure-control valve 1 is opened to the tank. In the present instance, the valve seat 25 is formed by the second part 26 of the lower part 4 , which also comprises the connection sleeve 38 .The second part 26 is pressed into the first part 23 , whereby the stroke of the armature 7 becomes adjustable during assembly. The second part 26 further comprises a second connection bore 27 which, in the present instance, is connected with a consumer 28 . The control pressure p 2 of the consumer 28 , which may, for example, be a variable oil pump or a vane cell pump configured to be variable, prevails at the second connection bore. A control bore 39 is provided in the connection sleeve 38 , which includes a second bearing bush 29 in which the control member 16 is supported with low friction, the control member 16 being designed as a piston in the present case. As schematically illustrated in FIG. 1 , the control pressure p 1 prevails at this control member 16 , which pressure represents the motor oil pressure in the present instance.
[0018] In the shown embodiment, the armature further has a transversal bore 30 and a longitudinal bore 31 that provide a connection between the interior 32 and atmospheric pressure p 0 . In particular, this substantially increases safety with respect to unintentional oil leakage from the pressure-control valve 1 to the environment. The electromagnetic drive 5 is furthermore not subjected to different pressures, whereby a precise control of the armature 7 is provided.
[0019] The resulting forces that result from the presence of the control pressure p 2 at the control member 16 and the valve member 14 , when the pressure-control valve 1 is closed, are compensated for by the special design of the valve rod 15 connecting the valve member 14 with the control member 16 .
[0020] The pressure-control valve 1 of the present invention operates as follows. In the present case, a motor oil pump 28 , known per se, is to be controlled, which pump is designed as a variable vane cell pump. The vane cell pump 28 conveys the motor oil to the motor 33 , the excess oil being returned to the tank at atmospheric pressure p 0 . The motor oil conveyed is at a pressure p 1 . A maximum delivery volume is achieved at maximum eccentricity of the rotary axis of the vane cell pump 28 , the eccentricity being obtained by displacement of a slide 34 in the vane cell pump 28 . A minimum delivery volume is achieved when the rotary axis is centric. The slide 34 cooperates with a first control chamber 35 and a second control chamber 36 , with the pressure p 2 prevailing in both the first and second control chambers 35 , 36 . The abutment surface of the slide 34 is, however, larger in the second control chamber 36 so that, when the pressure-control valve 1 is de-energized, the slide 34 causes maximum eccentricity and thus the greatest delivery volume (fail safe function). If a reduction in eccentricity and thus a reduction in delivery volume of the vane cell pump 28 are desired, the pressure-control valve 1 is actuated and the pressure in the control chamber 36 is appropriately reduced. The oil with the pressure p 2 is thus present at the second connection bore 27 . When an increase in delivery volume is desired, the pressure-control valve 1 can be closed; a nozzle 37 and the different surface ratio of the abutment surfaces of the slide 34 thus provide that a fast displacement of the rotary axis of the vane cell pump 28 into the eccentric position takes place. The motor oil pressure p 1 prevails at the control member 16 , whereby, in case it should be too high, the motor oil pressure is controlled even when the pressure-control valve 1 is not active. The pressure-control valve 1 is further used to discharge leakage oil which, due to leaks and movement gaps, occurs in the case of large delivery volumes.
[0021] The present invention is not limited to embodiments described herein; reference should be had to the appended claims.
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A pressure-control valve includes a housing, a coil carrier, a coil wound on the coil carrier, a first bearing, an armature comprising a valve member. The armature is configured to be axially displaced in the first bearing. A core. A flux guiding device. A connection sleeve comprises a valve seat for the valve member. A first connection bore is configured to be connected with a tank and with the connection sleeve. A second connection bore is configured to be connected with a consumer. An end of the connection sleeve distant from the core comprises a control bore with a control member supported therein. The armature and the control member are configured to be in a force-transmitting operative connection at least in an opening direction of the pressure-control valve
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TECHNICAL FIELD
[0001] The presently described subject matter relates to apparatus and methods for the cleaning, stimulation, and production enhancement of oil, gas and injection wells.
BACKGROUND
[0002] Sonic pulse tools that emit pressure waves to vibrate/pulse fluids and solids within the production formation of a petroleum or gas production well are commonly used in the oilfield industry to stimulate production or injection enhancement. Without restriction to a theory, it is believed that the propagation of pressure waves through the production or injection formation may cause the vibration at the molecular level of fluids and solids within the producing/injection zone, and that this in turn assists in the mobilization and production of fluids. Molecular vibration may also result in one or more of the following beneficial effects: repair and removal of naturally occurring or man-made formation damage; suspension of wellbore damage in suspension fluid; removal of scale, filter cake, wax, asphaltenes, bitumen or other materials; increasing reservoir connectivity, injectivity and production; selective enhancement of stimulation fluid; and decreasing viscosity of heavy oil to facilitate mobilization. Sonic pulse tools may also be used to facilitate the cleaning of the wellbore itself, or of individual production, injection or casing string components thereof.
[0003] By way of example, U.S. Pat. No. 8,069,914 describes a hydraulic actuated pump system that may include a sonic pulse tool comprising a hydraulic coupling or resonance assembly that generates pulsed pressure waves, which are emitted into a formation production zone through a plurality of jet members. The pressure waves propagate radially outward from the pulse tool through the formation, in some embodiments up to about 12 feet, and together with the venturi effect created by the action of the jet members generate a radial “push/pull” type of positive/negative pressure face at the formation to mobilize production fluids into the wellbore. The wave frequency is determined by the number of pulses per second, which can be used to calculate the wavelength being exerted on the production formation. The pressure or flowrate at which hydraulic fluid is injected through the sonic pulse tool determines the amplitude or power of the pressure waves.
[0004] U.S. patent publication no. US 2010/0290313 describes downhole pulse stimulation tools comprising a resonance chamber defining at least one pulse emitting opening, and a pulse generator that is either rotatably disposed within the resonance chamber and directly or indirectly rotated by the wellbore rod string, or that is slidingly disposed within the resonance chamber and directly or indirectly reciprocated by the rod string. The pulse generator defines at least one pulse generating opening that periodically aligns with the at least one pulse emitting opening as the pulse generator cycles within the resonance chamber housing. The fluid pressure within the pulse generator is at a higher pressure than the outside pressure due to pump action, so a pulse of fluid pressure is emitted outward from the resonance chamber with each cycle of the pulse stimulation tool.
[0005] As with the sonic pulse tools described in U.S. Pat. No. 8,069,914 and other prior-known pulse stimulation tools, each pressure pulse generated by the pulse stimulation tools of U.S. 2010/0290313 is emitted generally simultaneously through each of the plurality of pulse emitting openings (or jets) that are provided. In some embodiments of U.S. 2010/0290313, paired upper and lower pulse emitting openings generate two sequential pulses for each rotation of the single pulse generator. Nevertheless, in such embodiments, each sequential pulse continues to comprise a simultaneous pulse from each of the upper and lower pluralities of pulse emitting openings.
[0006] The pressure waves that are generated within a producing formation by prior-known pulse stimulation tools accordingly propagate outward from the tool in a generally radial “push/pull” positive/negative, but non-directional manner.
SUMMARY
[0007] Improvements in the cleaning, stimulation and/or production enhancement of a hydrocarbon production or injection well may be achieved by propagating successive pressure waves through the wellbore and/or the producing/injecting formation in a directional or vectored manner. The presently described subject matter is accordingly directed to hydrodynamic pulse tools and methods that generate sequential hydraulic pressure pulses that propagate pressure waves radially outward along successively different directional vectors. In some embodiments, sequential offsetting and/or reinforcing pressure pulses may also be generated.
[0008] In preferred embodiments, a hydrodynamic pulse tool comprises a resonance chamber defined by a generally cylindrical hollow tubular member adapted for connection to conventional coiled or jointed tubing, and at least one hydraulically driven pulse generator rotatably disposed within the resonance chamber. The hydraulic force of pressurized fluid pumped through the tool is employed to drive the rotation of the at least one pulse generator substantially about the longitudinal axis of the tubular resonance chamber.
[0009] The inner profile of the generally tubular resonance chamber may in some embodiments define one or more internal flanges or seats for retaining or limiting the longitudinal travel of the at least one pulse generator within the resonance chamber, and in some embodiments these flanges or seats may further include a taper that corresponds with an outside taper of the pulse generator. In some applications, annular bushings or bearings may also be used to facilitate the rotation and/or the longitudinal location of the at least one pulse generator within the resonance chamber.
[0010] In preferred embodiments, each of the at least one pulse generators of the tool comprises a generally cylindrical member with a central longitudinal bore. The outside diameter of at least a portion of each pulse generator comprises a zone that is dimensioned for rotational sliding fit within the resonance chamber, and a plurality of tangential jets extend through the annular body of the pulse generator tangentially from the central longitudinal bore surface to the outside radial surface of the pulse generator within the zone. In preferred embodiments, the tangential jets extend in an orientation that is substantially perpendicular to the longitudinal axis of the pulse generator and the tool.
[0011] The resonance chamber further comprises a plurality of spaced-apart pulse emitting outlets positioned to correspond with the tangential jets of the pulse generator, and through which pressurized fluid may exit the tool to create a hydraulic pressure pulse. At least one of the tangential jets is in fluid communication with a corresponding one of the plurality of pulse emitting outlets provided in the resonance chamber at any one time. As pressurized fluid passes through a tangential jet that is in fluid communication with a corresponding pulse emitting outlet, fluid pressure acts on a wall surface of the pulse emitting outlet and the reactionary force thereby created causes rotation of the pulse generator. The release of the pressurized fluid through the pulse emitting outlet also creates a pressure pulse that propagates a pressure wave through the wellbore and/or the producing/injection formation.
[0012] To sustain the rotational drive of the at least one pulse generator during use, the tangential jets of the pulse generator and the pulse emitting outlets of the resonance chamber are suitably oriented and dimensioned to provide a selected limited degree of overlap, such that fluid communication between a subsequent tangential jet/emitting outlet pairing is initiated just before the rotation of the pulse generator closes off the fluid communication between a current tangential jet/emitting outlet paring. Accordingly, apart from this required but limited overlap, only one tangential jet of each pulse generator (or, in the case of a “multi-level” hydrodynamic pulse tool, one tangential jet of each level—see, below) is substantially in fluid communication with a pulse emitting outlet at any one time. The degree of overlap that may be necessary to sustain rotational drive of the at least one pulse generator is dependent in part upon the pressure and viscosity of the fluid being pumped through the tool. In most embodiments, the cross-sectional dimensions of the pulse emitting outlets are larger than those of the tangential jets.
[0013] In order to generate sequential hydraulic pressure pulses that cause the propagation of pressure waves along successively different directional vectors (as opposed to the generally radial “push/pull” positive/negative, but non-directional propagation of pressure waves of prior-known devices) while sustaining rotational drive, in embodiments of the tool that employ a single one-level pulse generator, the resonance chamber comprises at least three pulse emitting outlets and the pulse generator comprises at least four corresponding tangential jets. In such a configuration, which may be designated a “3:4 tool” configuration, each of the three pulse emitting outlets are oriented about the radial periphery of the resonance chamber and spaced apart at roughly 120° intervals relative to the longitudinal axis of the resonance chamber, and each of the four tangential jets are spaced apart at roughly 90° intervals relative to the longitudinal axis of the pulse generator. As the pulse generator is rotated by the hydraulic force of the pressurized fluid, the pressurized fluid is sequentially released through each of the three pulse emitting outlets, thereby generating sequential hydraulic pressure pulses that propagate pressure waves radially outward at 0°, 120° and 240° vectors relative to the longitudinal axis of the tool.
[0014] Similar preferred single pulse generator embodiments include “4:5 tool” and “5:6 tool” configurations, in which sequential hydraulic pressure pulses propagate sequential pressure waves radially outward at 0°, 90°, 180° and 270° vectors (in the case of a “4:5 tool”), and at 0°, 72°, 144°, 216° and 288° vectors (in the case of a “5:6 tool”) respectively relative to the longitudinal axis of the tool. Single generator pulse stimulation tools in accordance with embodiments of the present subject matter may theoretically be provided in any ratio of “n” pulse emitting outlets to “n+1” tangential jets, but for tools that are adapted for connection to conventional coiled or jointed tubing, size and manufacturing constraints typically limit the upper ratio to tools with a configuration of about “7:8”.
[0015] In other preferred embodiments comprising a single pulse generator, the tangential jets and the corresponding pulse emitting outlets are arranged in two or more discrete levels along the longitudinal axis of the tool to provide a “multi-level” single pulse generator hydrodynamic pulse tool. In one such multi-level tool embodiment, which may be designated a “double 3:4 tool”, the upper level of pulse emitting outlets comprises three outlets that are spaced apart by 120° relative to one another about the longitudinal axis of the resonance chamber and the lower level of pulse emitting outlets similarly comprises three pulse emitting outlets that are also spaced apart by 120° relative to one another about the longitudinal axis of the resonance chamber, but that are out of phase with the outlets of the upper level by about 60°. In combination, this “double-deck” multi-level single pulse generator embodiment accordingly comprises a single pulse emitting outlet at roughly every 60° about the longitudinal axis of the tool. The single pulse generator of this embodiment comprises two sets of four tangential jets, each set of four being spaced apart at 90° intervals relative to the longitudinal axis of the pulse generator (for a total of eight tangential jets, four corresponding to the upper level of pulse emitting outlets and the other four corresponding to the lower level of pulse emitting outlets). The two sets of four tangential jets may be in phase or “aligned”, such that each of the four tangential jets of the upper level is located directly in line longitudinally above a corresponding one of the four tangential jets of the lower level, or the two sets of four tangential jets may alternatively be out of phase by a selected angle such as 60°.
[0016] If the two sets of tangential jets of this “double 3:4 tool” embodiment are aligned, then as the pulse generator is driven by the pressurized fluid, the tool will sequentially propagate offsetting pressure waves radially outward along simultaneous 0° and 180°; 120° and 300°; and 60° and 240° vectors relative to the longitudinal axis of the tool. Conversely, if the two sets of tangential jets of this embodiment are out of phase by 60°, then as the pulse generator is driven by the pressurized fluid, the tool will sequentially propagate reinforcing pressure waves along simultaneous 0°, 60°, 180° and 240°; followed by 0°, 120°, 180° and 300°; and then 60°, 120°, 240° and 300° vectors relative to the longitudinal axis of the tool.
[0017] As will be readily apparent to those of skill in the art from an appreciation of the present disclosure, numerous other degrees of phase shift or “offset” between the upper and lower levels of pulse emitting outlets and/or between the tangential jets, as well as other tool configurations (such as “double 4:5 tools”, “double 5:6 tools”, etc.) may also be selected to provide further alternate embodiments that generate pressure pulses to propagate pressure waves radially outward along, for example, sequential 0°, 60°, 120°, 180°, 240° and 300° vectors, or along offsetting 0° and 180° vectors alternating with 90° and 270° vectors.
[0018] By way of example, in one family of “double-deck” single pulse generator embodiments that may be designated “double 4:5 tools”, the upper level of pulse emitting outlets comprises four outlets that are spaced apart by 90° relative to one another about the longitudinal axis of the tool and the lower level of pulse emitting outlets similarly comprises four pulse emitting outlets that are also spaced apart by 90° relative to one another about the longitudinal axis of the tool. In one such embodiment, the upper and lower sets of pulse emitting outlets are longitudinally aligned so that twin pulse emitting outlets (one upper outlet and one lower outlet) are positioned at every 90° about the longitudinal axis of the tool. The single multi-level pulse generator of this embodiment comprises two sets of five tangential jets, each set of five being spaced apart at 72° intervals relative to the longitudinal axis of the pulse generator (for a total of ten tangential jets, five corresponding to the upper level of pulse emitting outlets and the other five corresponding to the lower level of pulse emitting outlets), and in which the upper and lower sets of tangential jets are either aligned or out of phase by a selected angle such as 45°. It will also be readily apparent to those of skill in the art from an appreciation of the present disclosure that numerous other single multi-level pulse generator embodiments comprising, for example, three or more levels of jets and corresponding outlets (such as “triple 3:4 tools”, “triple 4:5 tools”, “quadruple 4:5 tools”, etc.) may also be provided.
[0019] Further alternate embodiments that are within the scope of the presently disclosed subject matter include multiple independent pulse generator embodiments, in which two or more individual pulse generators (as opposed to a single pulse generator) are driven independently or in unison within a single resonance chamber to propagate sequential, offsetting and/or reinforcing pressure waves along successively different directional vectors. Yet further alternate embodiments within the scope of the presently disclosed subject matter comprise multiple independent pulse generators in which two or more individual pulse generators are driven independently or in unison within two or more individual resonance chambers to generate sequential, offsetting and/or reinforcing hydraulic pressure pulses that propagate pressure waves radially outward along successively different directional vectors.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] For a fuller understanding of the nature and advantages of the disclosed subject matter, as well as the preferred mode of use thereof, reference should be made to the following detailed description read in conjunction with the accompanying simplified drawings. The drawings are not necessarily to scale, with the emphasis instead being placed upon the principles of the disclosed subject matter. The drawings are intended to be illustrative, and therefore should not be used to limit the scope of the disclosed subject matter. In the following drawings, like reference numerals designate like or similar parts or steps.
[0021] FIG. 1 is a schematic perspective view of a hydrodynamic pulse tool in accordance with an embodiment of the presently disclosed subject matter.
[0022] FIG. 2 is a front elevational view of the hydrodynamic pulse tool of FIG. 1 .
[0023] FIG. 3 is a front elevational cage line view of the hydrodynamic pulse tool of FIG. 1 .
[0024] FIG. 4 is a front elevational cage line view of the pulse generator of the hydrodynamic pulse tool of FIG. 1 .
[0025] FIG. 5 is schematic perspective view of a hydrodynamic pulse tool in accordance with another embodiment of the presently disclosed subject matter.
[0026] FIG. 6 is a front elevational view of the hydrodynamic pulse tool of FIG. 5 .
[0027] FIG. 7 is a top plan cage line view of a “3:4 tool” hydrodynamic pulse tool in accordance with an embodiment of the presently disclosed subject matter.
[0028] FIG. 8 is a top plan cage line view of a “4:5 tool” hydrodynamic pulse tool in accordance with an embodiment of the presently disclosed subject matter.
[0029] FIG. 9 is a schematic perspective view of a representative downhole assembly comprising a hydrodynamic pulse tool in accordance with an embodiment of the presently disclosed subject matter.
DETAILED DESCRIPTION
[0030] With reference to FIGS. 1 to 4 , there is illustrated a hydrodynamic pulse tool 10 in accordance with an embodiment of the presently disclosed subject matter. Pulse tool 10 generally comprises cylindrical hollow resonance chamber 12 having upper 14 and lower 16 ends adapted respectively for connection to conventional coiled or jointed tubing, or other conventional downhole well elements (not shown), such as by conventional threaded connection recognized and accepted in the oilfield industry. Rotatably disposed within resonance chamber 12 is single one-level pulse generator 18 . Both the resonance chamber 12 and the pulse generator 18 may be constructed of 4140 steel or other materials suitable for downhole applications, the selection of which is within the ordinary knowledge of those of skill in the art.
[0031] Resonance chamber 12 further comprises a plurality of spaced-apart pulse emitting outlets 20 and, in the illustrated embodiment, a lower flange 22 for limiting downward longitudinal travel of pulse generator 18 within the resonance chamber 12 . Pulse generator 18 further comprises outside taper 24 for rotational sliding contact with flange 22 . In other embodiments, annular bushings or bearings (not shown) may be disposed between flange 22 and outside taper 24 .
[0032] Pulse generator 18 further comprises zone 26 having an outside diameter dimensioned for rotational sliding fit within the resonance chamber 12 , and a central longitudinal bore 28 extending therethrough. A plurality of tangential jets 30 , two of which are illustrated in FIG. 1 as tangential gets 30 a and 30 b respectively, extend through the annular body of the pulse generator 18 tangentially from the surface of central longitudinal bore 28 to the outside radial surface of the pulse generator within the zone 26 . As best seen in FIGS. 2 and 3 , pulse emitting outlets 20 of resonance chamber 12 have a cross-sectional dimension that is larger than that of tangential jets 30 , and are positioned to sequentially correspond with tangential jets 30 as pulse generator 18 rotates within resonance chamber 12 .
[0033] Pressurized fluid (indicated by arrow A in FIG. 1 ) is pumped through the hydrodynamic pulse tool 10 to drive the rotation of pulse generator 18 substantially about the longitudinal axis of the resonance chamber 12 . As pressurized fluid passes through a given tangential jet 30 that is in fluid communication with a corresponding pulse emitting outlet 20 (as best seen in FIG. 2 ), fluid pressure acts on a wall surface 32 of the pulse emitting outlet 20 and the reactionary force thereby created causes rotation of the pulse generator 18 . The release of the pressurized fluid through the tangential jet 30 and thence through pulse emitting outlet 20 also creates a pressure pulse that propagates a pressure wave through the wellbore and/or the producing/injection formation in the vicinity of hydrodynamic pulse tool 10 . The rotational sliding fit between zone 26 of the pulse generator 18 and the resonance chamber 12 substantially prevents bypass of pressurized fluid directly between the cylindrical hollow resonance chamber 12 and the pulse emitting outlets 20 .
[0034] As best understood with reference to FIGS. 1 , 7 and 8 , to sustain the rotational drive of the pulse generator 18 during use, tangential jets 30 and pulse emitting outlets 20 are oriented and dimensioned to provide a selected limited degree of overlap, such that fluid communication between a subsequent tangential jet/emitting outlet pairing ( 30 a and 20 respectively in FIG. 1 ) is initiated just before the rotation of the pulse generator 18 closes off the fluid communication between a current tangential jet/emitting outlet paring ( 30 b and 20 respectively in FIG. 1 ). Accordingly, apart from this required but limited overlap, only one tangential jet 30 of each pulse generator 18 is substantially in fluid communication with a pulse emitting outlet 20 at any one time. The degree of overlap that may be necessary to sustain rotational drive of pulse generator 18 is dependent in part upon the pressure and viscosity of the fluid being pumped through the tool, and the calculation thereof is within the ordinary skill of those in the art.
[0035] FIGS. 1 through 4 illustrate a single one-level pulse generator 18 , and FIGS. 5 and 6 illustrate an alternate embodiment comprising a single multi-level pulse generator 40 (discussed in further detail below). In order to generate sequential hydraulic pressure pulses that cause the propagation of pressure waves along successively different directional vectors (as opposed to the generally radial “push/pull” positive/negative, but non-directional propagation of pressure waves of prior-known devices) while sustaining rotational drive of a single one-level pulse generator 18 during use, the resonance chamber 12 comprises at least three pulse emitting outlets 20 and the pulse generator 18 comprises at least four corresponding tangential jets 30 . In such a configuration, which may be designated a “3:4 tool” configuration, each of the three pulse emitting outlets 20 are oriented about the radial periphery of the resonance chamber 12 and spaced apart at roughly 120° intervals relative to the longitudinal axis of the resonance chamber 12 , and each of the four tangential jets 30 are spaced apart at roughly 90° intervals relative to the longitudinal axis of the pulse generator 18 (see FIG. 7 ). As the pulse generator 18 is rotated by the hydraulic force of the pressurized fluid, the pressurized fluid is sequentially released through each of the three pulse emitting outlets 20 , thereby generating sequential hydraulic pressure pulses that propagate pressure waves radially outward at 0°, 120° and 240° vectors relative to the longitudinal axis of the tool 10 .
[0036] Referring now to FIG. 8 , there are illustrated in top plan cage line view a “4:5 tool” embodiment of a hydrodynamic pulse tool 50 from which sequential hydraulic pressure pulses propagate sequential pressure waves radially outward at 0°, 90°, 180° and 270° vectors. Apart from the number and size of the pulse emitting outlets and tangential jets, the structure of tool 50 is essentially parallel to that of tool 10 described above with reference to FIGS. 1-4 and 7 . As seen in FIG. 8 , tool 50 comprises resonance chamber 52 having four pulse emitting outlets 54 oriented about the radial periphery of the resonance chamber 52 and spaced apart at roughly 90° intervals relative to the longitudinal axis of the resonance chamber 52 . As pulse generator 56 is rotated by the hydraulic force of the pressurized fluid, the pressurized fluid is sequentially released through each of the five tangential jets 58 and the four pulse emitting outlets 54 , thereby generating sequential hydraulic pressure pulses that propagate pressure waves radially outward at 0°, 90°, 180° and 270° vectors relative to the longitudinal axis of the tool 50 .
[0037] Returning again to FIGS. 5 and 6 , a multi-level single pulse generator hydrodynamic pulse tool 40 is illustrated. As shown, multi-level single pulse generator tool 40 comprises a resonance chamber 41 with two opposing upper pulse emitting outlets 42 (one shown in FIG. 6 ), and two opposing lower pulse emitting outlets 43 (both shown in FIG. 5 ). Opposing pairs of pulse emitting outlets 42 and 43 are out of phase by 90°, so in combination, the illustrated “double-deck” multi-level single pulse generator tool 40 comprises a single pulse emitting outlet at roughly every 90° about the longitudinal axis of the tool 40 . As best seen in FIG. 5 , tool 40 further comprises pulse generator 44 with three upper tangential jets 45 and three lower tangential jets 46 . Each of the three upper tangential jets 45 and each of the three lower tangential jets 46 are spaced apart at roughly 120° intervals relative to the longitudinal axis of the pulse generator 40 , and the upper and lower sets of tangential jets 45 , 46 are out of phase by roughly 60° such that, in combination, the pulse generator 44 comprises a tangential jet at roughly every 60° about the longitudinal axis of the pulse generator 44 . Accordingly, as the pulse generator 44 is driven by the pressurized fluid in use, the tool 40 will sequentially propagate pressure waves radially outward along 0°, 90°; 180° and 270° vectors relative to the longitudinal axis of the tool 40 .
[0038] FIG. 9 illustrates a schematic perspective view of a representative downhole assembly comprising a hydrodynamic pulse tool in accordance with embodiments of the presently disclosed subject matter. Downhole assembly 60 comprises a hydrodynamic pulse tool 62 that may be constructed in accordance with any of the pulse tool embodiments described above with reference to any of the preceding Figures. However, for ease of reference, pulse tool 62 is described in the following discussion in relation to the embodiment of FIGS. 1-4 . Pulse tool 62 is connected such as by conventional thread means at its lower end 16 to a section of cylindrical tube 64 , and at the opposite end of tube 64 is similarly connected a tip portion 66 of a conventional well entry guide system that has a bevelled development to allow ease of access into well bores that may have inset or upset applications within the primary well bore itself (such as packer restrictions, profile nipples, etc. . . . ). Cylindrical tube 64 may or may not comprise “reflective focusing chambers” of conventional form and construction to provide an entry/exit point for fluid or fluid/gas, and/or to allow a pulse to enter and respectively exit the reflective focusing chambers.
[0039] Pulse tool 62 may similarly be connected such as by conventional thread means at its upper end 14 to a further cylindrical tube 68 that may again comprise reflective focusing chambers of conventional form and construction. If present, these upper reflective focusing chambers are typically oriented in the opposite manner relative to the lower reflective focusing chambers. A conventional jetted top 70 having an angle of declination away from the main central axis of downhole assembly 60 may optionally also be connected to the opposite end of tube 68 and used to facilitate downward thrust while providing for the appropriate removal of solids from around the assembly 60 to be evacuated from the well bore. The entire downhole assembly 60 may be connected such as by thread means to coiled or jointed tubing in a conventional manner.
[0040] The present description includes the best presently contemplated mode of carrying out the subject matter disclosed and claimed herein. While specific terminology may have been used herein, other equivalent features and functions are intended to be included. The description is made for the purpose of illustrating the general principles of the subject matter and not be taken in a limiting sense; the claimed subject matter can find utility in a variety of implementations without departing from the scope of the invention made, as will be apparent to those of skill in the art from an understanding of the principles that underlie the invention.
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A hydrodynamic pulse tool and method for cleaning, stimulation and production enhancement of oil, gas and injection wells by propagating successive pressure waves through the wellbore and/or the producing/injecting formation in a directional or vectored manner. The tool comprises a resonance chamber defined by a generally cylindrical hollow tubular member adapted for connection to conventional coiled or jointed tubing, and at least one hydraulically driven pulse generator rotatably disposed within the resonance chamber. The hydraulic force of pressurized fluid pumped through the tool drives the rotation of the at least one pulse generator, which generates successive sequential hydraulic pressure pulses in a sequential, sequential offsetting and/or sequential reinforcing manner.
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BACKGROUND OF THE INVENTION
During the formation of lockstitches which are formed by concatenating a needle thread around a bobbin thread, an undesirable effect is sometimes produced call haloing which has its results in producing uneven slack stitches particularly on the top side of the fabric as it is being sewn. It is believed that this effect is produced due to the frictional engagement of the work limb of the needle thread and the takeup limb between the casting off of the loop seized by the loop taker and the stitch setting operation. It is, of course, desirable in producing lockstitches that the stitches be relatively firmly and evenly set so as to firmly secure the plies of fabric being sewn without any undesirably slack thread appearing on the face of the fabric. In accordance with the present invention, this undesirable effect is substantially eliminated by providing a needle thread work limb retaining means which is disposed so as to seize the work limb of the needle thread substantially immediately after loop seizure by the beak of the loop taker. The work limb retainer means is positioned so as to keep the work limb separated from the take up limb of the needle thread during passage of the loop around the loop taker and is released therefrom after the thread loop has completed its passage about the loop taker. The take up limb may then be pulled up by the needle during its return stroke without any frictional engagement with the work limb to thereby set the stitch just formed without any excess thread from the work limb being pulled up through the fabric which might have caused a slack loop on the top side of the fabric. Thread detainers are known in the art for holding on to a thread loop after cast off for maintaining tension on the thread loop so as to prevent "pig tailing" which may be defined a twisting of the thread upon itself. This is a common defect in shuttles of the oscillating type and is not analogous to haloing. These thread detainers are disposed merely to hold on to the thread loop and do not act to separate the two limbs of the thread loop, namely the work limb and the take up limb, in order to prevent haloing. Further, such thread detainers are often mounted on the leading end of the usual thread guard or on the stationary bearing race frame in shuttle mechanisms.
As will be apparent from the following detailed description, a work limb thread retainer is provided which is supported apart from the loop taker and the bobbin in a position for substantially immediately seizing the work limb of the needle thread loop after it is seized by the beak of the loop taker. The work limb is retained by the retainer means during passage of the needle thread loop around the loop taker for concatenation with a thread from the bobbin case and is released after the thread loop has completed its passage about the loop taker. As mentioned above, the retainer serves to keep the work limb and the take up limb separated so that they do not come into frictional engagement during the cycle described above and thereby there is little, if any, chance of the take up limb frictionally engaging the work limb during the return stroke of the needle to thereby substantially prevent haloing. Other objects and advantages of the invention will be best understood when reading the following detailed description with the accompanying drawings.
DESCRIPTION OF DRAWINGS
FIG. 1 is a cross-sectional view of the loop taker section of a lockstitch sewing machine with a portion of the needle mechanism shown therewith;
FIG. 2 is a top plan view of the loop taker section shown in FIG. 1;
FIG. 3 is a perspective view of the work limb retainer mechanism;
FIG. 4 is a diagramatic representation of the production of a haloing effect; and
FIGS. 5a - 5d are diagramatic representations of a cycle of lock stitch formation illustrating the use of the mechanism of the present invention to eliminate haloing.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1, a portion of a sewing machine is illustrated therein in cross section as including a substantially U-shaped bed portion 10 having a top cover plate 12 connected thereto. A throat plate member 14 is disposed in an opening in the top plate 12 and includes an aperture 16 for permitting the needle 18 to pass therethrough during its end wise reciprocating movement for penetrating a ply or plies of fabric F with a thread for concatenation with a thread from a bobbin to form lock stitches in a manner which will be more fully described hereinafter. The mechanism for reciprocating the needle in its end wise motion is well known in the art and, therefore, only a portion of the mechanism is illustrated herein as including a needle carrier 22 and a needle bar 24 which needle bar is typically connected to a crank mechanism driven by the main shaft of the sewing machine. A feed dog mechanism generally illustrated at 26 is also disposed in an opening in the top plate 12 for cooperating with the fabric F in order to feed the same across the surface of the top plate 12 for forming continuous stitches. The feed mechanism including the feed dog 26 may also be of a well known type for feeding a fabric through a sewing machine and for purposes of the present invention only a portion thereof is illustrated as including a rockarm 28 connected to a base portion of the feed dog 26 as by having one end thereof inserted in a slot in the base portion of the feed dog 26 and the other end thereof secured to a rock shaft 30 for imparting rocking motion or to an fro motion to the feed dog.
The sewing machine illustrated herein also includes a loop taker including a cup shaped portion 32 and a cylindrical shaft portion 34 depending therefrom which is disposed within a bearing 36 fixed to a portion of the machine frame. A rotary loop taker drive member 38 is disposed in surrounding engagement with the bearing member 36 and is rotatable relative thereto. The rotary drive member 38 includes a key or tooth portion 40 extending perpendicular to the top surface of the rotary drive member and is disposed in driving engagement with a slot 42 formed in the bottom portion of the cup shaped rotary loop taker. Suitable means are provided for driving the rotary drive member such as a timing belt 44 illustrated as disposed in driving engagement with an outer surface of the rotary drive member 38. The timing drive belt may be suitably connected to a source of power such as an electric motor or the like for driving the rotary loop taker. It will be understood, however, that other means may used for driving the rotary loop taker as for example, a gear drive taken from a rotary bed shaft as is common in the sewing machine art. As is also well known in the sewing machine art, the rotary loop taker may be driven in timed relationship with the reciprocating motion of the needle 18 so that a beak portion 46 formed on the loop taker for seizing a loop of thread from the needle near or substantially near its lower most penetrating point will be in proper position for engaging the loop at the proper time.
As stated above, the rotary loop taker 32 is cup shaped and is so formed such that the rotary loop taker can carry a bobbin 20 within said cup shaped portion which is supported in a bobbin case 48. During operation of the machine, the bobbin and its bobbin case are held stationary during relative rotary movement of the rotary loop taker. In order to retain the bobbin and its bobbin case in a stationary condition during movement of the rotary loop taker, a bobbin case retainer member 50 is pivotably carried by a support plate 52 and includes a retaining portion which bears against a portion of the bobbin case for holding the same in a relatively fixed position when the retainer member is pivoted into engagement with the bobbin case. The bobbin case retainer member 50 is also provided with a pair of spaced lugs 54 for engagement with a spring retainer member 56 as illustrated in FIG. 2. In order to release the bobbin case retainer member, the spring member 56 may be lifted such that they one leg thereof will be disengaged from between the lugs 54 on the bobbin case retainer member and the bobbin case retainer member may then be pivoted away from the bobbin case 48 and out of engagement therewith in order to permit removal of the bobbin and its case. As also shown in FIG. 2, the support plate 52 is provided with appropriate apertures therein as for example for the feed dog 26, throat plate 14 and the bobbin 20 in its case 48 in order to permit these elements to properly function. Also, the support plate 52 is supported with the top plate 12 of the bed portion as by screws 58 when the mechanism is in the assembled condition.
Very briefly referring to FIGS. 5a through 5d, during penetration of the needle 18 through the fabric F with the needle thread, when the needle is substantially at its lower most position, a loop of thread is thrown out away from the needle which is seized by the beak portion 46 of the rotary loop taker 32 as shown in FIG. 5a. During further rotation of the rotary loop taker 32, the loop of thread is carried around the bobbin 20 and its case 48 and also around a bobbin thread B to a position where the loop will be cast off from the rotary loop taker and will be concatenated with the bobbin thread. During the return stroke of the needle, the needle loop will be pulled back up through the fabric to set the stitch with the bobbin thread securely locked therewith. Such stitch formation is well known in the art as lock stitch. It has been found that sometimes when forming such lockstitches, in particular during zig-zag stitching wherein the lateral position of the needle changes from penetration to penetration and more particularly when the zig-zag stitching is made with relatively wide widths, a defect in the stitching occurs which may be termed haloing. Haloing may be described as a looseness or undesirable amount of slack in the work limb of the needle loop after the stitch has been set. Of course, it is desirable to have the stitches relatively firmly set so that there is no loose or slack thread to give an even and neat appearness to the stitching and the plies of fabric will be firmly secured together.
Referring to FIG. 4, an example of what is believed to be at least one cause of the formation of haloing is illustrated therein. In the illustration of FIG. 4, the needle loop is in the position of having been cast off by the rotary loop taker and the slack therein is being taken up by the needle and takeup mechanism of the sewing machine during the return stroke of the needle. During such time, the work limb N 1 and the take up limb N 2 are disposed in a relationship such that they are in frictional engagement with one another. As the take up limb N 2 is withdrawn up through the fabric, due to the frictional engagement between the limbs N 1 and N 2 , the work limb N 1 may be dragged along with the take up limb N 2 such that a slack condition or a loop will form on the top side of the fabric F. As mentioned above, there is more likelihood of this condition occuring during zig-zag stitching wherein wide bight widths are used in that there is more thread required for the formation of such type stitches and, thus, more thread available to form a slack loop. As shown further in FIG. 4, some of the loops formed from the needle thread may have such a slack appearance and others may be relatively properly set so as to give an uneven and loose appearance to the stitching. It is the purpose of the present invention to overcome this type of defect in stitching.
In order to carry out the purpose of the invention, means are provided for physically separating the needle thread work limb and take up limbs during concatenation of the needle thread with the bobbin thread at least up until the time the thread has completed its passage around the bobbin case. Referring again to the drawings, as shown in FIGS. 2 and 3 in particular, a work limb retainer plate 60 is secured to the support plate 52 by screws 62 or the like and is provided with a work limb retainer finger member 64 at one end thereof. A finger like projection 66 is disposed in a vertically upward projecting relationship to the plate 60 and is positioned for seating within an aperture 68 and the support plate 52 and serves to help position the finger 64 for engaging a limb of the needle thread. As seen in FIG. 3, the retainer plate 60 is substantially C-shaped and when in position substantially surrounds one portion of the loop taker and is further provided with a finger like projection 69 which engages with the bobbin case retainer as illustrated in FIG. 2. It should be understood, however, that the invention is not restricted to the shape of the retainer plate 60 and said plate may take some other shape or form which will provide a proper positioning of the work limb retainer finger 64.
With further reference to FIG. 2 and FIGS. 5a and 5d, it will be seen that the plate 60 is supported with plate 52 such that the work limb retainer finger is supported so that its end will be disposed in the region of needle penetration and downstream with respect to the direction of rotary loop taker rotation. More specifically, the finger portion 64 is disposed such that substantially immediately after a loop is seized by the beak portion 46 of the rotary loop taker, it will engage the work limb N 1 of the new loop and is shaped such that the work limb N 1 will drape over the finger to an indented portion 70 thereof for retaining the work limb N 1 during the passage of the thread loop around the bobbin case 48 for concatenation with the bobbin thread B. Therefore, as seen in FIG. 5a, the work limb retainer finger is positioned for engagement with the work limb N 1 as the loop taker beak 46 is engaging the thread loop and as seen in FIG. 5b, as the beak portion continues to rotate with the rotary loop taker, the work limb N 1 is retained by the retaining finger 64 in the portion 70 thereof. In FIG. 5c, the thread loop is shown as having past substantially entirely around the bobbin case just prior to castoff of the loop from the beak 46 and there will be seen that the work limb N 1 and the take up limb N 2 are maintained in substantial separation from one another so that there is no frictional engagement therebetween. In FIG. 5d, it will be seen that the thread loop has been cast off from the beak and the loop is being taken up during the return stroke of the needle. As the needle is returning to its up position, the thread loop will be withdrawn from the work retainer finger 64 so that the loop may be properly set in the fabric to form even stitches without slack due to haloing. As seen in FIG. 5d, even at such time when the thread loop is just about to leave the work retainer finger 64, the work limb N 1 and the take up limb N 2 are still maintained in a state of substantial separation from one another. Therefore, there is little, if any, chance of the work limb being wrapped around the take up limb or in other words, the two limbs of the thread loop will have little opportunity to come into frictional engagement with one another so that as the take up limb is pulled up through the fabric it will not draw with it the work limb to bring about the effect defined herein as haloing.
It will be seen from the above detailed decription that a novel and improved mechanism is provided which is relatively simple in structure and relatively inexpensive to manufacture for preventing a defect in stitching called haloing. The retainer mechanism of the invention may be supported in a manner which has little effect on the working mechanism of the sewing machine such as the loop taker, the bobbin or the like and does not require any relatively complicated support structure or substantial modification to the support structure of the sewing machine. It will also be apparent to those skilled in the art that various changes and modifications may be made in the structure of the invention without departing from the spirit and scope thereof as defined in the appended claims.
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This disclosure relates to sewing machines and in particular to a means for reducing uneven and slack stitching due to frictional engagement between the work limb and the takeup limb of the needle thread which can cause pulling up of the work limb through the fabric between castoff of a loop from the loop taker and stitch setting. This undesirable effect is sometimes called "haloing". A work limb retainer is provided and is carried apart from the loop taker and thread carrying bobbin and is disposed for seizing the work limb of the needle thread substantially immediately after loop seizure by the loop taker, retaining of the work limb during the normal loop taker cycle, and discharging the work limb after the thread has completed its passage around the loop taker. The work limb is thereby prevented from frictionally engaging the take up limb during this cycle and thus eliminates the possibility of the take up limb pulling the work limb up to the fabric to cause a haloing effect.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a self-propelling road construction machine, particularly a road roller, according to the precharacterizing part of claim 1 , and a method for driving a road construction machine according to the precharacterizing part of claim 8 .
[0003] 2. Description of the Prior Art
[0004] A generic road construction machine is known from EP 1 573 134 A. The road roller will work e.g. behind a paver which used for the installing and pre-compacting of asphalt material. The road roller will several times run over the surfaces installed by the paver, so as to establish the final compaction and the planarity of the surface. In the process, the direction of travel will be changed several times. The portions of forward and rearward runs are normally approximately identical. To ensure safe operation of the road roller, it is required that, for the essential operating elements such as e.g. the driving direction control element (steering wheel, joystick) and the travel lever for speed selection, there exists a clear assignment to the direction of travel that is evident to the user.
[0005] From EP 1 573 134 A, it is also known to integrate the operating element for vehicle speed and steering into a rotatable driver's seat, wherein, in each rotary position of the seat, the set moving direction of the operating element will coincide with the direction of travel of the road construction machine.
[0006] It is an object of the invention, in a self-propelling road construction machine, particularly a road roller, and in a method for driving a road construction machine, to further improve the possibilities of control and thereby to increase the operational safety.
[0007] The above object is achieved by the features defined in claim 1 and in claim 8 .
SUMMARY OF THE INVENTION
[0008] The invention provides in an advantageous manner that the control device, in response to a first switching command, will automatically perform a reversing process with deceleration, seat rotation, change of the direction of travel and acceleration to the set vehicle speed in the opposite direction to the original direction of travel.
[0009] This has the advantage that it is not necessary anymore for the driver to manually coordinate the seat rotation and, during the seat rotation, the travel speed of the road construction machine, but that the seat rotation can be performed by a push of a button and is performed automatically while, at the same time, the control of the travel speed is coordinated automatically until the vehicle speed in the opposite direction has been reached. Thereby, when the direction is to be reversed, the vehicle operator is allowed to concentrate e.g. on the steering, thus improving not only the possibilities of control but also the operational safety because the driver does not need anymore to concentrate on a coordination of the seat rotation and the vehicle speed at the same time.
[0010] Preferably, it is provided that the operating element is integrated into a rotatable driver's seat.
[0011] It can be provided that, in an angular range of the seat rotation from 80° to 100°, preferably 85° to 95°, relative to the original direction of travel, the control device will reduce the vehicle speed until standstill has been reached.
[0012] Particularly, it can be provided that, upon initiation of the reversing process, up to a seat rotation of 90° relative to the original direction of travel, the control device will automatically, preferably continuously reduce the preselected vehicle speed to zero and then, with further seat rotation up to 180°, will set the vehicle speed again to the originally preselected vehicle speed in the opposite direction. In the automatically performed reversing process resulting from the switching command, the seat will start rotating while the road roller is getting slower. When the seat is passing through the 90° position relative to the original direction of travel, the travel speed is reduced to zero for reversal of the direction of travel and then will be increased again to the originally preselected travel speed. In the process, the standstill of the machine will occur at the 90° position of the seat or at least near the 90° position. When the seat is rotated into the new direction of travel, the operating element is switched to the new direction of travel.
[0013] Preferably, it is provided that, in case of a change of the position of the operating element or an application of force to the operating element during the reversing process, the control device will trigger a standstill of the machine and/or stoppage of the seat rotation.
[0014] Further, it can be provided that the control device, if the driver's seat at initiation of the reversing process has been set to a seat rotary position deviating from the initial positions of 0° and respectively 180°, will first transfer the seat rotary position into an initial position or will transfer the seat rotary position of the driver's seat, via the shortest path, to a desired seat rotary position.
[0015] When a desired travel speed of the road roller has been reached, the control device, in response to a second switching command, can transition to automatic operation in which the current control signals for the travel drive will be automatically held constant.
[0016] The driver, by way of his/her application of force on the operating element, e.g. a control lever designed in the manner of a joystick, can effect an acceleration or deceleration, wherein the direction and level of the force will be evaluated in relation to the direction of travel. When the desired speed has been reached, the driver will confirm this via a pushbutton. The machine will now run at a constant speed until an acceleration or deceleration will be initiated by application of a force on the operating element.
[0017] Preferably, it is provided that the control device will switch from automatic operation to manual operation when the level of the detected force acting on the operating element exceeds a predetermined force threshold value in a predetermined angular range of the operating lever actuation.
[0018] In case of a preselected travel speed above a predetermined speed threshold value, it can be provided that, first, a deceleration to a speed value below the speed threshold value will be initiated, then, the reversing process will be performed and, after completion of the reversing process, an acceleration will be performed again to the originally preselected travel speed beyond the speed threshold value.
[0019] It can also be provided that, at least in manual operation of the control device, sensors will detect the level and the direction of the force applied on the operating element, and that the control device, in dependence on the detected angle relative to the direction of travel and on the level of the force, will generate a control signal for acceleration, deceleration or emergency stoppage.
[0020] This has the advantage that, in manual operation, the acceleration can be controlled through application of force by the vehicle operator. This allows for a more sensitive control. Depending on the level of the force, it can be detected whether a high or low acceleration or a low deceleration, a high deceleration or even an emergency stoppage is desired.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] A full and enabling disclosure of the present invention, including the best mode thereof, enabling one of ordinary skill in the art to carry out the invention, is set forth in greater detail in the following description, including reference to the accompanying drawing in which
[0022] FIG. 1 illustrates the effects of the actuation of the operating element,
[0023] FIG. 2 is a view of the operating element,
[0024] FIG. 3 is a schematic representation of a road construction machine according to the invention comprising an operating element, and
[0025] FIG. 4 is a schematic representation of a reversing process.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0026] In FIGS. 1 and 3 , there is schematically illustrated a road roller 1 comprising two roller drums 2 , 3 , at least one of them being steerable. The roller drums 2 , 3 are coupled to each other by a chassis 4 on which a driver's cab for an operating person is arranged.
[0027] Arranged in said driver's cab is a rotatable driver's seat 5 comprising an integrated operating unit 8 for driving operation. Said operating unit 8 preferably comprises an operating lever whose function will be explained in detail in connection with FIG. 2 .
[0028] In manual operation, the driver will accelerate and resp. decelerate the travel speed preferably by application of force on the operating element 8 . When the desired travel speed has been reached, the driver can confirm this via a pushbutton. The road roller will then travel at a constant speed until, by application of force on the operating element 8 , an acceleration or deceleration will be triggered.
[0029] FIG. 2 illustrates the operating element 8 with its constructional components and its operating functions. The operating element 8 comprises switching means 10 for initiating a reversing process both in manual and in automatic travel operation, switching means 12 for rear-wheel steering and respectively crab steering, switching means 14 for switch-on and switch-off of vibration, and switching means 16 for unlocking the immobilizer. It is self-evident that the mentioned operating functions do not necessarily have to be arranged on operating element 8 but can also be arranged within reach of the driver, e.g. on the seat.
[0030] FIG. 4 illustrates the reversing process which can be actuated with the aid of a switching device 10 . The schematic diagram-like representation shows the level of the speed and the direction of travel in dependence on the seat position. When adjusted to the original direction of travel, the driver's seat 5 shall be in a seat rotary angle of 0°. During the reversing process, the driver's seat will move from this 0° position and respectively from its present state beyond a seat position of 90°, i.e. transversely relative to the original direction of travel, into a seat rotary position of 180° extending in the direction opposite to the original direction of travel. As soon as the reversing process is initiated by actuation of switching device 10 , the rotation of the seat will start, e.g. at 10°, while at the same time the travel speed is being reduced, preferably continuously, until a seat rotary position of about 90° has been reached. In case that, at initiation of the reversing process, the travel speed should happen to be above a predetermined speed threshold value, the road roller will first be decelerated to a speed below the speed threshold value and the seat rotation will be initiated only thereafter with a further deceleration. In the seat rotary position of about 90°, the travel speed has to be reduced to zero for switching to the opposite direction and, subsequently, during further rotation of the seat, it will increase again to the speed threshold value which will be reached at the latest at a seat rotary position of 180° relative to the original direction of travel. Thereafter, the road roller can be accelerated again to a predetermined travel speed. It is self-evident that the reversal of the direction of travel does not necessarily have to be performed in a seat rotary position of exactly 90° but can also be performed e.g. in an angular range of 80-100°, preferably 80-95°. Further, it could also be provided that the respective travel speeds can be preselected to be different in the forward and respectively rearward directions.
[0031] Possible initial states of the operating element 8 at initiation of the reversing process are either a neutral position of operating element 8 or a deflected position of operating element 8 with respect to the travel speed.
[0032] The driver's seat 5 can be arranged in the direction of travel (seat rotary position of 0°) or in a rotated position relative to the direction of travel.
[0033] At initiation of the seat rotation, the driver's seat 5 can have a seat rotary position deliberately preselected by the driver. If the driver's seat 5 is not arranged in the middle position, it is possible that, at initiation of the reversing process, there is first performed an automatic rotation of the seat to the 0° position. There can also occur the case that the operating person has laterally shifted the seat from a middle position. If the reversing process is initiated in such a position, the seat will first be transferred into the middle position, and then the reversing process will be initiated.
[0034] During the reversing process in the state of automatic operation, the machine will control the travel speed automatically as long as the operating element 8 is not actuated. When, after initiation of the reversing process, the operating element 8 is actuated, the reversing process will be discontinued so that, for resuming the reversing process, the switching device 10 has to be actuated again.
[0035] Depending on the initial rotary position of the seat, the control can choose the shortest way for rotation of the seat.
[0036] Evaluation of the control force exerted on operating element 8 is performed in two dimensions with the aid of force sensors 28 , 29 as shown in an exemplary manner in FIG. 2 .
[0037] The two-dimensional evaluation of the control force makes it possible to detect the level and the direction of the force applied on the operating element 8 , wherein the control device 30 will generate a control signal for acceleration, deceleration or an emergency stop in dependence on the detected angle relative to the direction of travel and on the level of the force.
[0038] The direction of the force will always be evaluated in parallel to the direction of travel. Also with a rotatable driver's seat, it is possible to always evaluate the direction of the force in parallel to the direction of travel. For this purpose, there is merely required angular information with respect to the seat rotary position relative the steering axis of the vehicle.
[0039] In FIG. 3 , it is schematically illustrated in which manner the detected force is evaluated in the direction of travel. The schematic illustration in FIG. 3 represents the angle- and force-dependent evaluation of the force exerted on the operating element 8 . When viewed in the forward direction, there are first provided e.g. two force threshold values 40 , 42 which, when exceeded, will first entail a small acceleration in a first angular range 44 and then a higher acceleration in an angular range 46 which preferably is narrower than the first angular range 44 . The small acceleration is marked by a “+” in the angular range 44 and the high is marked by a “++” in the angular range 46 . It is self-evident that the angular ranges can also have the same size.
[0040] Said angular ranges are angularly limited wherein, preferably, for the angular range 44 , a larger angular segment can be set for evaluation of the control force than for the second angular range 46 . The second angular range 46 for high acceleration can substantially comprise an angular range smaller than ±45° relative to the direction of travel, preferably ±35°, thus covering a total angular range of 50° to 80°.
[0041] The angular range 44 for smaller acceleration comprises a total angular range of preferably more than 90°, e.g. 80° to 150°.
[0042] When the control force is exerted in a direction which is outside the set force threshold value 40 in the narrower angular range 46 , change to a higher acceleration will be performed.
[0043] If the evaluation of the force exerted on operating element 8 has the result that this force falls below the first force threshold value 40 , a small deceleration will be set. In FIG. 1 , the field with the small deceleration in the entire angular range 44 , 48 is marked by “−”.
[0044] In the remaining angular range 48 outside the first angular range 44 , a small deceleration is set as long as a third force threshold value 54 is not exceeded. When this value is exceeded, a large deceleration “−−” will be set.
[0045] The force threshold values 42 and 54 can have the same amounts.
[0046] In case that, in the remaining angular range 48 outside the first angular range 44 , there is exceeded a fourth force threshold value 58 , an emergency stop “−−−” will be triggered.
[0047] In automatic operation, it can provided that, in the first angular range 44 , that forces acting on operating element 8 which are above a set force threshold value 52 will have the effect of a forced switchover from automatic operation to manual operation.
[0048] Although the invention has been described and illustrated with reference to specific illustrative embodiments thereof, it is not intended that the invention be limited to those illustrative embodiments. Those skilled in the art will recognize that variations and modifications can be made without departing from the true scope of the invention as defined by the claims that follow. It is therefore intended to include within the invention all such variations and modifications as fall within the scope of the appended claims and equivalents thereof.
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In a self-propelling road construction machine, particularly a road roller ( 1 ), comprising a travel drive, a steering device, a control device ( 30 ) for the travel drive and the steering device, and a driver's seat ( 5 ) rotatable by at least 180° and including an integrated operating element ( 8 ) for the vehicle speed, with the operating element ( 8 ) generating the control signals for the travel drive in dependence on the direction of the control movement of the operating element ( 8 ) or the direction of force application on the operating element ( 8 ), it is provided that, in response to a first switching command, the control device ( 30 ) will automatically perform a reversing process comprising deceleration, seat rotation, change of direction of travel, and acceleration to the set vehicle speed in opposite direction to the original direction of travel.
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BACKGROUND OF THE INVENTION
The present invention concerns a wire locater for use in electrical terminal crimping apparatus of the type in which an electric terminal of generally U-shaped transverse cross section is positioned upon a stationary anvil, an electric conductor is located within the U-shaped terminal, and a crimping die cooperable with the anvil is driven downwardly to fold the upstanding leg portions of the U-shaped portion of the terminal tightly around the conductor to mechanically crimp the terminal into assembled relationship on the end of the conductor. The wire locater of the present invention, while adaptable to other crimping apparatus, is especially designed for use in a crimping apparatus such as that disclosed in my co-pending application Ser. No. 06/690,256, filed Jan. 10, 1985, now U.S. Pat. No. 4,598,570.
In the apparatus disclosed in my aforementioned application, electric terminals to be crimped are fed in step-by-step movement to the apparatus integrally attached at one end to an elongate carrier strip, each step of movement of the carrier strip advancing a terminal into position upon a stationary anvil of the crimping apparatus. The anvil is formed with a flat front surface lying in a general vertical plane and a vertically movable cutter element slides in face-to-face engagement with the front surface of the anvil. The face of the cutter engaged with the anvil is formed with a horizontal slot which slidably receives the carrier strip to properly locate the terminal relative to the anvil and, in a normally maintained rest position, to guide the terminal onto the upper surface of the anvil. A vertically movable die assembly is mounted above the anvil and a terminal is advanced to the anvil by driving the carrier strip forwardly while the die assembly is in a raised position. When the terminal is located on the anvil, a wire is moved into alignment with the terminal and the die assembly is driven downwardly to perform the crimping operation. During this downward movement of the die assembly, the die assembly engages the cutter and drives the cutter downwardly. The carrier strip is trapped within the horizontal slot in the cutter, and upon downward movement of the cutter the terminal on the anvil is sheared from the carrier strip along the plane of engagement between the cutter and the vertical front face of the anvil. The die assembly is then raised and the cycle is repeated.
In order to produce a satisfactory mechanical and electrical connection between the wire and the terminal, the wire end which is to be crimped to the terminal must be moved into vertical alignment with the U-shaped portion of the terminal so that the wire is centered between the opposed legs of the U-shaped section immediately prior to the crimping of the legs onto the wire. Various wire locating devices for performing this function are known in the prior art. In general, many of the prior art devices have been found satisfactory for use with larger wire sizes where the wire and its insulation are reasonably rigid. However, the trend toward miniaturization of electric circuitry and circuit elements has resulted in the usage of increasingly smaller terminals and relatively small or fine wires. The reduction in size of the terminal itself increases the degree of precision required to accurately align the wire and terminal, while at the same time the finer wires employed with the smaller terminals are very flexible and easily bent.
With the smaller terminals, feeding of the terminals by means of a carrier strip as described above is almost the universal practice and usage of the carrier strip feeding method requires that the terminal be sheared from the carrier strip as it is crimped upon the wire. Because feeding the wire into position with respect to the terminal finds the wire passing across the top of the cutter, prior art wire locaters have been located at the side of the cutter remote from the terminal. Because a portion of the vertically movable die assembly conventionally engages the top of the cutter to drive it downwardly in shearing movement, apparatus for locating the wire relative to the terminal must be clear of the path of movement of the die assembly and thus, of necessity, spaced some distance (one-half inch or more) from the terminal. Where the wire is sufficiently rigid, this spacing does not pose any great problem; but when extremely fine wire is used, the end of the wire beyond the locater may be bent within this spacing to a degree where it may entirely miss the terminal.
The present invention is directed to the provision of a wire locater assembly for use in crimping apparatus of the type referred to above in which the wire may be gripped by the locater closely adjacent the front vertical surface of the anvil so that the only portion of the wire not supported by the locater is that which vertically overlies the terminal.
SUMMARY OF THE INVENTION
Conventional elements of a crimping die apparatus with which the present invention is employed include a stationary anvil having a flat front surface extending parallel to the direction in which the terminal carrier strip is fed to the apparatus. A vertically movable cutter is disposed in sliding face-to-face relationship with the front surface of the anvil and is normally biased to a ready position in which the carrier strip is received within the cutter slot to support the terminals on the strip at an elevation such that the terminal to be crimped rests upon the top of the stationary anvil. Downward movement of the cutter shears the strip from a terminal on the anvil as the cutter is slid vertically downwardly along the front surface of the anvil.
Mounted above the anvil is a vertically movable die assembly which carries crimping dies vertically aligned with the anvil. The dies are movable from a ready position spaced vertically above the anvil to a crimping position wherein the dies crimp a terminal supported upon the anvil about a conductor previously positioned within the terminal.
In accordance with the present invention, a locater finger actuator member is fixedly mounted on the die assembly immediately in front of the die generally in vertical alignment with the cutter. A stationary bracket is spaced in front of the actuator member and carries a vertically movable slide block which is normally spring biased upwardly relative to the bracket to a rest position determined by the engagement between a pin on the slide block and the top of a vertical slot in the bracket. On the face of the slide block facing the finger actuator member, a pair of opposed wire engaging fingers are mounted for pivotal movement about spaced horizontal axes. Actuator pins projecting forwardly from the stationary actuator member are engageable with the fingers to pivot the fingers between an open position wherein a wire may be advanced between the opened fingers and a closed position in which the fingers clampingly grip a wire between the two fingers. The lower wire gripping portion of the fingers is offset from the pivotally mounted upper portion of each finger to project beneath the actuator member to be vertically aligned with the top of the cutter on the stationary anvil when the fingers are in their closed position. Downward movement of the vertically movable die assembly causes the actuator member to close the fingers to grip the wire between the fingers and to drive the closed fingers downwardly into engagement with the top of the cutter, this downward movement of the fingers being resisted by the upwardly spring biased slide block on the bracket. Downward movement of the fingers is employed to actuate the cutter as the dies on the die assembly move into operative relationship with a terminal located on the anvil, the downwardly moving fingers carrying the wire into position upon the terminal immediately prior to the crimping of the terminal.
The lower portions of the fingers move in a path closely adjacent the front surface of the anvil; hence, the wire is held at a location substantially at the front end of the terminal to insure an accurate location of the wire relative to the terminal.
Other objects and features of the invention will become apparent by reference to the following specification and to the drawings.
IN THE DRAWINGS
FIG. 1 is a side elevational view of a crimping die assembly including a wire locater embodying the present invention, with certain parts omitted;
FIG. 2 is a top plan view of the apparatus of FIG. 1, again with certain parts omitted;
FIG. 3 is an exploded perspective view showing the individual structural elements of the wire locater assembly of FIG. 1;
FIG. 4 is a detailed view, with certain parts omitted, taken approximately on the line 4--4 of FIG. 1, showing the fingers of the wire locater in their open position;
FIG. 5 is a view similar to FIG. 4, showing the wire locater fingers in their closed position;
FIG. 6 is a detailed cross-sectional view taken on the line 6--6 of FIG. 2, showing the wire locater and front portion of the die assembly with the die assembly in the elevated position of FIG. 1;
FIG. 6A is a partial detailed cross-sectional view taken on the line 6A--6A of FIG. 6;
FIG. 7 is a detailed cross-sectional view similar to FIG. 6 but showing the die assembly in its lowered crimping position;
FIG. 7A is a partial detailed cross-sectional view taken on the line 7A--7A of FIG. 7;
FIG. 8 is an inner side view of one of the locater fingers;
FIG. 9 is a rear view of the finger of FIG. 8;
FIG. 10 is an outer side view of the finger of FIG. 8; and
FIG. 11 is a front view of the finger of FIG. 8.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring first to FIGS. 1 and 2, the wire locater assembly of the present invention designated generally 10 is disclosed mounted upon a die apparatus designated generally 12 of the type disclosed in my aforementioned application Ser. No. 06/690,256. Die apparatus 12 includes a stationary anvil-cutter assembly designated generally 14 and a vertically movable die assembly 16 driven in vertical recriprocation as by a fluid motor schematically illustrated at 18. Die assembly 16 is guided in vertical movement by suitable means, not shown, and the cylinder of motor 18 is mounted upon a stationary frame member, again not shown.
Anvil assembly 14 includes a pair of plate-like anvils 20, 22 which, as best seen FIGS. 6A and 7A, are formed at their top with terminal receiving seats as at 24 (FIGS. 6A, 7A) which underlie and support an electric terminal T during the crimping operation. Two anvils 20 and 22 are shown because typically one portion of the terminal will be crimped about the stripped end portion 26 of a wire W while another portion of the terminal will be crimped about an insulated portion of the wire 28 closely adjacent the stripped end 26. The supporting seats 24 of anvils 20, 22 will be shaped accordingly.
The front surface 30 of the front anvil 20 is a flat, vertically disposed surface and, as best seen in FIGS. 6 and 7, a cutter 32 is mounted in vertical sliding face-to-face engagement with front surface 30. A spring 34 normally biases cutter 32 to an elevated position in which a slot 36 extending horizontally across the rear face of the cutter is located at the same elevation as seats 24 of anvils 20 and 22.
As best seen in FIG. 2, the terminals T are fed into the die apparatus by means of a carrier strip C to which the terminals are attached at uniformly spaced intervals. Means for feeding carrier strips C to the die apparatus are well known in the art. The carrier strip C is slidably guided by the slot 36 in cutter 32 when the cutter is at its normal elevated position shown in FIG. 1 and the carrier strip feed means, not shown, advances the carrier strip in step-by-step movement synchronized with the operation of the die apparatus to advance the individual terminals T onto anvils 20 and 22.
A pair of crimping dies 38, 40 are fixedly mounted on the vertically movable die carrier 16 in respective vertical alignment with anvils 20 and 22. As best seen in FIGS. 6A and 7A, the dies 38, 40 are movable by the die carrier 16 between an elevated ready position shown in FIG. 6A and a lowered crimping position shown in FIG. 7A and are so conformed as to crimp the upwardly projecting legs of the U-shaped cross-sectional portion of terminal T around the wire W as shown in FIG. 7A. A holddown-stripper finger designated generally 42 may be carried by die carrier 16 to assist in steadying the terminal during the crimping operation and stripping the crimped terminal from dies 38, 40 as the die are elevated back to their ready position subsequent to the crimping of the terminal.
The structure described thus far is disclosed and described in greater detail in my aforementioned co-pending application Ser. No. 06/690,256 and does not, per se, constitute the present invention. The present invention is concerned with details of the apparatus 10 for locating the wire W in vertical alignment with a terminal upon the anvil to accurately position the wire relative to the terminal immediately prior to the crimping operation.
The structural components of wire locater apparatus 10 are shown, per se, in the exploded perspective view of FIG. 3.
The wire locater apparatus 10, referring now particularly to FIGS. 3, 6 and 7, includes an actuator member 44 which, as best seen in FIGS. 6 and 7, is fixedly mounted at the front end of die carrier 16 as by a bolt 46 which is also employed to mount dies 38 and 40 upon carrier 16. Actuator 44 is thus fixedly secured to die carrier 16 and moves upwardly and downwardly with the carrier during the crimping and return stroke of dies 38 and 40. As best seen in FIG. 3, actuator 44 is formed with a pair of spaced, opposed, downwardly projecting legs 48 which project downwardly from a horizontal, centrally located lower edge surface 50 on the actuator. Near the lower end of each of legs 48, actuating lugs 52 of generally triangular cross section project forwardly from the front surface of actuator 44.
A mounting bracket assembly designated generally 54 (FIGS. 1 and 2) includes a pedestal member 56 and a slide block carrying arm 58 which is fixedly secured, as by a bolt 61, to project from pedestal 56 laterally of the die apparatus in forwardly spaced relationship to actuator member 44. Pedestal 56 is fixedly mounted upon the machine frame by clamping the foot portion 60 of pedestal 56 upon a guide pin 62 (FIGS. 1 and 2) mounted at a fixed location on the frame. Pedestal 56 is slotted as at 64, with the slot intersecting a guide pin receiving bore 66 through foot 60, and a clamping screw 68 which passes through the slot is tightened into a threaded bore 70 to firmly clamp the pedestal to pin 62.
Referring now particularly to FIG. 3, a vertically extending T slot 72 is formed in that face of arm 58 opposed to actuator member 44 to slidably receive a vertical plate portion 74 of a slide block designated generally 76. At the upper end of vertical plate portion 74 of slide block 76, an integral horizontal web 78 projects into overlying relationship with arm 58 when the slide block is received within slot 72 in the arm. A pair of compression springs 80 have their lower ends seated within bores 82 in arm 58 and engage the underside of horizontal web 78 to continuously bias slide block 76 upwardly relative to arm 58. The upper end limit of movement of slide block 76 relative to arm 58 is determined by the engagement of a pin 84, fixedly secured to the lower end of vertical leg portion 74 of the slide block, with the upper end of a slot 86 extending upwardly from the lower surface of arm 58.
A pair of pivot pins 88 project horizontally from the side of vertical plate portion 74 of slide block 76 facing actuator 44. Pivot pins 88 pivotally support a pair of wire locater fingers designated generally 90a and 90b which are identical with each other, with the exception of being right and left-handed or mirror images of each other.
In FIG. 3, the front direction is indicated by arrow, and FIGS. 8, 9, 10 and 11 show the four sides of finger 90a.
Referring now to FIGS. 8 through 11, finger 90a is formed with a bore 92 which rotatively receives its associated pivot pin 88. The finger is formed with a flat front surface 94 which slidably engages the flat opposed surface of slide block 76. The finger is formed with upper 96 and lower 98 arm portions, each of which extends generally radially from the axis of bore 92 as best seen in FIGS. 9 and 11. As best seen in FIGS. 4 and 5, when the fingers 90a and 90b are mounted on pivot pins 88 of slide block 76, the fingers are in an opposed relationship to each other such that opposed edges of the respective fingers contact each other along a curved edge section 100 when the fingers are in the open position of FIG. 4, the curved edge section 100 being concentric about the axis of bore 92. When the fingers are in the closed position of FIG. 5, the fingers contact each other along a section 102 of the edge of the lower arm which extends downwardly in tangential relationship to curved section 100 to a downwardly facing shoulder 104 on lower arm 98. That portion of the edge section 106 which extends downwardly from shoulder 104 is offset inwardly of the finger from edge section 102 by a distance which is equal to one-half of the diameter of the wire which is to be gripped by the fingers, as in FIG. 5. Returning now to FIGS. 8 through 11, finger 90a includes a rearwardly offset or thickened gripping portion 108 having a flat upper surface 110, and a downwardly projecting extension 112. A slot 114 extends radially of bore 92 at the included angle side of the juncture of upper and lower arms 96 and 98.
The foregoing description of the finger 90a is equally applicable to finger 90b with the exception that finger 90b is constructed as a mirror image of finger 90a.
Referring now to FIGS. 4 and 5, the lugs 52 on actuator 44 are employed to shift the fingers between the open position of FIG. 4 and the closed position of FIG. 5 in accordance with the vertical position of actuator 44 relative to slide block 76. When die carrier 16 is in its elevated ready position (FIGS. 1 and 6) slide block 76 is in its elevated position relative to arm 58. At this time, the lugs 52, as best seen in FIG. 4, are at substantially the same elevation as pivot pins 88 on slide block 76 and are seated within the respective slots 114 of the fingers. This positions the fingers in the open position as shown in FIG. 4. With the fingers in their opened position, a wire W may be advanced between the fingers, moving in a direction from left to right as viewed in FIG. 1 until the wire is appropriately located in the front-to-rear direction relative to terminal T.
As the die carrier 16 begins to move downwardly in the initial portion of its crimping stroke, actuator 44 must move with the die carrier and the lugs 52 on the die carrier thus begin to move downwardly below the axes of pivot pins 88 as viewed in FIGS. 4 and 5. The engagement between the lowering lugs 52 and the bottom of slots 114 as viewed in FIG. 1 causes the respective fingers to pivot inwardly from the position shown in FIG. 4 toward that shown in FIG. 5. Eventually, the fingers are pivoted to the position shown in FIG. 5, at which time the lugs 52 pass out of their respective slots 114 to slide downwardly along the outer side of the lower arms of the respective fingers 90a and 90b. In FIG. 5, the lugs 52 are shown just after they have been moved downwardly out of slots 114, this action occurring at the beginning of the downward stroke of die carrier 16. Fingers 90a and 90b are now in their closed position and the wire W is gripped between the opposed lower edge sections 106 of the legs. Movement of the fingers to their closed position shown in FIG. 5 has also swung the extensions 112, at the lower ends of the fingers, into overlying relationship with the upper end of cutter 32. The wire at this time is lightly gripped between the opposed lower arms of fingers 90a and 90b and is, at this particular time, still spaced above the terminal T located on the anvil.
Further downward movement of die carrier 16 moves actuator 44 downwardly until the lower edge surface 50 engages the upper surfaces 110 of the rearwardly offset lower portions of the respective fingers.
Subsequent to the engagement between surface 50 on actuator 44 and surfaces 110 of the fingers, further downward movement of die carrier 16 and actuator 44 drives the fingers and slide block 76 downwardly relative to carrier arm 58 against the action of spring 80. This downward movement of the fingers in turn drives extensions 112 downwardly, driving cutter 32 downwardly to shear the terminal T from its carrier strip C. The downward stroke is continued until the terminal is crimped, the parts being in the position shown in FIG. 7 at this time. Upon conclusion of the crimping, die carrier 16 is elevated and returned to its original rest position, the lugs 52 on the elevating actuator 44 sliding upwardly along the outer sides of the lower arms of the fingers until they again enter slots 114 and moving upwardly until they engage the top portions of the respective slots 114 shortly prior to reaching the upper rest position to swing the fingers back to the open position shown in FIG. 4.
While one embodiment of the invention has been described in detail, it will be apparent to those skilled in the art that the disclosed embodiment may be modified. Therefore, the foregoing description is to be considered exemplary rather than limiting, and the true scope of the invention is that defined in the following claims.
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A crimping die apparatus for crimping an electric terminal upon the end of an electrical conductor and severing the terminal from a carrier strip during the crimping operation by means of a cutter driven in its severing action by crimping action of the die is provided with conductor or wire locating fingers opened and closed by motion of the die. The fingers are operable to grip the conductor closely adjacent the plane of action of the cutter and actuation of the cutter is accomplished by the fingers as the fingers align the conductor with the terminal which is to be crimped about the conductor.
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FIELD OF THE INVENTION
This invention generally relates to electrogaphic printing apparatus and is more particularly directed to such printing apparatus for effecting charge deposition including apparatus for maintaining the desired spacing to effect proper controlled charge deposition.
BACKGROUND OF THE INVENTION
The general apparatus within which the present invention is utilized is believed to be well known in the prior art to provide a dielectric belt arranged and supported in an endless tensioned loop, the belt being provided with an electrically conductive coating underneath the dielectric. The belt is continuously cleaned and electrically conditioned for re-use as it approaches a print head which modifies the charge thereon to form a latent image which is subsequently developed with a toner; the toned image is transferred to paper and fixed such as by application of heat at a fusing station.
In the prior art, Paschen ionization has been employed in electrographic printers and plotters utilizing treated paper wherein the paper is rendered conductive through, for example, the introduction of salts; the surface receiving the electrostatic charge is coated with a thin (few micron) layer of dielectric material. Additionally off-set systems have been reduced to practice employing conductive drums and belt structures which are dielelctrically coated.
The prior art paper systems have had limited application due to the cost of treated paper. The drum systems require precision alignment mechanisms to establish and maintain the necessary Paschen spacing over the full print width. Belt structures have been devised which employ textured surfaces to establish Paschen spacing but these surfaces are subject to wear and thus short life. Other spacing techniques have been deviced which employ abrupt discontinuities near the imaging region; these techniques suffer from contamination and abrasive wear.
The transfer of charge across an air gap has been described by Friedrich Paschen. In his experiments, Paschen discovered that the voltage necessary to initiate ionization was defined by a function that related the product of gas pressure and spacing of electrodes to voltage and determine that, at constant pressure, the voltage reduces to a function of distance only. Experiments have been conducted to establish the de-ionization potential and it is reported that ionization appears to extinquish at a level equal to or perhaps 20 volts below the Paschen function.
Clearly it is established in the prior art that air gap spacing is an exceedingly important consideration in electrographic printing.
OBJECTS OF THE INVENTION
It is a principal object of this invention to provide improved appratus to establish the desired spacing between a charge source or electrode and a charge carrier or dielectric with ground plane in apparatus which provides for charge deposition in connection with electrographic printing apparatus.
It is a further object of this invention to provide simplified support structure for the flexible dielectric belt of charge deposition electrographic printers whereby the desired spacing between the charge source and the dielectric is maintained.
It is a still further object of the invention to provide an improved print head to effect charge deposition on a dielectric member.
It is an additional object of the invention to provide improved electrographic printing apparatus of the type described having improved print head cleaning.
Other objects will be in part obvious and in part pointed out in more detail hereinafter.
A better understanding of the objects, advantages, features, properties and relations of the invention will be obtained from the following detailed description and accompanying drawings which set forth certain illustrative embodiments and are indicative of the various ways in which the principles of the invention are employed.
SUMMARY OF THE INVENTION
The present invention, in its simpliest form, provides a charge transfer endless-loop dielectric belt having an unsupported portion thereof disposed opposite the electrodes of conductive members of the print head. The unsupported portion results from careful selection of belt parameters, belt engagement with the print head in regions adjacent to the electrodes and provides critical spacing between the conductive members and the dielectric belt to effect controlled charge deposition from those conductive members through the air gap to the charge carrying dielectric belt. Apparatus for cleaning the conductive members is also provided.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 schematically illustrates a prior art electrostatic charge transfer drive;
FIG. 2 schematically illustrates a prior art dielectric belt support;
FIG. 3 also illustrates prior art fundamental considerations in belt support;
FIG. 4 is a schematic illustration of a cross section of preferred embodiment of the print head of this invention;
FIG. 5 is a view, similar to FIG. 4, showing use of snubbers;
FIG. 6 is a schematic view of the typical electrode construction;
FIG. 7 is a partial cross-section view of the print head;
FIG. 8 is a partial cross section view of the apparatus of FIG. 4 with head cleaning apparatus; and
FIG. 9 is a fragmentary view of a portion of the apparatus of FIG. 8.
DETAILED DESCRIPTION OF THE INVENTION
As seen in the prior art of FIG. 1, electric charge transport across air gap 10 between conductive pin 11 (mounted in insulating support 17) and moving dielectric 12 having a conductive ground plane layer 13 requires precise control of the thickness of dielectric 12, dielectric constant of the material, conductive element to dielectric surface potential difference as determined by voltage source 15 and spacing "S" between conductive pin or element and the dielectric surface. It is also to be recognized that as a point on the dielectric surface enters the region of the conductive element because of movement of the dielectric in the direction of the arrow, a large range of distances (S 1 and S 2 ) from the electrode 11 are encountered. The minimum distance is achieved along a line normal to the belt plane of tangency and passing through the conductive element surface. Analysis indicates that the spacing must reach a minimum of 0.4 mils (for a dielectric thickness of 0.25 mils and a dielectric constant of 3.0) in order to achieve maximum controlled charging of the dielectric. Larger distances will fail to achieve this charging, whereas conduction resulting in high charge transfer will occur under direct contact (pressure). At distances of 0 to 0.15 mils the conduction is erratic due to high field emission effects coupled with insufficient gap to support Townsend multiplication. Achieving a spacing of less than 0.4 mils, but greater than 0.15 mils, is a purpose of this invention.
Prior art devices have employed a textured dielectric surface to provide spacing by virtue of surface anomolies of the texture that are of the order of the desired spacing. In addition, it is known (see FIG. 2) to use rollers 20 act as a surface reference to position dielectric surface 21 relative to electrodes 22.
Textured surface spacing has been used successfully for direct printing on treated paper, however, in offset printing where the surface is reused, the surface texture is erroded resulting in a short surface life and, therefore, frequent replacement. Roller spacing has been employed experimentally, however, the precision control necessary to achieve the small dimensions dictated by the charge transfer physics is such that practical configurations have not been achieved.
FIG. 3 also illustrates a basic prior art structure wherein the supports 28 and 29 of insulating support 30 are raised the desired spacing distance S above the conductive element 31. Under dynamic conditions of high speed printing wherein dielectric 32 and conductive layer 33 are moving past the conductive element 31 at high speeds, it has been found that the spacing S will vary in an unacceptable manner due to the lack of a suitable holding force between belt 32 and supports of 28 and 29 as well as other considerations.
The present invention provides a spacing technique wherein a smooth, flexible dielectric surface is unsupported in the region of the electrodes or conductive element forming a part of an arcuate print head, the spacing being achieved by the formation of support surfaces that are interrupted in the region of the conductor together with careful construction of the flexible dielectric belt that provides the charge receiving surface.
FIG. 4 illustrates a preferred form of the invention wherein a generally cylindrical support surface 40 is provided for the flexible dielectric belt 41, support surface 40 having a essentially flattened region 42 provided in the region of and adjacent to the conductive element 44. Belt 41 is provided with a conductive coating member 43 and a reinforcing member 45 (of suitable material such as Mylar Plastic) and is suitably driven and very nearly conforms to the generally cylindrical support surfaces 46 and 47 (having common centers) except for the desired space S in the region of element 44. The spacing S is geometrically predictable and deviates from simple geometry when the belt 41 is under tension T as a function of that tension, the cylindrical radius and bending modulus of the belt.
It is to be particularly noted that the tensioned belt which consists of elements 41, 42 and 43 is formed of a material that has a sufficiently high bending modulus to ensure formation of the desired gap S and to preclude substantial conformity of belt 40 in print head area 42 so as to permit the belt 40 and the electrode 44 to touch; by the same token, the bending modulus must be low enough to permit the needed belt deflection to generally follow the cylindrical surface 40 under tension forces. It is also believed quite important that belt 40 shall have a smooth surface engaging the support surface 40 and that there are no abrupt surface discontinuities on print head support surface 40 to effect undue belt wear, accumulate foreign matter or to modify the desired spacing or electric characteristics. Clearly it is desirable to use materials for the belt and support surfaces to minimize unwanted static charging of the belt, which materials will also provide good release surface characteristics for avoiding unwanted accumulation of foreign matter which adversely affects the desired charging characteristics.
It has been found that dielectric belts under tension are subject to distortion resulting in "waves" appearing in the belt and such can be of sufficient amplitude to create an intolerable spacing error. It has been found that running a belt over a cylindrical guide member tends to inhibit wave formation. Additionally FIG. 5, which describes apparatus substantially identical to FIG. 4, schematically discloses a frame 60, suitably supported, to which snubbers 62 and 63 are secured. Snubbers 62 and 63 are formed from a resilient material and provided with a low-friction felt nap coating 65 which engages the foil coating of belt 67; such a structure has been found to be an acceptable technique for controlling such waves so as to maintain the desired spacing S between electrode 68 and dielectric belt 67.
Spacing variations due to electrostatic forces resulting from conductive element voltage variations are also effectively eliminated by proper snubber selection.
A likely form of construction of the print head of this invention is shown in FIGS. 6 and 7. In FIG. 6, wherein an end view of the electrode assembly is shown, it is seen that the assembly includes a pair of printed circuit boards 71 and 72 are utilized, each board having an insulating substrate 74 supporting a plurality of individual conductive electrodes 76 as desired. The electrode pattern is such that the electrodes on board 7 are off-set from those on board 72. Upon assembly, an insulating separator 78 being disposed between the boards (and conductors) with an expoxy cement 79 substantially filling any void or space.
FIG. 7 shows the dielectric member or belt 80 in dotted lines to show the cooperation with the print head generally designated 82, which print head is substantially as shown in the preceeding FIG. 4. FIG. 7 is a cross-section view showing the electrode assembly of FIG. 6 sandwiched between and supported by two contoured belt support elements 84 and 85, which elements are configured as previously described to provide the desired belt spacing S from the ends of electrodes 76. Elements 84 and 85 are preferably formed of laminated fiberglass and epoxy to provide suitable strength and electrical insulation and are thereafter lapped and polished to provide the desired support radius and flattened area.
A suitable connector 88 establishes electrical connection between the electrodes through cable 89 to drive circuit 90.
Not only does use of the present invention permit facile establishment of the desired spacing of the dielectric belt from electrodes, it also enables the facile cleaning of the electrodes to remove foreign matter associated with dielectric charge transfer printers wherein the belt is constantly reused and toner particles tend to accumulate. Turning next to FIG. 8 wherein the invention of FIG. 4 is partially illustrated but without electronics, conductive belt backing, etc., it is seen that cylindrical support 90 provides the desired cylindrical belt support surface 91 and 92 for dielectric belt 93, which belt is under tension and suitably driven in the direction of arrow 94. Tension forces belt thickness, etc. are selected as before, with particular attention being given to the bending modulus so as to establish the desired belt/electrode gap 96. The region 97 in the area of the electrodes 98 is a discontinuity in cylindrical support 90 but that discontinuity can be of any desired configuration so long as belt support surfaces are smooth, the belt is smooth and the desired gap 96 is provided and maintained. With all conditions and parameters achieved the cleaning apparatus generally designated 99 is effectively utilized. A fairly flexible cleaning member 100 is mounted on pivoted arm 101, the arm being biased to a non-use position by spring 102 and movable by solenoid 103 to insert cleaning member 100 beneath moving belt 94 and support surface 92. Movement of the cleaning member 100 into the region of the support area 92 thereafter to area 97 and support surface 91 is facilitated by movement of belt 93 which, in effect, drags the cleaning member along. Typically, cleaning member 100 is a soft, compressible fibrous material such as paper and its movement into the area to be cleaned is facilitated as best seen in FIG. 9, where like numbers are used for the like members and elements of FIG. 8.
Fibrous paper cleaning element has a typical thickness of 2 to 3 mils. Gap 96 (FIG. 8) is preferably in the range of 0.25 mils. Thus, the soft fibrous material fills the gap area 96, (and may be compressed) to the point of actually deflecting belt 93 because of its thickness as it moves across the support surfaces.
Upon energization of solenoid 103, the cleaning paper is withdrawn to further clean the support surfaces, flattened area and pins; however, without the proper modulus of bending for belt 93, such cleaning action would not be possible. Such cleaning clearly must be conducted in a non-print portion of the cycle of operation.
As will be apparent to persons skilled in the art, various modifications, adaptations and variations of the foregoing specific disclosure can be made without departing from the teachings of this invention.
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In electrographic printing apparatus, a charge transfer endless-loop dielectric belt including a conductive member to effect a ground plant is supported to tension with an unsupported portion thereof disposed opposite the electrodes of the print head. The unsupported portion results from belt engagement with the printhead in regions adjacent to the electrodes to provide the desired electrode/dielectric belt spacing.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a water-soluble pressure-sensitive adhesive composition and to a method for producing it. The present invention also relates to a pressure-sensitive adhesive tape with a water-soluble pressure-sensitive adhesive for use in papermaking processes or paper splicing in printing processes.
2. Description of Related Art
Paper manufacturers and print manufacturers use a pressure-sensitive adhesive tape containing a water-soluble pressure-sensitive adhesive when splicing two or more sheets of paper together in a processing step. The spliced portion is disintegrated to material pulp by means of a pulp disintegrator and reused. For this reason, the pressure-sensitive adhesive used in the splicing has to be dissolved in water and removed.
Usually, this completely water-soluble type pressure-sensitive adhesive comprises a highly polar polymer that contains significant amount of acrylic acid. However, such a pressure-sensitive adhesive by itself does not exhibit sufficient tack at ambient temperature and a large amount of a plasticizer is blended in order to decrease the modulus of elasticity so that sufficient tack can be developed. Blending a large amount of plasticizer causes various disadvantages. For example, although it has tack, it exhibits low shear resistance. After a pressure-sensitive adhesive tape is applied to a thin paper and stored for a certain period of time, the plasticizer component bleeds out from the adhesive into paper. Further, the plasticizer is subjected to a drastic change in water content and as a result, deformations such as so-called “telescoping” or “gapping” occur when the pressure-sensitive adhesive tape is stored in the form of a roll.
To avoid these problems, redispersible aqueous emulsion type acrylic pressure-sensitive adhesives have been proposed and are commercially available. The pressure-sensitive adhesive of this type is made hydrophilic by comprising high polar monomers and a surfactant. After the coating and drying, the emulsion particles bond to each other to form a film and they will not be redispersed in water unless a mechanical destructive force is applied to the pressure-sensitive adhesive. As a result, upon the disintegration of the spliced portion, the part where no mechanical destructive force has been applied remains as it is as an agglomeration or globule. In addition, the pressure-sensitive adhesive is not water-soluble in the strict sense, so that in the case where the pressure-sensitive adhesive is colored, the remaining pressure-sensitive adhesive, if any, makes paper recovered from the pulp unacceptable. The coloring of pressure-sensitive adhesive is often necessary in order to detect the spliced portion by means of a photomultiplier. Furthermore, the redispersible aqueous emulsion type acrylic type pressure-sensitive adhesives will hardly exhibit sufficient shear resistance at high temperatures encountered when they are used as a splice in a paper manufacturing process or in a printing process. This is because the polymers used therein have relatively small molecular weights and the crosslinking between the particles is difficult to achieve. U.S. Pat. No. 6,136,903 (Su, et al.) teaches blending a water-insoluble (non-redispersible) emulsified polymer to a water-soluble (redispersible) emulsion polymer as defined according to Technical Association of The Pulp and Paper Industry Useful Method 213 (TAPPI UM 213, incorporated herein by reference) so as to increase the adhesive properties. However, the shear resistance of this pressure-sensitive adhesive when it is used as a splice in a paper manufacturing process or in a printing process is insufficient.
A further problem of pressure-sensitive adhesives of the completely water-soluble type is that the adhesive property imparted is in a limited range. No water-soluble tackifier that is compatible with water-soluble polymers has been found yet. The definition of tackifier used herein is it gives tackiness to the polymer although its Tg is higher than room temperature. When conventional emulsified tackifiers are added, they are dispersed in the polymer but they exhibit insufficient effect as a tackifier. In most cases, the addition of an emulsified tackifier alone results in a loss of stability and formation of granular structures and it becomes a mass. In the case of ordinary water-insoluble pressure-sensitive adhesives, addition of a tackifier or alteration of the composition of the polymer may provide the necessary properties of the pressure sensitive adhesive. For example, addition of a selected tackifier or alteration of polymer composition to lower the polarity of the polymer results in an increased adhesion to a nonpolar substrate such as polypropylene or polyethylene.
Thus, currently available water-soluble pressure-sensitive adhesives can hardly bond to polyethylene-coated paper or base paper that has a rough surface and contains a lot of paper powder. However, there is no room to further improve the pressure-sensitive adhesive and there has been available no appropriate product yet.
Furthermore, the conventional water-soluble pressure-sensitive adhesives must be blended with a plasticizer in a large amount when it is intended to obtain high adhesion and high tack and this causes the problems of oozing and change of properties due to humidity. The definition of plasticizer used herein is Tg is lower than room temperature and it is liquid state at room temperature. Attempts have been made to use polymers having as low a Tg as possible in order to maintain the blending amount of a plasticizer to a low level as in U.S. Pat. No. 5,439,748 to Nakamura et al. However, no sufficient effect was obtained. As disclosed in U.S. patent application Ser. No. 09/385,946 (Contrada), improvements in humidity stability and in adhesion have been tried by addition of 2-alkyl-2-oxazoline, or the like. This is also insufficient to achieve high adhesion to non polar substrate.
Naturally, further improvements of pressure-sensitive adhesive compositions and methods for producing them are keenly demanded.
SUMMARY OF THE INVENTION
Therefore, an object of the present invention is to solve the above problems and provide a water-soluble pressure-sensitive adhesive composition having balanced adhesive properties.
Another object of the present invention is to provide a method for producing such a water-soluble pressure-sensitive adhesive composition.
Still another object of the present invention is to provide a pressure-sensitive adhesive tape with such a water-soluble pressure-sensitive adhesive composition.
With a view to achieving the above-mentioned objects, the present inventors have made extensive studies. As a result they discovered that the above objects are attained by providing a water-soluble pressure-sensitive adhesive composition having blended therein a water-soluble polymer, a water-insoluble component, a water-incompatible solvent that dissolves the water-insoluble component, a water-soluble plasticizer, and an optional water-soluble component other than the water-soluble polymer and water-soluble plasticizer. Further, use of such a water-soluble pressure-sensitive adhesive gives rise to a pressure-sensitive tape with a water-soluble pressure-sensitive adhesive having balanced adhesive properties that could not be obtained by the conventional pressure-sensitive adhesive tapes.
Accordingly, the present invention provides the following:
(1) A pressure-sensitive adhesive composition comprising a water-soluble polymer A, a water-insoluble component B, a water-incompatible solvent C that dissolves the water-insoluble component B and is incompatible with water, a water-soluble plasticizer D, and water, wherein the pressure-sensitive adhesive composition in a dry state has water solubility according to Technical Association of The Pulp and Paper Industry Useful Method 213 (TAPPI UM 213). As used herein, the phrase “in a dry state” means that the composition has been dried so that water and solvent are essentially evaporated.
(2) A pressure-sensitive adhesive composition according to (1) above, further comprising a water-soluble component E other than the water-soluble polymer A and water-soluble plasticizer D.
(3) A pressure-sensitive adhesive composition according to (1) above, wherein the water-soluble polymer A forms a true solution when it is dissolved in water.
(4) A pressure-sensitive adhesive composition according to (3) above, wherein the water soluble polymer A comprises at least about 30% by weight of at least one monomer selected from acrylic acid, vinyl pyrrolidone, a compound of the formula M1 and a compound of the formula M2 below:
wherein X is hydrogen or an alkyl group, N is 1 to 4, M is 1 to 20, L is 0 to 5, P is 1 to 10, and Q is 1 to 10.
(5) A pressure-sensitive adhesive composition according to (1) above, wherein the water-insoluble component B has a tack at ambient temperature and is a polymer or an adhesive composition containing a polymer and optionally a tackifier and/or a plasticizer.
(6) A pressure-sensitive adhesive composition according to (5) above, wherein the water-insoluble component B comprises a polymer formed from 2-ethylhexyl acrylate and acrylamide.
(7) A pressure-sensitive adhesive composition according to (6) above, wherein the water-insoluble component B further comprises at least one compound selected from the group consisting of a tackifier and a plasticizer.
(8) A pressure-sensitive adhesive composition according to (1) above, wherein the water-soluble plasticizer D comprises at least one polymer selected from the group consisting of polyoxyethylene glycol, polypropylene glycol, and polyoxypropylene sorbitol ether.
(9) A pressure-sensitive adhesive composition according to (1) above, wherein the composition comprises 100 parts by weight of the water-soluble polymer A, from about 5 to about 100 parts by weight of the water-insoluble component B, from about 5 to about 500 parts by weight of the water-incompatible solvent C, from about 10 to about 300 parts of the water-soluble plasticizer D, and from about 100 to about 800 parts by weight of water.
(10) A method for producing a pressure-sensitive adhesive composition according to (1) above, comprising the steps of:
preliminarily preparing a true nonaqueous solution comprising a water-insoluble component B in a water-incompatible solvent C, and
mixing the true nonaqueous solution with a true aqueous solution comprising at least one member selected from the group consisting of a water-soluble polymer A and a water-soluble plasticizer D.
(11) A pressure-sensitive adhesive comprising a pressure-sensitive adhesive composition formed according to claim 1, from which water and solvent have been essentially removed, said adhesive composition being in a dry state.
(12) A pressure-sensitive adhesive composition according to (11) above, which has a (water-insoluble dry part))/(total dry part) ratio by weight of about 0.5 or less in the dry state.
(13) A pressure-sensitive adhesive composition according to (12) above, wherein the (water-insoluble dry part))/(total dry part) ratio by weight is about 0.3 or less.
(14) A pressure-sensitive adhesive composition according to (12) above, wherein the (water-soluble part)/(water-insoluble part) ratio by weight is about 0.25 or less.
(15) A pressure-sensitive adhesive tape comprising a substrate having on at least a part of one or both surfaces thereof a pressure-sensitive adhesive according to any one of (11), (12), (13) or (14) above.
(16) A pressure-sensitive adhesive tape according to (15) above, wherein the pressure-sensitive adhesive tape is used in splicing paper in papermaking or printing process.
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, the present invention will be described in detail.
Water-soluble polymer A is not particularly limited and any conventional water-soluble polymer may be used in the present invention. For example, a polymer of 5 parts by weight of butyl acrylate (BA) and 95 parts by weight of acrylic acid (AA) partly neutralized with an alkali such as KOH, polymers obtained by polymerization in a water-soluble plasticizer as disclosed in U.S. Pat. No. 4,442,258 (the contents of which are incorporated herein by reference), polymers having a low Tg as disclosed in U.S. Pat. No. 5,439,748 (the contents of which are incorporated herein by reference) may be used. In this case, however, it must form a true solution when it is dissolved in water. For this purpose, the polymers must have sufficient polarity. Use of at least 30% by weight based on total monomer weight of monomer or monomers selected from the group consisting of acrylic acid, vinylpyrrolidone, monomer of the formula M1, and monomer of the formula M2 (each as described above) or combinations with one or other monomers can give the necessary polarity. Examples of the monomers that may be used in combination include methoxy ethyl acrylate, methoxy polyethyleneglycol methacrylate, and lauroxy polyethyleneglycol monoacrylate as M1, and caprolactone acrylate (Q=2 as average) as M2.
To the aqueous solution of polymer A, a water soluble plasticizer D is added to make a true aqueous solution. The water-soluble plasticizer D may be chosen from those conventionally used ones, preferably polyols, for example, polyethylene glycol, polypropylene glycol, polyoxypropylene sorbitol ether, polyglycerin, and polyoxyethylene glyceryl ether. Among these, polyethylene glycol and polypropylene glycol are preferred in view of tack and polyoxypropylene sorbitol ether is excellent in view of relatively low oozing. They may be used singly or two or more of them may be used in combination. Alternatively, they may be used in combination with water-soluble plasticizers other than polyethylene glycol, polypropylene glycol, and polyoxypropylene sorbitol ether.
On the other hand, the water-insoluble component B is dissolved in a solvent that is incompatible with water, such as toluene or ethyl acetate, to form a true nonaqueous solution. The nonaqueous solution is blended with the above-mentioned aqueous solution and well stirred. The solvent that is incompatible with water as used herein means a solvent that causes phase separation when it is mixed with water in a ratio of about 1:1.
The water-insoluble component B is a component that supplements the property that the conventional aqueous pressure-sensitive adhesive could not exhibit and includes the polymer itself, or a pressure-sensitive adhesive containing the polymer, and optionally a tackifier and/or a plasticizer, etc.
For example, in the case where paper having a rough surface and paper powder is attached thereon, the tack to be attained by blending a large amount of a plasticizer results in an insufficient inner cohesive force, which makes shearing force and resistance upon peeling insufficient. Accordingly, the conventional aqueous pressure-sensitive adhesives could not provide a sufficient splicing function. However, use of a polymer that is soluble in the solvent C alone or a polymer composition that contains a polymer, a tackifier and a plasticizer and has a sufficiently low modulus of elasticity (such as a copolymer composition that contains 2-ethylhexyl acrylate and acrylamide as the polymer B) can give rise to a sufficient tack and a sufficient cohesive force so that the property can be supplemented. In this case ethyl acetate may be used as the solvent C. Other examples of the water-insoluble component B include, without limitation, a copolymer of butyl acrylate and acrylic acid, and a copolymer of 2-ethylhexyl acrylate and acrylic acid.
In the case where bonding of the pressure-sensitive adhesive on a polyethylene-coated paper is needed, conventional pressure-sensitive adhesives can hardly bond on a polyethylene substrate, which is a nonpolar adherend, since they are very high in polarity. In this case, the adhesion to polyethylene can be supplemented by blending a polymer having a decreased polarity comprising 3 parts of acrylic acid and 97 parts of butyl acrylate, which are soluble in the solvent C, with polymerized rosin ester, Pensel D-125 (produced by Arakawa Chemical Industries Co., Ltd.), in an amount of 20 parts per 100 parts of the polymer. In this case, toluene may be used as the solvent C. Further, low oozing and high storage stability in high humidity can be expected since the amount of water soluble plasticizer can be reduced by adding water-insoluble component B.
One of the important factors in formulating of this kind of pressure-sensitive adhesives is to preliminarily prepare a true solution of a water-insoluble component B and a water-incompatible solvent C. The water-incompatible solvent C is an indispensable component. The term “water-incompatible solvent” means a solvent that causes phase separation when it is mixed with water in a ratio of 1:1 by weight.
Mixing a true aqueous solution obtained by dissolving a water-soluble plasticizer D in an aqueous solution of the water-soluble polymer A with a true solution of a water-insoluble component B in a water-incompatible solvent C with stirring results in emulsification. On this occasion, the polymer A or water-soluble plasticizer D serves as a surfactant. If the solvent C is absent, emulsification is difficult to achieve. If the water-insoluble component B is directly added to the aqueous solution of water-soluble polymer A without dissolving it in the solvent C, it is more difficult to make a dispersion due to its high viscosity. It may be possible to melt the water-insoluble component B at high temperatures before it can be mixed. However, this procedure is somewhat disadvantageous in that it incurs high costs when the operation is to be carried out on an industrial scale. It is not practical to use an aqueous emulsion pressure-sensitive adhesive or polymer for blending the water-insoluble component B. This is because they usually contain a surfactant, which is absorbed by the water-soluble polymer A or water-soluble plasticizer D so that as soon as the emulsion pressure-sensitive adhesive or polymer is blended with the water-soluble polymer A, the emulsion structure gives way to a non-uniform granular structure. In this case, if the emulsion pressure-sensitive adhesive or polymer contained the solvent C in the oil phase, it could be successfully blended with the aqueous solution of water-soluble polymer A. However, generally aqueous emulsion pressure-sensitive adhesives are used for constructing systems without using any solvent. Therefore, aqueous emulsion polymers or pressure-sensitive adhesives that contain solvents are not generally accepted.
To enable blending, it is only necessary that the water-insoluble component B be dissolved in the solvent C but the water-insoluble component B does not have to be converted into an aqueous emulsion before it can be blended into the aqueous solution of water-soluble polymer. The selection of the type of the solvent C is relatively important and which one is suitable depends on the combination of the water-soluble polymer and water-insoluble component B. Depending on the type of the solvent C, a decrease in adhesive force or tack feeling may occur. Although the reason for this phenomenon is not entirely clear at present, it is presumed that difference in the degree of mixing of components B and polymer A, cause such phenomenon.
A water-soluble or water-dispersible pigment or dye may be added as the other water-soluble component E for the detection by use of a photomultiplier upon splicing base paper as an adherend. To increase shear resistance and heat resistance of the pressure-sensitive adhesive, isocyanate- or epoxy-based crosslinking agent may be added as long as the water solubility is not lost.
In the pressure-sensitive adhesive composition of the present invention, ratios of the components in the composition are preferably from about 5 to about 100 parts by weight of the water-insoluble component B, from about 5 to about 500 parts by weight of the water-incompatible solvent C, from about 10 to about 300 parts of the water-soluble plasticizer D, and from about 100 to about 800 parts by weight of water per 100 parts by weight of the water-soluble polymer A.
The part by weight ratio (on dry basis) of the water-soluble components and the water-insoluble components has been determined to give rise to certain advantages when the following parameters are observed. This ratio, calculated herein as (water-insoluble dry part)/(total dry part)), is preferably about 0.5 or less, more preferably about 0.3 or less and even more preferably about 0.25 or less. If this ratio exceeds 0.5, the water solubility of the adhesive tends to be lost. The water-insoluble part mainly comprises the water-insoluble component B. However, in the case where the water-insoluble part contains a crosslinking agent, the crosslinking agent may react with the water-soluble polymer or the like to increase the water-insoluble part to some extent. The water-insoluble part may contain such a reaction product. Therefore, ratio may be measured with water or solvent extraction. To determine the amount of insoluble part, the adhesive was coated onto the release paper, dried for 5 minutes at room temperature and then for 5 minutes at 70° C., then cured at 150° C. for 30 seconds. Dry film thickness was about 75 micrometers. A sample of the dry adhesive with about 0.2 g weight was placed into the porous Teflon film, tied with a cotton thread and immersed in water for 7 days. The sample was removed from water, and dried at 130° C. to a constant weight. The ratio of insoluble part to total dry part was calculated as follows: (C−A)/(B−A), where A is the weight of the cotton thread and Teflon film; B is the initial total sample weight, which includes adhesive, cotton thread and Teflon film; and C is the final total sample weight (including adhesive, cotton thread and Teflon film) after immersion in water and drying. Teflon film used was a bi-oriented polytetrafluoroethylene film having a pore size of about 0.2 micrometer, NTF-1122 grade produced by Nitto Denko Corporation.
By coating the pressure-sensitive adhesive on at least a part of one or both sides of a substrate or base material, such as a disintegrable paper or water-soluble film and drying, one or double sided water-soluble pressure-sensitive adhesive tape can be prepared.
EXAMPLES
The present invention will be described in more detail by examples and comparative examples. However, the present invention should not be construed as being limited to the examples. In the examples and comparative examples below, all parts and percents are by weight.
Example 1
40 Parts of caprolactone acrylate neutralized with 7.5 parts of KOH, 45 parts of methoxyethyl acrylate, and 3 parts of sodium styrenesulfonate were polymerized with ammonium persulfate (APS) as an initiator to form a water-soluble polymer A1. 100 Parts of the water-soluble polymer A1, 30 parts of polypropylene glycol (molecular weight: about 400) as a water-soluble plasticizer D1, 0.3 part of a water-soluble blue pigment (Unisperse Green G-E, produced by Ciba) as an other water-soluble component E1, and 304 parts of water were mixed with stirring to obtain an true aqueous solution.
100 Parts of a copolymer of 95 parts of butyl acrylate and 5 parts of acrylic acid, 30 parts of a terpene phenol resin (Sumilite Resin PR12603N, produced by Sumitomo Durez Co., Ltd.), and 5 parts of a xylene resin (Nikanol, produced by Mitsubishi Gas Chemical) were blended to obtain a water-insoluble component B1. 40 Parts of the water-insoluble component B1 per 100 parts by weight of the water-soluble polymer Al were dissolved in 60 parts of toluene as a water incompatible solvent C1 to form a true nonaqueous solution.
The aqueous solution and the nonaqueous solution thus obtained were mixed with stirring for 0.5 hours (in the case of 300 lb batch scale) and then the resultant mixture was coated on one side of a 100 μm-thick disintegrable base paper to form a pressure-sensitive adhesive layer having a thickness of 80 μm (on dry basis). This was dried in an oven at 110° C. for 3 minutes to prepare a sample pressure-sensitive adhesive tape.
Example 2
60.27 Parts of acrylic acid neutralized with 4.7 parts of KOH, 3.17 parts of butyl acrylate, and 31.74 parts of polyoxypropylene sorbitol ether (Sannix SP-750 produced by Sanyo Kasei Co., Ltd.) were polymerized with ammonium persulfate (APS) as an initiator in water to form a water-soluble polymer A2. 100 Parts of the water-soluble polymer A2, 190 parts of a water-soluble plasticizer D2 (Sannix SP-750 produced by Sanyo Kasei Co., Ltd.), and 0.025 part of 1,3,5-triglycydyl isocyanurate (TEPIC-P, produced by Nissan Chemical Co., Ltd.), a crosslinking agent for water-soluble polymers as an other water-soluble component E2 were dissolved in 435 parts of water with stirring to form an true aqueous solution.
50 Parts of a 2-ethylhexyl acrylate/acrylamide copolymer (HRJ-4326, produced by Schenectady) as a water-insoluble component B2 per 100 parts of the water-soluble polymer A2 were dissolved in 75 parts of ethyl acetate as a water-incompatible solvent C2 to form a true nonaqueous solution.
The aqueous solution and nonaqueous solution thus obtained were mixed with stirring for 0.5 hours (in the case of 300 lb batch scale) to form a pressure-sensitive adhesive.
The pressure-sensitive adhesive was coated on one side of a 100 μm-thick disintegrable base paper to form a pressure-sensitive adhesive layer having a thickness of 80 μm (on dry basis). This was dried in an oven at 110° C. for 3 minutes to prepare a sample pressure-sensitive adhesive tape.
Example 3
100 Parts of polyoxypropylene sorbitol ether (SP-750 produced by Sanyo Kasei Co., Ltd.) as the water-soluble plasticizer D2 and 60 parts of polyoxyethylene glycol (molecular weight: about 200) as a water-soluble plasticizer D3, both per 100 parts of the water-soluble polymer A2, are dissolved in 450 parts of water to form an true aqueous solution.
On the other hand, a copolymer obtained by polymerizing 100 parts of butyl acrylate, 3 parts of acrylic acid and 5 parts of vinyl acetate, 20 parts of polymerized rosin ester (Pensel D-125, produced by Arakawa Chemical Industries, Co., Ltd.), which is known as a rosin ester improving the adhesion to a nonpolar adherend, and 5 parts of methyl ester of hydrogenated rosin (Hercolyn D, produced by Rika-Hercules Inc.) as a softening agent are blended to form a water-insoluble component B3. Then, 20 parts of the water-insoluble component B3 per 100 parts of the water-soluble polymer A2 is dissolved in 45 parts of toluene as the water-incompatible solvent C1 to form a true solution. These solutions are mixed with stirring for 0.5 hours (in the case of 300 lb batch scale). The resultant mixture are coated on one side of a 100 μm-thick disintegrable base paper to a pressure-sensitive adhesive layer having a thickness of 80 μm (on dry basis). This is dried in an oven at 110° C. for 3 minutes to prepare a sample pressure-sensitive adhesive tape.
Comparative Example 1
100 Parts of the water-soluble polymer A2, 190 parts of SP-750 mentioned above as a water-soluble plasticizer D2, and 0.025 part of 1,3,5-triglycydyl isocyanurate (TEPIC-P, produced by Nissan Chemical Co., Ltd.), i.e., a crosslinking agent for water-soluble polymer as the other water-soluble component E2, were dissolved in 435 parts of water with stirring for 0.5 hours (in the case of 300 lb batch scale) to form a water-soluble pressure-sensitive adhesive solution.
The adhesive solution thus obtained was coated on one side of a 100 μm-thick disintegrable base paper to form a pressure-sensitive adhesive layer having a thickness of 80 μm (on dry basis). This was dried in an oven at 110° C. for 3 minutes to prepare a sample pressure-sensitive adhesive tape.
Comparative Example 2
100 Parts of the water-soluble polymer A2, 190 parts of SP-750 mentioned above as a water-soluble plasticizer D2, and 0.025 part of 1,3,5-triglycydyl isocyanurate (TEPIC-P, produced by Nissan Chemical Co., Ltd.), a crosslinking agent for water-soluble polymer as the other water-soluble component E2 were dissolved in 435 parts of water with stirring to form an true aqueous solution.
300 Parts of a copolymer of 2-ethylhexyl acrylate and acrylamide (HRJ-4326, produced by Schenectady) as the water-insoluble component B per 100 parts of the water-soluble polymer A2 was dissolved in 450 parts of ethyl acetate as the water-incompatible solvent C2 to form a true nonaqueous solution.
The aqueous solution and nonaqueous solution were mixed with stirring for 0.5 hours (in the case of 300 lb batch scale) to form a pressure-sensitive adhesive.
The pressure-sensitive adhesive thus obtained was coated on was coated on one side of a 100 m-thick disintegrable base paper to form a pressure-sensitive adhesive layer having a thickness of 80 μm (on dry basis) and dried in an oven at 110° C. for 3 minutes to prepare a sample pressure-sensitive adhesive tape.
Evaluation
1. Water Solubility:
The water solubility of the pressure-sensitive adhesive was evaluated according to TAPPI UM213.
2. Peel Strength:
2a) Polyethylene-Coated Paper
A sample tape of 25 mm in width was pressed onto a polyethylene-coated paper by a reciprocation of 2 kg roller, and a 180′-peel adhesive strength was measured within 1 minute.
2b) Base Paper for Newspaper
A sample tape of 25 mm in width was pressed onto a sheet of base paper for newspaper by a reciprocation of 2 kg roller and a 180′-peel adhesive strength was measured within 1 minute.
Comparative
Comparative
Example 1
Example 2
Example 3
Example 1
Example 2
Dry
Dry
Dry
Dry
Dry
parts
parts
parts
parts
parts
Water-soluble
A1
100
A2
100
A2
100
A2
100
A2
100
polymer A
Water-insoluble
B1
40
B2
50
B3
20
—
—
B2
300
component B
Water -
C1
60
C2
75
C1
45
—
—
C2
450
incompatible
solvent C
Water-soluble
D1
30
D2
190
D2
100
D2
190
D2
190
plasticizer D
D3
60
Other water-
E1
0.3
E2
0.029
E2
E2
0.025
E2
0.025
soluble
component E
Water
304
435
450
435
435
Water-insoluble
0.235
0.147
0.07
0
0.508
part/Total dry
part),
theoretical
[B/(A + B + D + E)]
Water- insoluble
0.223
0.136
0.04
0
0.515
part/Total dry
part),
experimental
[B/(A + B + D + E)]
Results or Evaluation
TAPPI UM213 Water
Solubility Test
OK
OK
OK Expected
OK
NG
Adhesive power
830
1000
About 1,500
360
2,000 or more
to
Expected
(Base
polyethylene-
Material of
coated paper
Tape
(g /23 mm)
Destructed)
Adhesive power
1700
1700
About 1,700
710
1700
to base paper
Newspaper
Newspaper
(Destruction
Newspaper
for newspaper
destructed
destructed
of Newspaper
destructed
(g/25 mm)
Expected)
In the above table, “OK” means that the composition exhibited the desired water solubility, while “NG” means that it did not.
While the invention has been described in detail and with reference to specific examples thereof, it will be apparent to one of ordinary skill in the art that various changes and modifications can be made therein without departing from the spirit and scope thereof.
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A pressure-sensitive adhesive composition comprising a water-soluble polymer A, a water-insoluble component B, a water-incompatible solvent C that dissolves the water-insoluble component B and is incompatible with water, a water-soluble plasticizer D, and water, wherein the pressure-sensitive adhesive composition in a dry state has water solubility according to Technical Association of The Pulp and Paper Industry Useful Method 213 (TAPPI UM 213). Also disclosed are a method for producing a pressure-sensitive adhesive composition according to the present invention, comprising the steps of: preliminarily preparing a true nonaqueous solution of a water-insoluble component B in a water-incompatible solvent C, and mixing the true nonaqueous solution with an aqueous solution of at least one member selected from the group consisting of a water-soluble polymer A and a water-soluble plasticizer D, and a pressure-sensitive adhesive and a pressure-sensitive adhesive tape that use the composition.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional Patent Application No. 61/930,694 filed Jan. 23, 2014, which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] The present invention is in general related to the methods for managing application performance, in particular subscribers' service level agreements (SLAs), in multi-subscriber networks.
[0003] Via consolidation and sharing of resources including networks, servers, storage, software and content, Cloud Computing essentially makes computing a commodity and significantly helps businesses reduce capital expenses (CAPEX) and operational expenses (OPEX), simplify management, and improve agility and elasticity. Cloud Computing is changing the way people work and live, as well as the operation and management of today's enterprises. The IT infrastructure—the building blocks of Cloud Computing—is facing unprecedented challenges in system performance and SLA management. Today's data centers have evolved far beyond simple collections of computing and networking equipment and have become ultra-large-scale collaborative computing systems with distributed data processing, computing and network virtualization, and complex business logic. In addition, resource virtualization and multi-tenancy makes it even more challenging for performance guarantee and SLA management for the IT infrastructure for Cloud Computing.
[0004] One of the key tools for any SLA management system is the anomaly detection mechanism. However, most existing SLA management systems react to SLA violations after the defects occur and/or do not differentiate the detected SLA violations according to their significance, both of which lead to costly SLA violations and slow defect management responses. Thus, it is desired by the system operators and service providers to develop an SLA management mechanism that can detect potential SLA violations before the events take place and that can filter and prioritize the SLA anomaly alerts according to their importance.
SUMMARY OF THE INVENTION
[0005] The preferred embodiment describes a predictive SLA anomaly detection mechanism for multi-subscriber IT infrastructure. The mechanism is composed of a Data Fusion module, an SLA-aware Skeleton Modeling module, a Shadow Baselining module, a System Analysis and Alerts Generation module, and an SLA-aware Alerts Prioritization module. In one embodiment, the Skeleton Modeling module takes as input the preprocessed system monitoring data and generates a skeleton network describing the system characteristics. In another embodiment, the Shadow Baselining module takes as input the preprocessed monitoring data and the skeleton network and generates a list of shadow baselines for each metric. In another embodiment, the Alerts Prioritization module takes as input the alerts accumulated over a certain time interval and generates as the output a ranked list of alerts according to their significance of the potential SLA violations.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] The foregoing summary, as well as the following detailed description of preferred embodiments of the invention, will be better understood when read in conjunction with the appended drawings. For the purpose of illustrating the invention, there are shown in the drawings embodiments that are presently preferred. It should be understood, however, that the invention is not limited to the precise arrangements and instrumentalities shown.
[0007] FIG. 1 illustrates the general scenario of a multi-subscriber utility infrastructure;
[0008] FIG. 2 illustrates the components and steps of an SLA anomaly detection system for multi-subscriber utility facilities;
[0009] FIG. 3 illustrates the input and output of the Data Fusion module;
[0010] FIG. 4 describes the procedure of constructing a skeleton network;
[0011] FIG. 5 illustrates an exemplary skeleton network;
[0012] FIG. 6 describes the procedure of constructing the shadow baseline of a skeleton network;
[0013] FIG. 7 describes the procedure of conducting an SLA-aware Prioritization for alerts triggered according to a given skeleton network and its shadow baseline.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0014] Certain terminology is used in the following description for convenience only and is not limiting. The words “right,” “left,” “lower,” and “upper” designate directions in the drawings to which reference is made. The terminology includes the above-listed words, derivatives thereof, and words of similar import. Additionally, the words “a” and “an,” as used in the claims and in the corresponding portions of the specification, mean “at least one.”
[0015] In general, preferred embodiments of the present invention relate to the methods for managing application performance, in particular subscribers' service level agreements (SLAs), in multi-subscriber networks.
[0016] FIG. 1 is an exemplary generic structure of a multi-subscriber utility facility, which is composed of a plurality of subscribers 100 and a shared resource pool 101 . Resources in the resource pool 101 can be located in a single facility or be geographically distributed. Resources in a resource pool include, but are not limited to, compute 102 (i.e., physical or virtual computer servers), network 103 (network switches, routers and the interconnects), storage 104 (i.e., local, remote, or Cloud storage), and middleware 105 (i.e., firewall, load balancer, intrusion detection systems, and other appliances). A plurality of subscribers 100 deploys their own applications on the shared resource pool 101 , utilizing a combination of a certain amount of compute 102 , network 103 , storage 104 , middleware 105 and other resources.
[0017] For each subscriber, the operator or service provider of the shared resource pool 101 specifies a pre-determined service level agreement (SLA), defining a set of performance guarantees for the subscriber's services as a whole or for each individual application component deployed in the shared resource pool 101 . An exemplary set of SLAs includes system uptime, network bandwidth, latency, storage access rate, recovery time, etc. These SLAs can be quantitatively defined as a set of static threshold values or time-varying baseline functions. In practice, the operator or service provider monitors the service performance according to the SLAs, triggers alerts if certain SLAs are violated, and takes actions to resolve or mitigate the violated SLAs. Since these actions are reactive, i.e., triggered after the violations take place, they cannot prevent, but only mitigate, the losses cost by the SLA violations. In this invention, a method that is able to proactively detect and react to potential SLA anomaly before the actual violations occur.
[0018] In the preferred embodiment, referring to FIG. 2 , a proactive SLA anomaly detection system 200 is composed of a Data Fusion module 201 that performs sanitization, extraction and transformation of raw monitoring data such that the resulting data are easier for further analysis, an SLA-aware Skeleton Modeling module 202 that constructs a set of time-invariant mathematical constraints of a given system while embedding the service level agreement information in the mathematical model, and Shadow Baselining module 203 that constructs a set of expected baseline functions for each metric according to the mathematical relationships between any pair of metrics modeled by the skeleton modeling, a System Analysis and Alerts Generation module 204 that analyzes the system situation and accordingly generates alerts following predefined fault criteria, and an SLA-aware Alerts Prioritization module 205 that filters and prioritizes SLA alerts based on the significance of the alerts. The SLA anomaly detection system 200 takes as input real-time system monitoring data 206 and generates as output a ranked list of alerts 207 according to the significance of the potential SLA violations.
[0019] In one embodiment, referring to FIG. 3 , the input, real-time system monitoring data 206 , of the Data Fusion module 201 can be any combination of SDN-based monitoring and tapping data 303 , agent-based passive and active measurement data 304 , software and hardware appliance data 305 , and any other monitoring data 306 , including SNMP, sFlow, NetFlow, IP-FIX, jFlow, syslog, and CMDB. Given the real-time monitoring data 206 , the Data Fusion module 201 generates the structured data 307 for further processing after sanitization 300 , extraction 301 , and transformation 302 . Other approaches, techniques and designs to achieve the above data preprocessing functionality are known to those skilled in the art, and are within the scope of this disclosure.
[0020] In another embodiment, the Skeleton Modeling module 202 takes as input the preprocessed system monitoring data 307 and generates a skeleton network describing the system characteristics using a set of time-invariant mathematical constraints of a given system while embedding the service level agreement information in the mathematical model. Referring to FIG. 4 , the procedure of constructing a skeleton network is described as follows. The procedure starts at step 400 , where each pair of metrics x and y in the input data is iterated. In each iteration, the procedure, at step 401 , finds a transfer function f satisfying x=f(y). An exemplary method of finding such a transfer function is the Auto-Regressive method with Exogenous inputs. But other approaches and techniques to achieve the above functionality are known to those skilled in the art, and are within the scope of this disclosure. At step 402 , the system examine transfer function f with the existing transfer function that was constructed for metrics x and y and checks whether transfer function f exists. If function f does not exist, the procedure skips to the next iteration; otherwise, the procedure checks whether link x->y exists in the skeleton network at step 403 . If the link does not exist in the skeleton network, at step 405 , add link x->y to the skeleton network and assign a weight to the link according to its significance to the SLAs of the affected subscribers. If the link x->y already exists in the skeleton network, at step 404 , compare f with the transfer function of the existing link x->y in the network. According to the examination result, the links of the skeleton network is updated as follows. If the two transfer functions are consistent, keep the link x->y in the skeleton network and go to the next iteration; otherwise, at step 407 , remove the link x->y from the skeleton network and go to the next iteration. The procedure iterates until no new input data are received.
[0021] An exemplary skeleton network is illustrated in FIG. 5 . Each node in the skeleton network represents a metric 500 . Each link connecting two nodes A and B is associated with a transfer function f AB 501 and a weight W AB 502 . A skeleton network is not static, but is continuously and dynamically validated and adjusted according to the procedure 400 .
[0022] In another embodiment, the Shadow Baselining module 203 takes as input the preprocessed monitoring data 307 and the skeleton network and generates a list of shadow baselines for each metric using monitoring data, which represent a set of expected baseline functions for each metric according to the mathematical relationships between any pair of metrics modeled by the skeleton modeling. FIG. 6 illustrates the procedure of constructing the shadow baselines. The procedure starts at step 600 , where the system takes the input data. At step 601 , the system constructs a baseline function b x x for each metric x (or node 500 ) in the skeleton network using any baselining or profiling technique. The system at step 602 identifies all nodes y reachable from x in the skeleton network and at step 603 calculates the baseline function by x propagated from node x following the transfer function associated with the link in the skeleton network. Then, the vector of shadow baseline S x of metric x is defined as S x =<by x >. If all metrics have been iterated at step 604 , the system outputs the list of shadow baselines for metric x; otherwise, the system goes back to step 602 and iterates the next metric.
[0023] Shadow baselines of a metric x represent the expected baselines of all metrics y that are reachable from x in the skeleton network. These expected baselines are further used to verify a triggered alert is a true positive or false positive. This information is further used to filter and rank the importance of the alerts triggered by the System Analysis and Alerts Generation module 204 .
[0024] In another embodiment, the System Analysis and Alerts Generation module 204 takes as input the preprocessed monitoring data 307 and the baseline for each metric and compares the monitored value of each metric with its baseline function to analyze the system situation and accordingly generate alerts following predefined fault criteria. Specifically, if the baseline function is violated according to a predefined fault model, then the system reports an alert and feeds the alert to the Alerts Prioritization module 205 . Approaches, techniques and designs to detect the above baseline violations are known to those skilled in the art, and are within the scope of this disclosure.
[0025] In another embodiment, the Alerts Prioritization module 205 takes as the input the alerts accumulated over a certain time interval and generates as the output a filtered and prioritized list of alerts according to their significance of the potential SLA violations. Referring to FIG. 7 , the procedure of ranking the triggered alerts starts at step 700 , in which, for each alert x, the metric x affected by this alert is identified. At step 701 , for all metrics y that are reachable from x in the skeleton network, calculate the projected value of y propagated from metric x by following the transfer function of each link in the path from metric x to metric y. At step 702 , for each link in the reachable paths from x, examine whether the link is broken according to both of its regular and shadow baselines. Then, let W x be the sum of the weights of all broken links in the reachable paths from x. At step 704 , sort the alerts according to their weights W x and output the sorted list.
[0026] In the above procedure, it is possible that the weight of an alert is zero or has a very low value, which implies that this alert is a false positive and should be removed from the alert list. Other approaches, techniques and designs to achieve the above fault suppression functionality are known to those skilled in the art, and are within the scope of this disclosure. This way, the operator or service provider can focus on the more important alerts and process these alerts according to their significance.
[0027] The procedures described in FIGS. 3-4 and 6 - 7 constitute a proactive SLA anomaly detection mechanism for multi-subscriber IT infrastructures. Instead of reactively respond to SLA violations, which already caused costly damages to the quality of service and user experience, the present invention is able to predict potential SLA violations leveraging robust deep system modeling such as skeleton networks and shadow baselining. The proposed method of prioritizing SLA anomaly alerts is able to filter out false or irrelevant alerts and allows the service providers to efficiently pinpoint and treat the more significant alerts, significantly improving the defect management responsiveness and resolution efficiency.
[0028] It will be appreciated by those skilled in the art that changes could be made to the embodiments described above without departing from the broad inventive concept thereof. It is understood, therefore, that this invention is not limited to the particular embodiments disclosed, but it is intended to cover modifications within the spirit and scope of the present invention as defined by the appended claims.
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A predictive service level agreement (SLA) anomaly detection mechanism is provided for multi-subscriber IT infrastructure. Also, a method of filtering and prioritizing SLA anomaly alerts is provided. Furthermore, a method of constructing a skeleton network given historical and real-time monitoring data and a method of constructing a shadow baseline for each metric in a skeleton network are provided.
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This is a division of application Ser. No. 172,631, filed July 25, 1980, now U.S. Pat. No. 4,347,714.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to systems for space heating and cooling and, more particularly, to such systems particularly adapted to provide improved efficiency for residential use.
2. Description of the Prior Art
Heat pumps have long been used for efficiently transferring heat from one medium to another, thus permitting the heating or cooling of a given space with the heat being transferred from some readily available medium (ambient air, water in an adjacent lake or well, a body of rocks or salt, or the like) for heating, and being delivered to the medium (often the same body of water, etc.) for cooling.
For example, the Carleton patent, U.S. Pat. No. 3,135,318 describes a heat pump system using a turbo-compressor which provides power and waste heat to a standard vapor cycle refrigeration system. Two turbines are employed in the system, one driving the turbo-compressor and a second turbine driving a recirculating air fan and the refrigerant compressor.
The Miller patent, U.S. Pat. No. 3,822,561, describes a self-contained, portable air cooling unit comprising a refrigeration circuit, a thermal reservoir consisting of an ice bank in a flexible tank, and a heat exchanger for transferring heat between the air in the space to be cooled and chilled water circulated from the ice bank and reservoir. Means are provided to selectively and alternatively operate the refrigeration circuit and the circulating system to heat or to cool the space as desired.
The Lodge patent, U.S. Pat. No. 3,407,620 describes a system for heating and cooling using a recirculating water loop. Heating is supplied by a standard heater using combustible fuel, and cooling is provided by a cooling tower. Although the patent represents the system as a heat pump, it is not a heat pump by the usual thermodynamic definition.
The La Fleur patent, U.S. Pat. No. 3,355,903, describes a closed reverse-Brayton-cycle refrigeration system to provide refrigeration for air liquefaction. Repetitive stages of compression and cooling are employed.
A heat-actuated space conditioning system utilizing a Brayton engine is described in an article entitled "Light Commercial Brayton/Rankine Space Conditioning System" by David Friedman, beginning at page 172 of the August, 1977 Proceedings of the 12th IECEC (Intersociety Energy Conversion Engineering Conference). This article describes a Brayton cycle system utilizing a combustor driving a turbo-compressor, the latter being magnetically coupled to a second compressor in an associated Rankine cycle system.
Such systems as are known may provide improved efficiency over the standard air conditioning system including a furnace for heating and a refrigeration type air conditioner for cooling, but the cost of such a heat pump system is generally substantially greater because of the increased complexity. However, with the recent substantial increases in the cost of fuel, it becomes more worthwhile, indeed essential, to develop systems of improved efficiency.
The present invention is directed to the provision of a simplified heat pump system of improved efficiency for selectively heating or cooling a residential space in a temperate zone region where extreme low and high temperatures are seldom encountered.
SUMMARY OF THE INVENTION
In brief, arrangements in accordance with the present invention incorporate a turbo-compressor, a pair of heat exchangers, and suitable control valves in a basic reverse-Brayton-cycle heat pump adapted for residential use. The control valves may be adjusted to cause the system to operate in either a heating or a cooling mode. High efficiency is achieved by, among others, regeneratively heat exchanging with inlet ambient air and expanding the ambient air through a turbine prior to exhaust. In addition, other waste heat from the system is used in heating the conditioned space.
In one arrangement in accordance with the invention, a recuperated Brayton cycle engine is mounted on a common shaft with the aforementioned turbo-compressor to provide the primary drive. In this embodiment, the Brayton engine uses a heat source in the form of a combustor and heat exchanger adapted to burn natural gas. An additional sink heat exchanger is provided and arranged, in the heating mode, to add the waste heat from the drive portion of the system to the air for the residential conditioned space.
In a second embodiment, the primary source of driving power is provided by an electric motor coupled to the shaft of the turbo-compressor. In the heating mode, air is directed through a heat exchanger coupled to the motor so that motor heat is added to the air supplied to the load heat exchanger for the conditioned space.
In both embodiments, the Brayton cycle portion of the system is operated at sub-atmospheric pressure. In the cooling mode, advantage is taken of this condition to provide additional cooling through the injection of water spray into the low pressure side of the load heat exchanger. Evaporation of water is enhanced because of the sub-atmospheric pressure level, and additional cooling is effected through the removal of the latent heat of vaporization.
Because the working fluid for both the Brayton cycle engine and the Brayton conditioning cycle is air, the two systems can share a common compressor.
BRIEF DESCRIPTION OF THE DRAWING
A better understanding of the present invention may be had from a consideration of the following detailed description, taken in conjunction with the accompanying drawing in which:
FIG. 1 is a schematic diagram illustrating one particular arrangement of a heat driven heat pump in accordance with the invention, shown in the heating mode;
FIG. 2 is a schematic diagram illustrating the arrangement of FIG. 1 for operation in the cooling mode;
FIG. 3 is a schematic diagram showing a variation of the system of FIGS. 1 and 2;
FIGS. 4A and 4B are schematics illustrating another arrangement of the invention in the heating and cooling modes, respectively;
FIG. 5 is a schematic diagram of an arrangement of an electrically driven heat pump in accordance with the invention, shown for operation in the heating mode; and
FIG. 6 is a schematic diagram of the arrangement of FIG. 5, shown for operation in the cooling mode.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIGS. 1 and 2 represent schematically a heat-driven, air cycle heat pump system 10 in accordance with the invention, particularly adapted for residential use. In these figures, the system 10 is shown comprising a load heat exchanger 12 connected to ducting 14 through which air to be heated or cooled is driven by a fan 16.
The air cycle, or Brayton cycle, portion of the system 10 comprises a turbo-compressor 18 having a turbine 20 and compressor 22 interconnected with a regenerative heat exchanger 24 for ambient air and the load heat exchanger 12 via heat/cool control valves 26, 28.
The drive portion of the system 10 is shown comprising a Brayton cycle turbine 30 coupled on a common shaft 32 with the turbo-compressor 18 and connected to receive heated air from a combustor/heat exchanger 34 fed by natural gas. The exhaust of the turbine 30 is fed to a second regenerative heat exchanger 36 from whence it passes to a sink heat exchanger 38 connected in an air duct 40 having a fan 42. The duct 40 is connected via ducting 44 to the main air duct 14 and by ducting 46 to outlets for ambient air. Dampers 48 are provided to select the path for air flowing through the duct 40.
As shown in FIG. 1, the valves 26, 28 and the dampers 48 are positioned for operation of the system in the heating mode. In this mode, cold ambient air ducted from outside the house is first heated in the regenerative heat exchanger 24 to near the temperature of the heated space and then is directed through valve 28 to the common compressor 22. This air is mixed with air from the sink heat exchanger 38 and compressed by the compressor 22. The temperature of the compressed air is raised well above that required for the heated space and a portion is ducted through valve 26 to the load heat exchanger 12 where it provides the heat for the recirculated air. This air then returns through the regenerative heat exchanger 24, providing the source of heat for the ambient air, and thus is cooled to near ambient temperature. Next it passes through the valve 28 to the turbine 20 where it is expanded to a temperature well below ambient and is exhausted to ambient through the valve 26. This expansion process in the turbine 20 provides a portion of the energy needed to drive the compressor 22. The remaining energy is provided by the Brayton turbine 30.
Air from the sink heat exchanger 38 is mixed with the preheated ambient air at the inlet of the compressor 22 where it is compressed and a portion is directed through the recuperator 36 and combustor/heat exchanger 34, where the temperature is increased to approximately 1500 degrees F. The air is then expanded across the turbine 30 to provide the remaining energy to drive the compressor 22. The air leaving the turbine 30 then passes through the recuperator 36 and the sink heat exchanger 38. A portion of the recirculated air from the duct 14 passes via ducts 44 and 40 through the sink heat exchanger 38 to add the waste heat from the Brayton engine drive portion of the system 10 to the recirculated air as additional heating.
FIG. 2 shows the system of FIG. 1 for operation in the cooling mode. The various components of the system are shown with the same reference numerals and are the same as depicted in FIG. 1 with the exception that the valves 26, 28 and the dampers 48 are changed to the cool positions, and a water spray system (omitted from FIG. 1 for simplicity) is shown. The water spray system comprises a spray unit 50 at the inlet of the cool side of the heat exchanger 12 and water recirculation is provided by a sump 52 and pump 54 through recirculating line 56. A water make-up line 57 is also provided.
In the operation of the arrangement of FIG. 2 for cooling residential space air, warm ambient air is first cooled in the regenerative heat exchanger 24 to near the temperature of the conditioned space and then is directed to the turbine 20 where it is expanded to sub-atmospheric pressure. The temperature of the ambient air is thus decreased well below the temperature of the conditioned space. The expansion energy provides a portion of the energy required to drive the compressor 22. The remainder of the energy will be provided by the Brayton turbine 30, as previously described.
After leaving the turbine 20, the cooled air is directed through the heat exchanger 12 to provide the cooling for the conditioned space. The air is then directed through the regenerative heat exchanger 24 and the valve 28 to the inlet of the compressor 22 where it is mixed with air from the sink heat exchanger 38. Waste heat removed by the sink heat exchanger 38 is ducted to atmosphere via the ducts 40, 46, as propelled by the fan 42. Air from the inlet of the compressor 22 is compressed back to ambient pressure and the portion not returned to the drive portion of the system is exhausted to atmosphere through the valve 26.
In the cooling mode, the inlet of the compressor 22 is sub-atmospheric, and thus the Brayton cycle engine must operate in the closed mode. Starting at the inlet of the compressor 22, the air is compressed and directed through the recuperator 36 and combustor/heat exchanger 34 where the temperature is increased to about 1500 degrees F. The air is then expanded across the turbine 30 to provide the necessary energy to drive the compressor 22. The hot turbine discharge air is now directed through the recuperator 36 and the sink heat exchanger 38.
The water evaporation from the spray unit 50 within the load heat exchanger 12 provides a significant additional cooling in the system. The chamber is flooded for maximum evaporation; excess water is drawn off in the sump 52. Any condensation from ambient air may also be used in the spray system.
In a variant of the arrangements of FIG. 1 and 2, shown schematically in FIG. 3, the waste heat from the recuperator 36 is introduced to the recirculated air duct in a somewhat different fashion. In FIG. 3, in which like elements have been given like reference numerals, the auxiliary heat ducting 40, 44 has been replaced by ducts 41, 43 and 45. Ducts 43 and 41 interconnect to the inlet of the compressor 22 via a valve 49 at the outlet of the sink heat exchanger 38. Duct 45 extends from the inlet side of the heat exchanger 38 (recuperator 36 outlet) to the downstream side of the air circulation duct 14 to transmit air from the recuperator 36 directly into the air circulation return. A valve 37 is provided in the duct 45 to block backflow into the sub-atmospheric cycle during operation in the cooling mode.
In the heating mode operation as shown in FIG. 3, auxiliary air from the recirculation duct 14 is taken off upstream of load heat exchanger 12 and passes via ducts 43, 41 and the valve 49 directly to the inlet side of the compressor 22. Valve 49 blocks the outlet of the sink heat exchanger 38 so that no air passes through the exchanger 38. Instead, the air from the recuperator 36, which is still at an elevated temperature and possesses substantial heat, passes to the air circulation return 14 by way of the duct 45. In the heating mode, this air provides about 60% of the heating capacity for the system. Except for this variation, the operation of the system of FIG. 3 is the same as previously described for FIG. 1 in the heating mode. In the cooling mode, the valve 49 is turned so as to block air flow through the ducts 41 and 43 and to direct air from the sink heat exchanger 38 to the compressor 22. In the cooling mode, no air flows through the duct 45.
Still another variation of the heat-driven air-cycle heat pump of the present invention is illustrated schematically in FIGS. 4A and 4B. This is essentially like the arrangement of FIG. 3 except that a pair of turbo-compressors are provided in place of the single three-wheel turbo machine of FIG. 3. In the schematic diagrams of FIGS. 4A and 4B, the transfer valves have been omitted for the sake of simplicity.
FIGS. 4A and 4B represent the operation of the dual turbo-compressor system in the heating and cooling modes, respectively. As depicted, the system includes a pair of turbo-compressors 60, 64. The unit 64 is in the Brayton cycle heat pump portion of the system which is driven pneumatically by the Brayton power cycle portion of the system, comprising the turbo-compressor 60. As a further modification, ducting 68, including fan 69, is provided to introduce ambient air into the recirculation air for the house after the ambient air passes through the regenerator 24.
In this arrangement, both the power and conditioning cycle compressors 62, 66 take in house air as the cycle working fluid. The air is compressed with a consequent increase in temperature, and about 40% of the power cycle air from compressor 62 is added to the conditioning cycle at the outlet of the compressor 66. This high pressure air eventually expands through the conditioning cycle turbine 65--after passing through the load heat exchanger 12 and the regenerator 24--to provide the power that drives the conditioning cycle turbomachine 64. In this process, the conditioning cycle air is cooled to near house air temperature by the recycled house air in the load heat exchanger 12. The house air in turn gains heat and is ducted back to the house at an elevated temperature to provide heating. In passing through the regenerator 24, the cycle air is cooled by ambient air coming into the house, which in turn is heated to approximately the temperature of the house and is mixed with the house return air via duct 68. This fresh air replaced the conditioned cycle air which is leaving the house and preserves air flow balance within the house.
The cycle air at the conditioned air turbine 65 expands to ambient pressure and is released to atmosphere. The power generated by the turbine 65 drives the compressor 66.
After the approximately 40% of the power cycle air is bled off to the outlet of the compressor 66, as described above, the remaining 60% passes through the recuperator 36 and combustion heat exchanger 34 where it is heated to its maximum temperature. This air is then expanded through the power cycle turbine 61, generating the power to drive the power cycle compressor 62. This air is still hot and passes through to the other side of the recuperator 36 and is returned to the house via the auxiliary return duct 68A which joins the main return duct 14. The sink heat exchanger 38 is not utilized in the system when in the heating mode corresponding to FIG. 4A.
When the two transfer valves (see FIG. 1) are rotated to switch from heating to cooling, thus developing the system configuration as shown in FIG. 4B, the conditioning cycle also shifts from pressurized operation to sub-atmospheric. A comparison of FIGS. 4A and 4B indicates that the power cycle air is routed through the power cycle turbomachinery as before, but the conditioning cycle air now goes through the turbine 65 first, instead of the compressor 66. The conditioning cycle air is taken from the house via duct 67 and expanded through the turbine 65 to sub-atmospheric pressure where the work of expansion causes a drop in air temperature. Next, water is sprayed into the lower pressure air by a spray head 50 at the input to the load heat exchanger 12. This water evaporates to remove the heat of vaporization from the house air in the load heat exchanger 12. Because of the low sub-atmospheric pressure, the air will hold more water than normal, and the evaporative cooling capability of the cycle air is increased. The recirculated house air in turn is cooled by the cycle air, and any excess moisture condenses on the downstream side of the load heat exchanger 12. This moisture, along with a minor amount of makeup water, is used for the water spray supply (not shown). The regenerator 24 then cools the ambient air introduced into the house to replace the air expelled from the house by the cycle. Any condensation from the ambient air is also used for the spray system 69.
The low pressure air is next pumped up to ambient levels by the two compressors 62, 66. The power generated by the conditioning cycle turbine 65 is enough to pump about 50% of the cycle flow, and the power cycle compressor 62 compresses the remainder, along with the power cycle turbine flow. Thus, the power cycle in this arrangement provides pneumatic power by evacuating the low pressure side of the conditioning cycle. The conditioning cycle air, compressed to atmospheric pressure by the compressors 62, 66, is vented to ambient.
Because in the cooling mode the cycle is run at sub-atmospheric pressure, the Brayton power cycle must be run in a closed loop. Therefore the discharge air from the turbine 61, after passing through the recuperator 36, is cooled by the sink heat exchanger 38 before returning to the power cycle compressor inlet. In the cooling mode, none of the power cycle air enters the house, and the cooling is provided by the conditioning cycle portion only.
FIGS. 5 and 6 illustrate schematically an electrically driven heat pump system in accordance with the invention which is essentially the same as the systems depicted in FIGS. 1-3 except that an electric motor is substituted for the primary drive which was supplied by a Brayton cycle turbine in the heat driven systems. Thus FIGS. 5 and 6 use corresponding reference numerals to designate corresponding elements which are common to the arrangements of FIGS. 1-3. This electrically driven system includes a turbo-compressor 70 comprising turbine 72 and compressor 74 as the conditioning cycle turbomachine. Mounted on the turbo-compressor shaft is an electric motor 76, shown for connection to electric mains and controlled by a suitable control circuitry (not shown). The motor 76 includes a heat exchange element 78 in the form of a coil carrying air from the compressor 74. A by-pass valve 79 is mounted in the outlet line from the compressor 74 and, for the heating mode operation as shown in FIG. 5, is in the blocked position.
As shown in FIG. 5, cold ambient air ducted from outside the house is first heated in the regenerative heat exchanger 24 to near the temperature of the heated space and is then ducted through valve 28 to the compressor 74. The air is then compressed and its temperature is raised well above that required for the heated space and is ducted through the load heat exchanger 12 where it provides the heat for the recirculated air. It then returns through the regenerative heat exchanger 24, is cooled to near ambient temperature, and is then expanded across the turbine 72 to a temperature well below ambient and is exhausted through the valve 26. This expansion process provides a portion of the energy required to drive the compressor 74. The remaining energy is provided by the electric motor 76. The air from the compressor 74 passes through the loop 78, cooling the motor 76 and picking up the motor heat for further heating of the house circulation air in the load heat exchanger 12.
In the cooling mode, depicted in FIG. 6, the electrically driven heat pump system operates to initially cool the warm ambient air in the regenerator 24. This air then flows to the turbine 72 where it is expanded to sub-atmospheric pressure. The temperature decreases well below the temperature of the conditioned space and this cooled air draws heat from the circulation air in the load heat exchanger 12. Water is injected at the inlet of the load heat exchanger 12, as already described, for further cooling due to evaporation of the water. As before, the expansion energy at the turbine 72 provides a portion of the energy required for the compressor 74. The remainder of the necessary energy is provided by the electric motor 76. Cycle air from the regenerator 24 is directed to the compressor 74 where it is compressed back to ambient pressure and is exhausted through valve 26.
If desired, the system of FIGS. 5 and 6 may be modified along the lines shown and described for the system of FIG. 3 to divert a portion of the recirculation air through the cooling element associated with the motor 76 so that the waste motor heat is transferred directly into the recirculation air.
By virtue of the various arrangements in accordance with the present invention as shown in the accompanying drawings and described hereinabove, a particularly effective and efficient heat pump system for residential use may be realized. Each of the various components incorporated in the systems are readily available, off-the-shelf items. For example, the recuperator (and other heat exchanger components, as desired) may utilize structure corresponding to the formed plate type heat exchanger of U.S. Pat. No. 4,073,340 of Kenneth O. Parker, assigned to the Assignee of this invention. The combustor may correspond to that described in the above-mentioned article by Friedman. The coefficient of performance (COP), as defined by Friedman, compares favorably with the COP of existing systems, with which the systems of the present invention are designed to compete. In one embodiment of the heat driven air cycle heat pump, the system is estimated to have a heating COP of approximately 1.6 on a 45° F. day (in the heating mode). It is worth noting that as the ambient temperature falls below 45° F., this system does not have a reduction in total heating capacity, as is common with conventional vapor compression equipment. In addition, the heating COP will also not diminish to any great extent. Another important advantage of this system is the fact that, since the ambient air is heated in the regenerated heat exchanger, there is no frost problem commonly associated with vapor compression equipment. In the cooling mode, the system is capable of achieving a COP of 0.8, which is improved to a value exceeding 1.0 through the utilization of the water spray technique as shown in FIG. 2.
Systems in accordance with the present invention, when compared with existing installed gas furnaces and electrical air conditioning systems have been estimated to have a favorable pay-out time, by virtue of their improved efficiency and reduced operating costs, of five to ten years. With economies to be realized from higher volume production, and at the presently high and apparently increasing cost of fuel, the pay-out time from economy of operation should reduce substantially.
Although there have been described above specific arrangements of heat pump systems for residential use in accordance with the invention for the purpose of illustrating the manner in which the invention may be used to advantage, it will be appreciated that the invention is not limited thereto. Accordingly, any and all modifications, variations or equivalent arrangements which may occur to those skilled in the art should be considered to be within the scope of the invention.
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An air conditioning system of the air cycle heat pump type for selectively heating and cooling a residence or similar space environment. In one embodiment, a combustor and associated Brayton cycle turbine provide the primary drive to a compressor constituting the heat pump. In a second embodiment, the Brayton turbine is replaced by an electric motor coupled to drive the compressor shaft. An auxiliary turbine is also coupled to the drive shaft to provide auxiliary drive derived from the operation of a portion of the system at sub-atmospheric pressure. In this portion, during the cooling mode, water is evaporated into the system to further assist in cooling by removing the latent heat of vaporization.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates to devices for choking a fluid flow path. More specifically, this invention relates to ceramic choke designs that have multiple sections of ceramic with retaining mounts shrunk fit around them, which in turn are mounted into a housing.
[0003] 2. Description of Related Art
[0004] A variety of choke devices have been used for some time in the control of fluid through a conduit. Typically, these prior devices consist of one large piece of ceramic, with a one piece housing that is shrunk to fit over the ceramic, thereby making a tight fit when cooled. The housing is typically composed of titanium. For general background material, the reader is directed to U.S. Pat. Nos. 4,774,914 and 5,246,074 each of which is hereby incorporated by references in its entirety for the material contained therein.
SUMMARY OF THE INVENTION
[0005] It is desirable to provide a choke device for controlling the flow of fluid through a conduit. In particular, it is desirable to provide a choke design, which reduces thermal stresses. Moreover, it is desirable to provide a choke design that facilitates the use of sensors within the choke. It is also desirable to provide a choke design with improved manufacturability and maintenance.
[0006] Therefore, it is the general object of this invention to provide a choke device that has a retainer and sleeve walls with smaller overall wall thickness, which reduces the thermal stresses created when the fluid temperature fluctuates.
[0007] It is a further object of this invention to provide a choke device that uses a plurality of ceramic segments, each of which fits into a relatively thin walled retainer, thereby allowing the retainer to be more complaint.
[0008] It is another object of this invention to provide a choke device that provides reduced stress variations associated with variances in choke clearances.
[0009] Another object of this invention is to provide a choke device that uses a ductile retainer thereby providing the ability to withstand additional fluctuations in stress than is possible with brittle ceramic alone.
[0010] A further object of this invention is to provide a choke device, which uses shorter segments that are easier to construct, and which can be produced with tighter tolerances.
[0011] A still further object of this invention is to provide a choke device, which can more easily be assembled by shrink fitting with the retainers.
[0012] Another object of this invention is to provide a choke device which has segmented members that can be replaced individually, allowing for reductions in maintenance costs.
[0013] It is another object of this invention to provide a choke device that more accurately controls compressive stresses during construction of the choke.
[0014] It is a further object of this invention to provide a choke device that accommodates the inclusion of sensors into individual segments of the choke, allowing for indicators of choke segment integrity without disassembly of the choke and taking it out of service.
[0015] These and other objects of this invention are achieved by the device described herein and are readily apparent to those of ordinary skill in the art upon review of this disclosure and/or ordinary experimentation with the device described herein.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] [0016]FIG. 1 is a section view of the preferred segmented choke of this invention.
[0017] [0017]FIGS. 2 a and 2 b are detailed section and end views of the sleeve of the first segment of the preferred segmented choke of this invention.
[0018] [0018]FIGS. 3 a and 3 b are detailed section and end views of the sleeve of the second segment of the preferred segmented choke of this invention.
[0019] [0019]FIGS. 4 a and 4 b are detailed section and end views of the sleeve of the third segment of the preferred segmented choke of this invention.
[0020] [0020]FIGS. 5 a and 5 b are detailed section and end views of the upper inner ring of the preferred choke of this invention.
[0021] [0021]FIGS. 6 a and 6 b are detailed section and end views of the lower inner ring of the preferred choke of this invention.
[0022] [0022]FIGS. 7 a and 7 b are detailed section and end views of the first housing section of the preferred choke of this invention.
[0023] [0023]FIGS. 8 a and 8 b are detailed section and end views of the second housing section of the preferred choke of this invention.
[0024] [0024]FIGS. 9 a and 9 b are detailed section and end views of upper flange ring of the preferred choke of this invention.
[0025] [0025]FIGS. 10 a and 10 b are detailed section and end views of the lower flange ring of the preferred choke of this invention.
DETAILED DESCRIPTION OF THE INVENTION
[0026] Referring now to the figures and particularly to FIG. 1, which is a section view of the preferred embodiment 100 of the segmented choke of this invention. In this embodiment three ceramic sections 101 , 102 , 103 are provided within a retainer fixtures 104 , 105 , 106 . The first ceramic section 101 , containing a sleeve 200 and a first ceramic region 113 , is held in place by the first retainer 106 . The second ceramic section 102 , containing a sleeve 300 and a second ceramic region 114 , is held in place by the second retainer 105 . The third ceramic section 103 , containing a sleeve 400 and a third ceramic region 115 , is held in place by the third retainer 104 . Each ceramic section 101 , 102 , 103 is shrunk fit into its retainer fixture 104 , 105 , 106 . The retainer fixtures 104 , 105 , 106 are then mechanically mounted into a housing, which is composed of two parts an upper housing 111 and a lower housing 112 . The first 106 and second 105 retainer fixtures are held together by an upper mount 107 . The second 105 and third 104 retainer fixtures are held together by a lower mount 108 . The upper housing 111 and the lower housing 112 are held together by two flange rings 109 , 110 .
[0027] [0027]FIG. 2 a , a section view of the sleeve 200 of the first ceramic section 101 and associated retainer 106 , provides additional dimensional detail of the preferred embodiment of this invention. This sleeve 200 has a first end 202 and a second end 203 . In the preferred embodiment, the first end 202 has an inner diameter of 6.50 inches and an outer diameter of 6.750 inches. The second end 203 has an outer diameter of 7.250 inches. The length 205 of the side 204 of this preferred embodiment is 7.330 inches. FIG. 2 b shows the end view of the sleeve 200 of the first ceramic section 101 and retainer 106 . The ceramic section 101 is adapted to permit the inclusion of a sensor for making a variety of flow rate, temperature, pressure and content measurements.
[0028] [0028]FIG. 3 a , a section view of the sleeve 300 of the second ceramic section 102 and associated retainer 105 , provides additional dimensional detail of the preferred embodiment of this invention. This sleeve 300 has a first end 302 and a second end 303 . In the preferred embodiment, the first end 302 has an inner diameter of 6.50 inches and an outer diameter of 6.750 inches. The second end 303 has an outer diameter of 7.250 inches. The length 305 of the side 304 of this preferred embodiment is 7.330 inches. FIG. 3 b shows the end view of the sleeve 300 of the second ceramic section 102 and retainer 105 . This ceramic section 102 is also adapted to permit the inclusion of a sensor for making a variety of flow rate, temperature, pressure and content measurements.
[0029] [0029]FIG. 4 a , a section view of the sleeve 400 of the third ceramic section 103 and associated retainer 104 , provides additional dimensional detail of the preferred embodiment of this invention. This sleeve 400 has a first end 402 and a second end 403 . In the preferred embodiment, the first end 402 has an inner diameter of 8.80 inches and an outer diameter of 9.50 inches. The second end 403 has an outer diameter of 9.180 inches. FIG. 4 b shows the end view of the sleeve 400 of the third ceramic section 103 and retainer 104 . This ceramic section 103 is also adapted to permit the inclusion of a sensor for making a variety of flow rate, temperature, pressure and content measurements.
[0030] [0030]FIG. 5 a , a section view of the upper inner ring 107 , provides additional dimensional detail of the preferred embodiment of this invention. The preferred embodiment of this upper inner ring 107 has an outer diameter of 9.910 inches and an inner opening 502 diameter of 6.760 inches. The preferred ring 501 is composed of titanium. FIG. 5 b shows the end view of the upper inner ring 107 .
[0031] [0031]FIG. 6 a , a section view of the lower inner ring 108 , provides additional dimensional detail of the preferred embodiment of this invention. The preferred embodiment of this lower inner ring 108 has an outer diameter of 9.740 inches and an inner opening 602 of 6.760 inches. The preferred ring 601 is composed of titanium. FIG. 6 b shows the end view of the lower inner ring 108 .
[0032] [0032]FIG. 7 a , a section view of the first housing section 111 , provides additional dimensional detail of the preferred embodiment of this invention. This housing 111 has a first end 703 and a second end 704 . The preferred dimensions of this housing section 111 are shown in inches in this FIG. 7 a . A first gasket surface 701 and a second gasket surface 702 are provided. In its preferred embodiment the first housing section 111 is composed of titanium. FIG. 7 b shows the end view of the first housing section 111 .
[0033] [0033]FIG. 8 a , a section view of the second housing section 112 , provides additional dimensional detail of the preferred embodiment of this invention. This housing 112 has a first end 801 and a second end 802 . The preferred dimensions of this housing section 112 are shown in inches in this FIG. 8 a . In its preferred embodiment the first housing section 112 is composed of titanium. FIG. 8 b shows the end view of the second housing section 112 and retainer 106 .
[0034] [0034]FIG. 9 a , a section view of the upper flange ring 109 , provides additional dimensional detail of the preferred embodiment of this invention. This flange ring 109 has a first end 903 and a second end 904 . A ring 902 is provided with a plurality of openings 905 a - j , each of which is adapted to receive and accommodate bolt and nut fasteners. Alternative fasteners, such as rivets, screws and the like can be substituted without departing from the concept of this invention. The preferred material for the ring 109 is titanium. The preferred dimensions of this flange ring 109 are shown in inches in this FIG. 9 a . FIG. 9 b shows the end view of the upper flange ring 109 .
[0035] [0035]FIG. 10 a , a section view of the lower flange ring 110 , provides additional dimensional detail of the preferred embodiment of this invention. This flange ring 110 has a first end 1003 and a second end 1004 . The ring 1002 is provided with a plurality of openings 1005 a - j , each of which is adapted to receive and accommodate bolt and nut fasteners. Alternative fasteners, such as rivets, screws and the like can be substituted without departing from the concept of this invention. The preferred material for the ring 110 is titanium. The preferred dimensions of this flange ring 110 are shown in inches in this FIG. 10 a . FIG. 10 b shows the end view of the lower flange ring 110 .
[0036] It is to be understood that the above-described embodiment of the invention is merely illustrative of numerous and varied other embodiments, which may constitute applications of the principles of the invention. Such other embodiments may be readily devised by those skilled in the art without departing from the spirit or scope of this invention and it is our intent that they are deemed as within the scope of our invention.
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A new segmented choke is provided. Designed to reduce thermal stresses created when the fluid temperature fluctuate, this invention is constructed of segmented ceramic members fit within a relatively thin-walled retainer, shrunk fit thereto, thereby allowing the retainer to be more compliant. Shorter, multiple segments used in this invention are also easier to manufacture, can be produced with tighter tolerances, provide easier access thereby reducing maintenance costs and allow for the inclusion of sensors in the individual ceramic segments. This invention also provides improvements in size, manufacturing cost, ease of use and operating efficiency over prior choke devices.
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This application claims the benefit of Korean Application No. P2003-085616, filed on Nov. 28, 2003, which is hereby incorporated by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a dryer, and more particularly, to a heater bracket assembly for securing a heater case in a dryer.
2. Discussion of the Related Art
Generally, a laundry dryer is a home appliance for drying a wet laundry automatically. The dryer is provided with a heater for drying a laundry and a heater bracket assembly supporting the heater. The heater bracket assembly is explained in detail by referring to the attached drawings as follows.
Referring to FIG. 1 , a dryer 1 consists of a case 10 forming an exterior and a base plate 20 forming a bottom side. An opening 30 is formed in a front side of the case 10 to put/pull a laundry in/from the case and a door 40 is provided to the opening 30 to open/close. And, a drum 50 is rotatably provided within the case 10 to dry a wet laundry therein. Meanwhile, a heater 61 providing hot air to the drum 50 and a heater case 62 accommodating the heater 61 are provided within a space between the drum 50 and the base plate 20 . And, the heater case 62 is fitted in a duct 80 having one open end and the other end communicating with the drum 50 to be coupled thereto without a separate fixing member.
In order to fix the heater case 62 to the base plate 20 , a heater bracket assembly 70 is provided. A process of assembling the heater bracket assembly 70 , base plate 20 , and heater case 62 is explained by referring to FIG. 2 as follows. The heater bracket assembly 70 has a type cross-section. Holes 21 and 71 are formed at both lower ends of the heater bracket assembly 70 and the base plate 20 , respectively. A fixing member is fitted in the corresponding holes 21 and 71 to fix the heater bracket assembly 70 to the base plate 20 .
Meanwhile, an upper end of the heater bracket assembly 70 supports the heater case 62 without a separate fixing member. However, when the heater bracket assembly supports the heater case in the above-explained manner, the following problems are inevitable.
First of all, the heater bracket assembly 70 and the heater case 62 are shaken when the dryer is carried or installed. Namely, when the dryer is shaken, the heater case is detached from the duct to be movable within the dryer. Secondly, in fixing the heater bracket to the base plate, it takes quite a long working time to align the holes of the base plate and heater bracket assembly to each other. Moreover, the corresponding fixing work is not facilitated.
SUMMARY OF THE INVENTION
Accordingly, the present invention is directed to a heater bracket assembly for a dryer that substantially obviates one or more of the problems due to limitations and disadvantages of the related art.
An object of the present invention, which has been devised to solve the foregoing problem, lies in providing a heater bracket assembly for a dryer, by which a heater case is prevented from being separated from a duct.
Another object of the present invention to provide a heater bracket assembly for a dryer, by which the heater bracket assembly is easily fixed to a base plate and by which a corresponding working time is shortened.
Additional features and advantages of the invention will be set forth in the description which follows, and in part will be apparent to those having ordinary skill in the art upon examination of the following or may be learned from a practice of the invention. The objectives and other advantages of the invention will be realized and attained by the subject matter particularly pointed out in the specification and claims hereof as well as in the appended drawings.
To achieve these objects and other advantages in accordance with the present invention, as embodied and broadly described herein, a heater bracket assembly for securing a heater case in a dryer includes a supporting part secured to a bottom end of the heater case for supporting the heater case, a fixing part secured to a base plate of the dryer, and a connecting part connecting the supporting part and the fixing part, wherein the supporting part comprises a first extension member extended therefrom which engages with an aperture provided to the bottom end of the heater case such that the supporting part is initially secured to the heater case.
Herein, the fixing part may include a second extension member extended therefrom which engages with an aperture provided on the base plate such that the fixing part is initially secured to the base plate. The second extension member may include a first protrusion protruding downward from a portion of the fixing part to penetrate the aperture provided on the base plate, and a second protrusion protruding forward from a tip of the first protrusion to be in contact with and be supported by a bottom side of the base plate. A tip portion of the second protrusion is tilted such that the second extension member easily engages with the aperture provided on the base plate.
The supporting part may include at least one through-hole adopted to receive a fastener for securing the bottom end of the heater case to the supporting part. Herein, the fixing part may include at least one through-hole adopted to receive a fastener for securing the fixing part to the base plate. Also, at least one bead is provided to the connecting part for rigidity reinforcement, and the connecting part is tilted forward.
In another aspect of the present invention, a heater bracket assembly for securing a heater case in a dryer includes a supporting part secured to a bottom end of the heater case for supporting the heater case, a fixing part secured to a base plate of the dryer, a connecting part connecting the supporting part and the fixing part, a first extension member extended from the supporting part for engaging with an aperture provided to the bottom end of the heater case, and a second extension member extended from the fixing part for engaging with an aperture provided on the base plate.
In a further aspect of the present invention, a heater bracket assembly for securing a heater case in a dryer includes a supporting part secured to a bottom end of the heater case for supporting the heater case, a fixing part secured to a base plate of the dryer, a connecting part connecting the supporting part and the fixing part, the connecting part being tilted forward, a first extension member extended from the supporting part for engaging with an aperture provided to the bottom end of the heater case, a second extension member extended from the fixing part for engaging with an aperture provided on the base plate, and at least one bead provided to the connecting part for rigidity reinforcement.
It is to be understood that both the foregoing explanation and the following detailed description of the present invention are exemplary and illustrative 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 embodiments of the invention and together with the description serve to explain the principle of the invention. In the drawings:
FIG. 1 is a cross-sectional diagram of a dryer according to a related art;
FIG. 2 is a perspective diagram of a heater bracket assembly according to a related art;
FIG. 3 is a cross-sectional diagram of a dryer according to the present invention;
FIG. 4 is a perspective diagram of the heater bracket assembly according to the present invention; and
FIG. 5 is perspective diagram of the heater bracket assembly coupled to a heater case according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Reference will now be made in detail to the preferred embodiments of the present invention, examples of which are illustrated in the accompanying drawings. Throughout the drawings, like elements are indicated using the same or similar reference designations where possible.
FIG. 3 is a cross-sectional diagram of a dryer 100 provided with a heater bracket assembly 300 according to the present invention. Referring to FIG. 3 , a dryer 100 includes a base plate 120 forming a bottom side and a case 110 on the base plate 120 to form an exterior and. An opening 130 is formed in a front side of the case 110 to put/pull a laundry in/from the case and a door 140 is provided to the opening 130 to open/close. A drum is rotatably provided within the case 110 to hold a laundry therein. Front and rear sides of the drum are rotatably coupled to front and rear supports 160 and 170 , respectively. An inlet duct 180 provided in rear of the drum and an outlet duct 190 is provided in front of the drum, whereby the drum can be externally ventilated. The inlet and outlet ducts 180 and 190 are coupled to upper and lower parts of the drum, respectively.
A motor 200 is provided under the drum to generate a rotational force. In order to transfer the rotational force generated from the motor 200 to the drum, a pulley 210 is coupled to one side of the motor 200 and the pulley 210 is connected to the drum via belt 220 . A blower fan 230 is connected to the other side of the motor 200 . The blower fan 230 is connected to the outlet duct 190 to suck the air inside the drum to discharge outside the case 110 . A heater 240 is provided under the drum to dry the laundry held within the drum. The heater 240 heats air to supply the heated air to the drum. The heater 240 is provided within a heater case 250 . In order for the heater 240 to heat the air, one side of the heater case 250 is open and the other side of the heater case 250 is connected to the inlet duct 180 .
Meanwhile, the heater case 250 is provided over the base plate 120 via a heater bracket assembly 300 . The heater bracket assembly 300 is explained by referring to FIGS. 4 and 5 as follows. The heater bracket assembly 300 includes a supporting part 310 , a fixing part 320 , and a connecting part 330 . The supporting part 310 supports a bottom side of the heater case 250 . Specifically, the supporting part 310 is fixed (or secured) to a bottom of an open side of the heater case 250 to support the heater case 250 . Holes 251 and 311 are formed in the heater case 250 and the supporting part 310 , respectively, so as to allow a fixing member 260 to pass through. The fixing member 260 is inserted in both of the holes 251 and 311 to fix the heater case 250 to the supporting part 310 .
Meanwhile, the fixing part 320 is fixed to a topside of the base plate 120 . Holes 321 and 121 are formed in the fixing part 320 and base plate 120 to be penetrated by a fixing member 260 . The corresponding fixing member 260 is inserted in the holes 321 and 121 to fix the fixing part 320 to the base plate 120 . The fixing member 260 preferably includes a bolt and nut or a rivet. The connecting part 330 connects the fixing part 320 and the supporting part 310 . And, the connecting part 330 is tilted forward from the supporting part 310 to the fixing part 320 . Moreover, the connecting part 330 is provided with at least one bead 340 for rigidity reinforcement.
The bead 340 prevents the connecting part 330 from being bent by a weight applied to the connecting part 330 by the heater case 250 . In this case, the bead 340 is preferably projected toward a rear side of the connecting part 330 . In order to facilitate to manufacture the heater bracket assembly 300 , the heater bracket assembly 300 includes one plate. The one plate is bent to form the fixing, supporting, and connecting parts 320 , 310 , and 330 .
The heater bracket assembly 300 further includes an extension member 350 provided to at least one portion of the supporting part 310 and/or the fixing part 320 to temporarily fix the heater bracket assembly 300 to the heater case 250 and/or the base plate 120 and to guide a corresponding fixing position. Specifically, the extension member 350 includes a first extension member 351 guiding to maintain a corresponding installing position before the heater case 250 is fixed to the heater bracket assembly 300 by the fixing member 260 . The first extension member 351 is provided to the supporting part 310 to protrude upward from the supporting part 310 . And, the heater case 250 has a hole 252 to be penetrated by the first extension member 351 . Moreover, the extension member 350 penetrates the heater case 250 to prevent from moving on the supporting part 310 .
And, the extension member 350 includes a second extension member 355 guiding to maintain a corresponding installing position before the heater bracket assembly 300 is fixed to the base plate 120 by the corresponding fixing member 260 . The second extension member 355 is provided to the fixing part 320 to protrude downward from the fixing part 320 . And, the base plate 120 has a hole 122 to be penetrated by the second extension member 355 . The second extension member 355 is explained in detail in the following.
First of all, the second extension member 355 includes a first protrusion 356 protruding from a lower part of the fixing part 320 to penetrate the base plate 120 and a second protrusion 357 protruding forward from a tip of the first protrusion 356 to be supported by a bottom side of the base plate 120 . The first protrusion 356 guides a fixing position when the heater bracket assembly 300 is fixed to the topside of the base plate 120 . And, the second protrusion 357 is supported by the bottom side of the base plate 120 to maintain a balance of the heater bracket assembly 300 and to fix the heater bracket assembly 300 to the topside of the base plate 120 . In this case, in order to facilitate to insert the second protrusion 357 in the base plate 120 , a tip of the second protrusion 357 is tilted toward a ground in a front direction.
A process of assembling the heater bracket assembly 300 to the base plate 120 and the heater case 250 is explained as follows. First of all, the heater bracket assembly 300 is fixed to the topside of the base plate 120 using the second extension member 355 . In doing so, the first protrusion 356 is inserted in the base plate 120 and the second protrusion 357 is supported by the bottom side of the base plate 120 . Thus, the heater bracket assembly 300 enables to maintain its balance.
Secondly, the holes 321 and 121 of the fixing part 320 and base plate 120 are aligned to each other. The fixing member 260 is then inserted in the holes 321 and 121 to completely fix the heater bracket assembly 300 to the base plate 120 . In this case, the fixing member 260 includes the bolt and nut or rivet.
Thirdly, the heater case 250 is temporarily fixed to the supporting part 310 . In doing so, the first extension member 351 penetrates the lower part of the heater case 250 . Once the first extension member 351 temporarily fixes the heater case 250 to the supporting part 310 , the holes 251 and 311 of the heater case 250 and supporting part 310 are aligned to each other. The corresponding fixing member 260 then penetrates the holes 251 and 311 to completely couple the heater case 250 to the supporting part 310 .
Accordingly, the heater bracket assembly according to the present invention includes the extension member temporarily fixing the heater bracket assembly to the heater case and the base plate, thereby facilitating to be fixed to the heater case and base plate and shortening a working time. And, the heater case is completely fixed to the heater bracket assembly and the heater bracket assembly is completely fixed to the base plate. Therefore, the heater case is prevented from being detached from the inlet duct.
It will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the spirit or scope of the invention. Thus, it is intended that the present invention cover such modifications and variations, provided they come within the scope of the appended claims and their equivalents.
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A heater bracket assembly for securing a heater case in a dryer is disclosed. The heater bracket assembly includes a supporting part secured to a bottom end of the heater case for supporting the heater case, a fixing part secured to a base plate of the dryer, and a connecting part connecting the supporting part and the fixing part, wherein the supporting part comprises a first extension member extended therefrom which engages with an aperture provided to the bottom end of the heater case such that the supporting part is initially secured to the heater case.
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BRIEF DESCRIPTION OF THE INVENTION
[0001] The present invention relates to 2-aryl oxazole and thiazole derivatives that are useful for the prevention, reduction of the risk of, amelioration and/or treatment of diseases associated with the activity of the Transient Receptor Potential cation channel subfamily M member 8 (hereinafter TRPM8) also known as Cold Menthol Receptor 1 (CMR-1), and in particular for the prevention, reduction of the risk of, amelioration and/or treatment of itch, irritable bowel diseases, cold induced and/or exhacerbated respiratory disorders, ischaemia, pain, neurodegeneration, psychiatric disorders, stroke and urological disorders. The invention further relates to pharmaceutical compositions containing the above compounds.
BACKGROUND OF THE INVENTION
[0002] Transient Receptor Potential (TRP) channels are one of the largest group of ion channels and, based on their sequence homology, are classified into 6 sub-families (TRPV, TRPM; TRPA, TRPC, TRPP and TRPML). TRP channels are cation-selective channels activated by several physical (such as temperature, osmolarity and mechanical stimuli) and chemical stimuli. TRPM8, which was cloned in 2002, is a non-selective cation channel of the TRP family expressed on a subpopulation of somatic sensory nerves on dorsal root ganglion and trigeminal ganglia that causes sensory nerve excitation. It is activated by mild cold temperatures and synthetic cool-mimetic compounds such as menthol, eucalyptol and icilin [McKemy D. D. et al., Nature (2002) 416, 52-58; Peier A. M. et al. Cell (2002) 108, 705-715]. Like several other TRP channels, TRPM8 is also gated by voltage [Nilius B. et al., J. Physiol. (2005) 567, 35-44]. The voltage dependence of TRPM8 is characterized by a strong outward rectification at depolarized transmembrane potential and a rapid and potential-dependent closure at negative membrane potentials. Cooling agents and menthol application shifts the activation curve towards more negative potentials, increasing the possibility for the opening of the channel and boosting inward currents at physiological membrane potentials. Other endogenous factors, such as phospholipase A 2 products [Vanden Abeele F. et al., J. Biol. Chem. (2006) 281, 40174-40182], endocannabinoids [De Petrocellis L. et al., Exp. Cell. Res. (2007) 313, 1911-1920] and PIP2 [Rohacs T. et al., Nat. Neurosci. (2005) 8, 626-634] also participate in channel regulation.
[0003] There is a lot of direct and indirect evidence of a pivotal role of TRPM8 channel activity in diseases such as pain, ischemia and itch, irritable bowel diseases, cold induced and/or exhacerbated respiratory disorders. Further, it has been demonstrated that TRP channels transduce reflex signals that are involved in the overactive bladder of patients with damaged or abnormal spinal reflex pathways [De Groat W. C. et al., Urology (1997) 50, 36-52]. TRPM8 is activated by temperatures between 8° C. and 28° C. and expressed on the primary nociceptive neurons, including bladder urothelium, dorsal root ganglia, A-delta and C-fibers. The intravesical ice water or menthol also induce C-fiber mediated spinal micturition reflex in patients with urgency and urinary incontinence [Everaerts W. et al., Neurol. Urodyn. (2008) 27, 264-73].
[0004] Furthermore, TRPM8 is known to regulate Ca 2+ concentration influxes in response to cold temperature or pharmacological stimuli. Finally, in a recent paper, the potential role of TRPM8 in cold-induced asthma and in asthma exacerbation has been proposed, suggesting TRPM8 also a relevant target for the management of these pathologies [Xing H. et al., Molecular Pain (2008), 4, 22-30].
[0005] The expression of the channel in brain, lung, bladder, gastrointestinal tract, blood vessels, prostate and immune cells provide further possibility for therapeutic modulation of the activity of TRPM8 in a wide range of pathologies. In particular, the disorders or diseases that have been proven to be affected by the modulation of TRPM8 are pain such as chronic pain, neuropathic pain including cold allodynia and diabetic neuropathy, postoperative pain, osteoarthritic pain, rheumatoid arthritic pain, cancer pain, neuralgia, neuropathies, algesia, fibromyalgia, nerve injury, migraine, headaches; ischaemia, neurodegeneration, stroke, psychiatric disorders, including anxiety and depression, and itch, irritable bowel diseases, cold induced and/or exhacerbated respiratory disorders such as cold induced and/or exhacerbated pulmonary hypertension, asthma and COPD; urological disorders such as painful bladder syndrome, interstitial cystitis, detrusor overactivity (overactive bladder), urinary incontinence, neurogenic detrusor overactivity (detrusor hyperflexia), idiopathic detrusor overactivity (detrusor instability), benign prostatic hyperplasia, lower urinary tract disorders and lower urinary tract symptoms [Nilius B. et al. Science STKE (2005), 295, re8; Voets T. et al., Nat. Chem. Biol. (2005), 1, 85-92; Mukerji G. et al., Urology (2006), 6, 31-36; Lazzeri M. et al., Ther. Adv. Urol. (2009), 1, 33-42; Nilius B. et al., Biochim. Biophys. Acta (2007), 1772, 805-12; Wissenbach U. et al., Biol. Cell. (2004), 96, 47-54; Nilius B. et al., Physiol. Rev. (2007), 87, 165-217; Proudfoot C. J. et al., Curr. Biol. (2006), 16, 1591-1605].
[0006] Along the last few years, several classes of non peptide TRPM8 antagonists have been disclosed. WO 2006/040136, WO 2007/017092, WO 2007/017093, WO 2007/017094, and WO 2007/080109 describe benzyloxy derivatives as TRPM8 antagonists for the treatment of urological disorders; WO 2007/134107 describes phosphorous-bearing compounds as TRPM8 antagonists for the treatment of TRPM8-related disorders; WO 2009/012430 describes sulfonamides for the treatment of diseases associated with TRPM8; WO 2010/103381 describes the use of spirocyclic piperidine derivatives as TRPM8 modulators in prevention or treatment of TRPM8-related disorders or diseases; and, WO 2010/125831 describes sulfamoyl benzoic acid derivatives as modulators of the TRPM8 receptor and their use in the treatment of inflammatory, pain and urological disorders.
[0007] A therapeutic area in which there is a particularly high need for the development of antagonists of TRPM8 is that of urological-related disorders. In fact, traditional drugs and medications currently available for the treatment of urinary incontinence and disorders are characterized by several side effects. For example, at the moment, the therapy of overactive bladder syndrome is based on the use of drugs, especially anticholinergic agents that affect peripheral neural control mechanisms or bladder detrusor smooth muscle contraction. These drugs inhibit parasympathetic nerves exerting a direct spasmolytic effect on the muscle of the bladder. The result of this action is the decrease of intravesicular pressure, an increase in capacity and a reduction in the frequency of bladder contraction. However, the use of anticholinergic agents is associated with serious side effects, such as dry mouth, abnormal visions, constipation and CNS disturbances, that impair the overall patient compliance. The inadequacies of the actual therapies highlight the need for novel, efficacious and safe drugs with fewer side effects.
SUMMARY OF THE INVENTION
[0008] The aim of the present invention is to provide novel antagonists of TRPM8 with high selectivity for this specific receptor and an adequate pharmacokinetic profile for use in therapy.
[0009] The present inventors have now found a class of 2-aryl oxazole and thiazole compounds acting as selective antagonists of Transient Receptor Potential cation channel subfamily M member 8 (hereinafter referred to as TRPM8) and satisfying the above desiderata.
[0010] These compounds are useful in the treatment of pathologies associated with the activity of TRPM8.
DETAILED DESCRIPTION OF THE FIGURES
[0011] FIG. 1 shows a graphical representation of the 384 wells Compound Dilution Plate Layout used for the biological evaluation of the compounds of the invention as described in Example 119 wherein: in Column 1 wells contain assay buffer plus 0.5% DMSO; in Column 2: wells alternate Max signal control in first injection (Cooling agent 10 at 100 μM, corresponding to EC 100 ) and Min signal control in first injection (assay buffer plus 0.5% DMSO final); in columns 3-22: wells contain assay buffer plus 0.5% DMSO final and to each of these wells a compound to be tested is added, at 3× concentrations; in Column 23: wells alternate Max signal control in second injection (Assay Buffer) and Min signal control in second injection (Capsazepine at 50 mm, corresponding to IC 100 ); in Column 24: wells contain Capsazepine at 8 different concentrations in duplicate as reported in Example 119.
[0012] FIG. 2 shows a graphical representation of the 384 wells Activator Plate Layout used for the biological evaluation of the compounds of the invention as described in Example 119 wherein in Column 1 wells contain Cooling Agent 10 at 8 concentrations dose-response in duplicate at different concentrations as reported in Example 119; in Columns 2-24 wells contain Cooling Agent 10 at at EC 80 (3× concentrations, the highest being 20 μM final).
[0013] FIG. 3 shows a graph with a typical kinetic response obtained in the test described in Example 119(b) for the compounds of Table 1. Signal expressed as Relative Light Units (y-axis), is reported vs time (sec. (x-axis) following the injection of a definite amount of control/the test compounds. CA refers to the phase of Compound Addition, while TA to the Target Activation Phase perfomed in presence of the agonist, to increase the MAX Signal control, followed by the injection of a reference inhibitor for the complete abolition of the signal and the registration of the MIN Signal control.
[0014] FIG. 4 shows the value of Maximum Possible Effect, measured as described in Example 120(b), observed after 2 hours from treatment with Control (1), Compound 10 (2) or Compound 45 (3).
DETAILED DESCRIPTION OF THE INVENTION
[0015] A first object of the present invention are compounds of formula (I):
[0000]
and pharmaceutically acceptable salts thereof,
wherein
X is selected from S or O;
R 1 is selected from the group consisting of:
—OR 5 wherein R 5 is selected from H; C 1 -C 4 alkyl, trifluoromethanesulfonyl, benzyl, (trifluoromethyl)benzyl, (halo)benzyl, (trifluoromethyl)benzoyl, N-benzylcarbamoyl, cyclohexyloxyacetoyl substituted with at least one C 1 -C 3 alkyl group, (C 1 -C 3 alkoxy)methyl, C 1 -C3 alkanoyl and CH 2 CH 2 NHR 6 , wherein
R 6 is selected from H and (furan-2-yl)methyl; and
—NHR 7 wherein R 7 is selected from H, tert-butoxycarbonyl, C 1 -C3 alkanoyl, (4-trifluoromethyl)benzoyl, N-phenylaminoacarbonyl, CH 2 R 8 , wherein
R 8 is selected from phenyl, benzo[d][1,3] dioxole, pyridin-3-yl, (pyrrolidin-1-yl)methyl, —CH 2 NHR 9 wherein
R 9 is selected from H, C 1 -C 3 alkyl and cycloalkyl;
R 2 is selected from the group consisting of
—COOR 10 wherein
R 10 is selected from H, C 1 -C 3 alkyl and cyclohexyl, optionally substituted with at least one C 1 -C3 alkyl group;
—OH; —CONH 2 ; CN; -tetrazol-5-yl, 1-(C 1 -C 3 alkyl)tetrazol-5-yl, 2-(C 1 -C 3 alkyl)tetrazol-5-yl, 5-(C 1 -C 3 alkyl)1,2,4 triazol-3-yl, 5-(C 1 -C 3 alkyl) 1,2,4-oxadiazol-3yl, 5-(C 1 -C 3 alkyl) 1,3,4-oxadiazol-2-yl;
R 3 is selected from F or H,
R 4 is selected from H; CH 3 ; halogen; dimethylamino; pyridin-4yl; phenyl; 2- or 4-(halo)phenyl; 2- or 4-(trifluoromethyl)phenyl; 2- and/or 4-halobenzyloxy.
[0032] According to a preferred embodiment of the invention, in said compounds of formula I, R 5 may be selected from H, C 1 -C 4 alkyl, trifluoromethanesulfonyl, benzyl, (trifluoromethyl)benzyl, (chloro)benzyl, (trifluoromethyl)benzoyl, N-benzylcarbamoyl, cyclohexyloxyacetoyl substituted with at least one C 1 -C 3 alkyl group, (methoxy)methyl, propanoyl and CH 2 CH 2 NHR 6 wherein R 6 is as above. Particularly preferred among these compounds are compounds wherein R 5 is selected from H, methyl, isobutyl, trifluoromethanesulfonyl, benzyl, 4-(trifluoromethyl)benzyl, (chloro)benzyl, 4-(trifluoromethyl)benzoyl, N-benzylcarbamoyl, 2-isopropyl-5-methylcyclohexyloxyacetoyl, (methoxy)methyl, propanoyl and CH 2 CH 2 NHR 6 wherein R 6 is as above.
[0033] According to a further preferred embodiment of the invention, also in combination with any of the preceding embodiment, in said compounds of formula I R 7 may be selected from H, tert-butoxycarbonyl, acetyl, 4-(trifluoromethyl)benzoyl, N-phenylaminoacarbonyl, CH 2 R 8 , wherein
R 8 is selected from phenyl, benzo[d][1,3] dioxole, pyridin-3-yl, (pyrrolidin-1-yl)methyl, —CH 2 NHR 9 wherein
R 9 is selected from H, C 1 -C 3 alkyl and cyclopentyl.
[0037] According to a further preferred embodiment of the invention, also in combination with any one of the preceding embodiments, in said compounds of formula I R 10 may be selected from H, C 1 -C 3 alkyl and 2-isopropyl-5-cyclohexyl.
[0038] According to a further preferred embodiment of the invention, also in combination with any one of the preceding embodiments, in said compounds of formula I R 4 may be selected from H, CH 3 , F, Cl, dimethylamino, preferably in position para, pyridin-4y1, phenyl, 2-F-penyl, 2-trifluoromethylphenyl and 2- or 4-halobenzyloxy, wherein said halo is preferably F or Cl.
[0039] According to a further preferred embodiment of the invention, in said compounds of formula I
X is selected from S or O; R 1 is selected from the group consisting of: —OR 5 wherein R 5 is selected from H, C 1 -C 4 alkyl, trifluoromethanesulfonyl, benzyl, (trifluoromethyl)benzyl, (chloro)benzyl, (trifluoromethyl)benzoyl, N-benzylcarbamoyl, cyclohexyloxyacetoyl substituted with at least one C 1 -C 3 alkyl group, (methoxy)methyl, propanoyl and —CH 2 CH 2 NHR 6 , wherein
R 6 is selected from H and (furan-2-yl)methyl
—NHR 7 wherein R 7 is selected from H, tert-butoxycarbonyl, acetyl, (4-trifluoromethyl)benzoyl, N-phenylaminocarbonyl, CH 2 R 8 , wherein
R 8 is selected from phenyl, benzo[d][1,3] dioxole, pyridin-3-yl, (pyrrolidin-1-yl)methyl, —CH 2 NHR 9 wherein
R 9 is selected from H, C 1 -C 3 alkyl and cyclopentyl
R 2 is selected from the group consisting of —COOR 10 wherein
R 10 is selected from H, C 1 -C 3 alkyl and 2-isopropyl-5-methylcyclohexyloxycarbonyl, —OH; —CONH 2 ; CN; tetrazol-5-yl or 1-(C 1 -C 3 alkyl)tetrazol-5-yl; 2-(C 1 -C 3 alkyl)tetrazol-5-yl; 5-(C 1 -C 3 alkyl)1,2,4 triazol-3-yl; -5-(C 1 -C 3 alkyl) 1,2,4-oxadiazol-3yl; -5-(C 1 -C 3 alkyl) 1,3,4-oxadiazol-2-yl;
R 3 is selected from F or H, R 4 is selected from H, F, CL, dimethylamino, preferably in position para, pyridin-4y1, phenyl, 2-F-penyl, 2-trifluoromethylphenyl, 2- and/or 4-F-benzyloxy.
[0053] Particularly preferred compounds of the invention are compounds of formula I wherein R 1 is selected from:
—OR 5 , wherein R 5 is selected from H, benzyl, (chloro)benzyl, (trifluoromethyl)benzoyl, CH 2 —CH 2 NH 2 ; and —NHCH 2 CH 2 R 9 wherein R 9 is selected from H and C 1 -C 3 alkyl.
[0056] Particularly preferred among the compounds of the invention are also compounds of formula I wherein R 2 is selected from COOR 10 wherein R 10 is selected from H, C 1 -C 3 alkyl.
[0057] Particularly preferred among the compounds of the invention are also compounds of formula I wherein R 3 is H.
[0058] Particularly preferred among the above compounds are those compounds of formula I wherein:
R 1 is selected from: OR 5 , wherein R 5 is selected from H, benzyl, (chloro)benzyl, (trifluoromethyl)benzoyl; and CH 2 —CH 2 NH 2 ; and NHCH 2 CH 2 R 9 wherein R 9 is selected from C 1 -C 3 alkyl and H; R 2 is COOR 10 wherein R 10 is selected from H, C 1 -C 3 alkyl R 3 is H.
[0065] According to a preferred embodiment of the invention, also in combination with any preceding embodiment, when X is S, in the above compounds of formula I when R 1 is OH and R 2 is COOH, R4 is different from Cl in meta position on the aromatic ring. According to another preferred embodiment of the invention, also in combination with any preceding embodiment, when R 1 is OH and R 2 is COOH or COOEt, R 3 and R 4 are not H at the same time. According to a further preferred embodiment of the invention, also in combination with any preceding embodiments, in said compounds of formula I when R 3 is F, R 3 is in position ortho of the aromatic ring and R 4 is F in position para of the aromatic ring, and when R 3 is H, R 4 is in position para or meta on the aromatic ring.
[0066] According to a further preferred embodiment of the invention, the compounds of formula I are selected from:
2-(4-chlorophenyl)-4-hydroxy-1,3-thiazole-5-carboxylic acid (compound n. 1) 4-hydroxy-2-(4-methylphenyl)-1,3-thiazole-5-carboxylic acid (compound n. 2) 2-(3-fluorophenyl)-4-hydroxy-1,3-thiazole-5-carboxylic acid (compound n. 3) 2-(4-fluorophenyl)-4-hydroxy-1,3-thiazole-5-carboxylic acid (compound n. 4) methyl 4-hydroxy-2-phenyl-1,3-thiazole-5-carboxylate (compound n. 5) methyl 2-(2,4-difluorophenyl)-4-hydroxy-1,3-thiazole-5-carboxylate (compound n. 6) ethyl 4-hydroxy-2-phenyl-1,3-thiazole-5-carboxylate (compound n. 7) ethyl 2-(4-chlorophenyl)-4-hydroxy-1,3-thiazole-5-carboxylate (compound n. 8) ethyl 4-hydroxy-2-(4-methylphenyl)-1,3-thiazole-5-carboxylate (compound n. 9) ethyl 2-(3-fluorophenyl)-4-hydroxy-1,3-thiazole-5-carboxylate (compound n. 10) ethyl 2-(4-fluorophenyl)-4-hydroxy-1,3-thiazole-5-carboxylate (compound n. 11) ethyl 4-hydroxy-2-(pyridin-4-yl)-1,3-thiazole-5-carboxylate (compound n. 12) ethyl 2-[4-(dimethylamino)phenyl]-4-hydroxy-1,3-thiazole-5-carboxylate (compound n. 13) ethyl 2-(3-chlorophenyl)-4-hydroxy-1,3-thiazole-5-carboxylate (compound n. 14) ethyl 4-hydroxy-2-[2′-(trifluoromethyl)biphenyl-3-yl]-1,3-thiazole-5-carboxylate (compound n. 15) ethyl 2-(2′-fluorobiphenyl-3-yl)-4-hydroxy-1,3-thiazole-5-carboxylate (compound n. 16) ethyl 4-hydroxy-2-[2′-(trifluoromethyl)biphenyl-4-yl]-1,3-thiazole-5-carboxylate (compound n. 17) ethyl 2-(2′-fluorobiphenyl-4-yl)-4-hydroxy-1,3-thiazole-5-carboxylate (compound n. 18) ethyl 2-{4-[(2-fluorobenzyl)oxy]phenyl}-4-hydroxy-1,3-thiazole-5-carboxylate (compound n. 19) ethyl 2-{4-[(4-fluorobenzyl)oxy]phenyl}-4-hydroxy-1,3-thiazole-5-carboxylate (compound n. 20) ethyl 2-(4-fluorophenyl)-4-{[(trifluoromethyl)sulfonyl]oxy}-1,3-thiazole-5-carboxylate (compound n. 21) ethyl 4-methoxy-2-(4-methylphenyl)-1,3-thiazole-5-carboxylate (compound n. 22) ethyl 2-(4-methylphenyl)-4-(2-methylpropoxy)-1,3-thiazole-5-carboxylate (compound n. 23) ethyl 4-(benzyloxy)-2-phenyl-1,3-thiazole-5-carboxylate (compound n. 24) ethyl 4-[(3-chlorobenzyl)oxy]-2-(4-chlorophenyl)-1,3-thiazole-5-carboxylate (compound n. 25) ethyl 4-[(3-chlorobenzyl)oxy]-2-(3-fluorophenyl)-1,3-thiazole-5-carboxylate (compound n. 26) ethyl 4-[(4-chlorobenzyl)oxy]-2-phenyl-1,3-thiazole-5-carboxylate (compound n. 27) ethyl 4-[(4-chlorobenzyl)oxy]-2-(3-chlorophenyl)-1,3-thiazole-5-carboxylate (compound n. 28) ethyl 4-[(4-chlorobenzyl)oxy]-2-(4-methylphenyl)-1,3-thiazole-5-carboxylate (compound n. 29) ethyl 4-[(4-chlorobenzyl)oxy]-2-(3-fluorophenyl)-1,3-thiazole-5-carboxylate (compound n. 30) ethyl 4-[(2-chlorobenzyl)oxy]-2-phenyl-1,3-thiazole-5-carboxylate (compound n. 31) ethyl 4-[(2-chlorobenzyl)oxy]-2-(4-fluorophenyl)-1,3-thiazole-5-carboxylate (compound n. 32) ethyl 4-[(2-chlorobenzyl)oxy]-2-(4-chlorophenyl)-1,3-thiazole-5-carboxylate (compound n. 33) ethyl 4-[(2-chlorobenzyl)oxy]-2-(3-chlorophenyl)-1,3-thiazole-5-carboxylate (compound n. 34) ethyl 4-[(2-chlorobenzyl)oxy]-2-(4-methylphenyl)-1,3-thiazole-5-carboxylate (compound n. 35) ethyl 2-phenyl-4-{[4-(trifluoromethyl)benzoyl]oxy}-1,3-thiazole-5-carboxylate (compound n. 36) ethyl 2-(3-fluorophenyl)-4-{[4-(trifluoromethyl)benzoyl]oxy}-1,3-thiazole-5-carboxylate (compound n. 37) ethyl 2-(4-methylphenyl)-4-{[4-(trifluoromethyl)benzoyl]oxy}-1,3-thiazole-5-carboxylate (compound n. 38) ethyl4-(2-((1R,2S,5R)-2-isopropyl-5-methylcyclohexyloxy)acetoyloxy)-2-(4-methylphenyl)-1,3-thiazole-5-carboxylate (compound n. 39) ethyl 4-[(benzylcarbamoyl)oxy]-2-(4-chlorophenyl)-1,3-thiazole-5-carboxylate (compound n. 40) ethyl 4-(2-aminoethoxy)-2-(4-chlorophenyl)-1,3-thiazole-5-carboxylate (compound n. 41) ethyl 2-(4-chlorophenyl)-4-{2-[(furan-2-ylmethyl)amino]ethoxy}-1,3-thiazole-5-carboxylate (compound n. 42) 4-[(4-chlorobenzyl)oxy]-2-(4-methylphenyl)-1,3-thiazole-5-carboxylic acid (compound n. 43) 4-[(4-chlorobenzyl)oxy]-2-phenyl-1,3-thiazole-5-carboxylic acid (compound n. 44) 4-[(4-chlorobenzyl)oxy]-2-(4-chlorophenyl)-1,3-thiazole-5-carboxylic acid (compound n. 45) 4-[(4-chlorobenzypoxy]-2-(3-chlorophenyl)-1,3-thiazole-5-carboxylic acid (compound n. 46) 4-(benzyloxy)-2-phenyl-1,3-thiazole-5-carboxylic acid (compound n. 47) 4-[(3-chlorobenzyl)oxy]-2-(3-fluorophenyl)-1,3-thiazole-5-carboxylic acid (compound n. 48) 4-[(2-chlorobenzyl)oxy]-2-phenyl-1,3-thiazole-5-carboxylic acid (compound n. 49) 4-[(2-chlorobenzyl)oxy]-2-(4-fluorophenyl)-1,3-thiazole-5-carboxylic acid (compound n. 50) 4-[(2-chlorobenzyl)oxy]-2-(4-chlorophenyl)-1,3-thiazole-5-carboxylic acid (compound n. 51) 4-[(2-chlorobenzyl)oxy]-2-(3-chlorophenyl)-1,3-thiazole-5-carboxylic acid (compound n. 52) 4-[(2-chlorobenzyl)oxy]-2-(4-methylphenyl)-1,3-thiazole-5-carboxylic acid (compound n. 53) 4-[(2-chlorobenzyl)oxy]-2-(3-fluorophenyl)-1,3-thiazole-5-carboxylic acid (compound n. 54) 2-phenyl-4-{[4-(trifluoromethyl)benzyl]oxy}-1,3-thiazole-5-carboxylic acid (compound n. 55) 2-(3-fluorophenyl)-4-{[4-(trifluoromethyl)benzyl]oxy}-1,3-thiazole-5-carboxylic acid (compound n. 56) 2-phenyl-4-{[4-(trifluoromethyl)benzoyl]oxy}-1,3-thiazole-5-carboxylic acid (compound n. 57) 2-(3-fluorophenyl)-4-{[4-(trifluoromethyl)benzoyl]oxy}-1,3-thiazole-5-carboxylic acid (compound n. 58) 2-(4-methylphenyl)-4-{[4-(trifluoromethyl)benzoyl]oxy}-1,3-thiazole-5-carboxylic acid (compound n. 59) 4-methoxy-2-(4-methylphenyl)-1,3-thiazole-5-carboxylic acid (compound n. 60) 2-(4-methylphenyl)-4-(2-methylpropoxy)-1,3-thiazole-5-carboxylic acid (compound n. 61) ethyl 4-[(tert-butoxycarbonyl)amino]-2-(4-fluorophenyl)-1,3-thiazole-5-carboxylate (compound n. 62) ethyl 4-amino-2-(4-fluorophenyl)-1,3-thiazole-5-carboxylate hydrochloride (compound n. 63) ethyl 4-(acetylamino)-2-(4-methylphenyl)-1,3-thiazole-5-carboxylate (compound n. 64) ethyl 2-(4-methylphenyl)-4-{[4-(trifluoromethyl)benzoyl]amino}-1,3-thiazole-5-carboxylate (compound n. 65) ethyl 2-(4-methylphenyl)-4-[(phenylcarbamoyl)amino]-1,3-thiazole-5-carboxylate (compound n. 66) ethyl 4-[(2-aminoethyl)amino]-2-(4-methylphenyl)-1,3-thiazole-5-carboxylate (compound n. 67) ethyl 2-(4-chlorophenyl)-4-{[2-(methylamino)ethyl]amino}-1,3-thiazole-5-carboxylate (compound n. 68) ethyl 2-(4-chlorophenyl)-4-{[2-(propylamino)ethyl]amino}-1,3-thiazole-5-carboxylate (compound n. 69) ethyl 4-[(2-aminoethyl)amino]-2-(4-chlorophenyl)-1,3-thiazole-5-carboxylate (compound n. 70) ethyl 4-{[2-(methylamino)ethyl]amino}-2-(4-methylphenyl)-1,3-thiazole-5-carboxylate (compound n. 71) ethyl 4-[(2-aminoethyl)amino]-2-[2′-(trifluoromethyl)biphenyl-4-yl]-1,3-thiazole-5-carboxylate (compound n. 72) ethyl 4-[(2-aminoethyl)amino]-2-[2′-(trifluoromethyl)biphenyl-3-yl]-1,3-thiazole-5-carboxylate (compound n. 73) ethyl 2-(4-chlorophenyl)-4-{[2-(cyclopentylamino)ethyl]amino}-1,3-thiazole-5-carboxylate (compound n. 74) ethyl 2-phenyl-4-{[2-(pyrrolidin-1-yl)ethyl]amino}-1,3-thiazole-5-carboxylate (compound n. 75) ethyl 4-(benzylamino)-2-(3-fluorophenyl)-1,3-thiazole-5-carboxylate (compound n. 76) ethyl 4-[(1,3-benzodioxol-5-ylmethyl)amino]-2-(3-fluorophenyl)-1,3-thiazole-5-carboxylate (compound n. 77) ethyl 2-(3-fluorophenyl)-4-[(pyridin-3-ylmethyl)amino]-1,3-thiazole-5-carboxylate (compound n. 78) 4-[(2-aminoethyl)amino]-2-(4-methylphenyl)-1,3-thiazole-5-carboxylic acid (compound n. 79) 4-{[2-(methylamino)ethyl]amino}-2-(4-methylphenyl)-1,3-thiazole-5-carboxylic acid (compound n. 80) 4-[(2-aminoethyl)amino]-2-(3-fluorophenyl)-1,3-thiazole-5-carboxylic acid (compound n. 81) sodium4-[(3-chlorobenzyl)oxy]-2-(3-fluorophenyl)-1,3-thiazole-5-carboxylate (compound n. 82) sodium4-[(4-chlorobenzyl)oxy]-2-(4-methylphenyl)-1,3-thiazole-5-carboxylate (compound n. 83) sodium4-(4-chlorobenzyloxy)-2-(4-chlorophenyl)-1,3-thiazole-5-carboxylate (compound n. 84) sodium4-(2-chlorobenzyloxy)-2-(4-chlorophenyl)-1,3-thiazole-5-carboxylate (compound n. 85) sodium4-(2-chlorobenzyloxy)-2-(4-methylphenyl)-1,3-thiazole-5-carboxylate (compound n. 86) sodium4-(2-chlorobenzyloxy)-2-(3-fluorophenyl)-1,3-thiazole-5-carboxylate (compound n. 87) sodium4-(4-chlorobenzyloxy)-2-(3-fluorophenyl)-1,3-thiazole-5-carboxylate (compound n. 88) (1R,2S,5R)-2-isopropyl-5-methylcyclohexyl-4-(benzyloxy)-2-(4-methylphenyl)-1,3-thiazole-5-carboxylate (compound n. 89) (1R,2S,5R)-2-isopropyl-5-methylcyclohexyl-4-hydroxy-2-(4-methylphenyl)-1,3-thiazole-5-carboxylate (compound n. 90) ethyl 2-(4-chlorophenyl)-4-(methoxymethoxy)-1,3-thiazole-5-carboxylate (compound n. 91) 2-(4-chlorophenyl)-4-(methoxymethoxy)-1,3-thiazole-5-carboxylic acid (compound n. 92) 2-(4-chlorophenyl)-4-(methoxymethoxy)-1,3-thiazole-5-carboxamide (compound n. 93) 2-(4-chlorophenyl)-4-(methoxymethoxy)-1,3-thiazole-5-carbonitrile (compound n. 94) 2-(4-chlorophenyl)-5-(1H-tetrazol-5-yl)-1,3-thiazol-4-ol (compound n. 95) 2-(4-chlorophenyl)-5-(1-methyl-1H-tetrazol-5-yl)-1,3-thiazol-4-ol (compound n. 96) 2-(3-fluorophenyl)-5-(1-methyl-1H-tetrazol-5-yl)-1,3-thiazol-4-ol (compound n. 97) 2-(4-chlorophenyl)-5-(5-methyl-4H-1,2,4-triazol-3-yl)-1,3-thiazol-4-ol (compound n. 98) 2-(3-fluorophenyl)-5-(5-methyl-4H-1,2,4-triazol-3-yl)-1,3-thiazol-4-ol (compound n. 99) 2-(4-chlorophenyl)-5-(5-methyl-1,2,4-oxadiazol-3-yl)-1,3-thiazol-4-ol (compound n. 100) 2-(3-fluorophenyl)-5-(5-methyl-1,2,4-oxadiazol-3-yl)-1,3-thiazol-4-ol (compound n. 101) 3-{4-[(4-chlorobenzyl)oxy]-2-(3-fluorophenyl)-1,3-thiazol-5-yl}-5-methyl-1,2,4-oxadiazole (compound n. 102) 2-(4-chlorophenyl)-5-(5-methyl-1,3,4-oxadiazol-2-yl)-1,3-thiazol-4-ol (compound n. 103) 2-(3-fluorophenyl)-5-(5-methyl-1,3,4-oxadiazol-2-yl)-1,3-thiazol-4-ol (compound n. 104) ethyl 4-hydroxy-2-phenyl-1,3-oxazole-5-carboxylate (compound n. 105) ethyl 2-(3-fluorophenyl)-4-hydroxy-1,3-oxazole-5-carboxylate (compound n. 106) ethyl 4-hydroxy-2-(4-methylphenyl)-1,3-oxazole-5-carboxylate (compound n. 107) ethyl 4-[(4-chlorobenzyl)oxy]-2-phenyl-1,3-oxazole-5-carboxylate (compound n. 108) ethyl 4-[(4-chlorobenzyl)oxy]-2-(3-fluorophenyl)-1,3-oxazole-5-carboxylate (compound n. 109) ethyl 4-[(4-chlorobenzyl)oxy]-2-(4-methylphenyl)-1,3-oxazole-5-carboxylate (compound n. 110) ethyl 2-phenyl-4-{[4-(trifluoromethyl)benzoyl]oxy}-1,3-oxazole-5-carboxylate (compound n. 111) 4-[(4-chlorobenzyl)oxy]-2-phenyl-1,3-oxazole-5-carboxylic acid (compound n. 112) 4-[(4-chlorobenzyl)oxy]-2-(3-fluorophenyl)-1,3-oxazole-5-carboxylic acid (compound n. 113) 4-[(4-chlorobenzyl)oxy]-2-(4-methylphenyl)-1,3-oxazole-5-carboxylic acid (compound n. 114) 2-(3-fluorophenyl)-5-(5-methyl-1,2,4-oxadiazol-3-yl)-1,3-oxazol-4-ol (compound n. 115) 3-{4-[(4-chlorobenzyl)oxy]-2-(3-fluorophenyl)-1,3-oxazol-5-yl}-5-methyl-1,2,4-oxadiazole (compound n. 116) ethyl 2-(3-fluorophenyl)-5-hydroxy-1,3-thiazole-4-carboxylate (compound n. 117). 2-(3-fluorophenyl)-5-(2-ethyl-2H-tetrazol-5-yl)-1,3-thiazol-4-ol (compound n. 118)
[0185] As it will be described in details in Example 119, the present inventors have found that the above compounds 1-118 are potent antagonists of TRPM8.
[0186] In details, all of the above compounds have been tested in a high-throughput screening (HTS) cellular-based assay for the human TRPM8 and have shown an antagonist activity with a IC 50 below 30 μM. Compounds 10, 45 and 118 have also been tested in a calcium influx assay, which has confirmed the antagonist activity of the tested compounds.
[0187] Thus, a second object of the present invention are the above compounds of formula (I) for use as antagonists of TRPM8, preferably of human TRPM8.
[0188] In order to obtain confirmation of the data obtained in vitro compounds 10, 45 and 118 have also been tested in two in vivo models.
[0189] In details, as will be described in Example 120 and 121 compounds 10 and 45 have been tested in an isovolumetric bladder model, an animal model for the evaluation of drugs active on pain induced by contractions of bladder, and compounds 10, 45 and 118 in a Chronic Constriction Injury of sciatic nerve (CCI), an animal model of neuropathic pain.
[0190] In the first model, the compounds showed significant efficacy in inhibiting rhythmic bladder contractions and micturition frequency. Moreover, both the compounds did not change Amplitude of Micturition (AM) when compared to basal values, suggesting that they are selective for the afferent arm of micturition reflex with no effect on the efferent pathway.
[0191] In the second model, the tested compounds showed a significant antiallodynic activity both in mechanical and cold allodynia.
[0192] As will be demonstrated in Example 122, the compounds of the invention show a high selectivity for TRPM8 and are thus devoid of side effects due to interference with other ion channels and GPCRs. In fact, both 10, 45 and 118 have been demonstrated to be selective in a wide range of ion channel and GPCRs.
[0193] Furthermore, as shown in Example 123 the compounds of the invention have an optimal pharmacokinetic profile.
[0194] Thus, the compounds of the invention are particularly suitable to be used in therapy.
[0195] Accordingly, a third object of the present invention are the above compounds for use as medicaments.
[0196] A fourth object of the present invention are the above compounds for use in the prevention, reduction of the risk of, amelioration and/or treatment of a disease associated with activity of TRPM8.
[0197] According to the present invention, by “disease that is associated with activity of TRPM8” it is preferably meant a disease selected from pain, itch, irritable bowel diseases, cold induced and/or exhacerbated respiratory disorders, ischaemia, neurodegeneration, stroke, urological disorders, and psychiatric disorders.
[0198] Preferably, said pain is selected from chronic pain, cancer pain, neuropathic pain, which is meant to include cold allodynia and diabetic neuropathy, postoperative pain, osteoarthritic pain, rheumatoid arthritic pain, neuralgia, neuropathies, fibromyalgia, algesia, nerve injury, migraine, headaches.
[0199] Preferably, said cold-induced and/or exhacerbated respiratory disorder is selected from cold-induced and/or exhacerbated pulmonary hypertension, COPD and asthma.
[0200] Preferably, said urological disorders are selected from painful bladder syndrome, interstitial cystitis, detrusor overactivity (also known as overactive bladder), urinary incontinence, neurogenic detrusor overactivity (also known as detrusor hyperflexia), idiopathic detrusor overactivity (also known as detrusor instability), benign prostatic hyperplasia, lower urinary tract disorders and lower urinary tract symptoms.
[0201] Preferably, said psychiatric disorders are selected from anxiety and depression.
[0202] A fifth object of the present invention are pharmaceutical compositions comprising the at least one of the above said compounds of formula I in combination with pharmaceutically acceptable excipients and/or diluents.
[0203] According to a prefered embodiments said pharmaceutical composition is for the prevention, reduction of the risk of, amelioration and/or treatment of a disease associated with activity of TRPM8.
[0204] According to an embodiment, said pharmaceutical composition contains at least one of the above compounds of formula I as the sole active principle(s). According to an alternative embodiment, said pharmaceutical composition contains at least one of the above compounds of formula I in association with at least one other active principle.
[0205] According to a preferred embodiment of the invention, also in combination with the preceding embodiments, the pharmaceutical compositions may be for intravescical, intravenous, topical or oral administration.
[0206] The compounds of the invention of formula (I) are conveniently formulated in pharmaceutical compositions using conventional techniques and excipients such as those described in “Remington's Pharmaceutical Sciences Handbook” MACK Publishing, New York, 18th ed., 1990.
[0207] A sixth object of the present invention is a therapeutic method for the prevention, reduction of the risk of, amelioration and/or treatment of said diseases associated with activity of TRPM8 comprising the administration of the above compound of Formula I in a subject in need thereof.
[0208] The compounds of the invention can be administered as the sole active principles or in combination with other therapeutically active compounds.
[0209] The administration of the compounds of the invention can be effected by intravesical instillation, by intravenous injection, as a bolus, in dermatological preparations (creams, lotions, sprays and ointments), by inhalation as well as orally in the form of capsules, tablets, syrup, controlled-release formulations and the like.
[0210] The average daily dose depends on several factors such as the severity of the disease, the condition, age, sex and weight of the patient. The dose will vary generally from 1 to 1500 mg of compounds of formula (I) per day optionally divided in multiple administrations.
[0211] The present invention shall be illustrated by means of the following examples which are not construed to be viewed as limiting the scope of the invention.
EXAMPLES
Synthesis of Preferred Compounds
[0212] The compounds listed in Table IV have been synthetised following the procedures described in the following examples.
Materials and Methods
[0213] All reagents were purchased from Sigma-Aldrich, Fluorochem and Alfa Aesar and used without further purification. Nuclear magnetic resonance (NMR) spectra were recorded in the indicated solvent with tetramethylsilane (TMS) as internal standard on a Bruker Avance3 400 MHz instrument. Chemical shifts are reported in parts per million (ppm) relative to the internal standard. Abbreviations are used as follows: s=singlet, d=doublet, t=triplet, q=quartet, m=multiplet, dd=doublets of doublet, br=broad. Coupling constants (J values) are given in hertz (Hz). Analytical HPLC-MS spectra were recorded on a Thermo Finnigan Surveyor coupled with a Thermo Finnigan LCQ DECA XP-PLUS apparatus and equipped with a C18 (10 μM, 4.6mm×150mm) Phenomenex Gemini reverse phase column. The eluent mixture consisted of 10 mM (pH 4.2) ammonium formate/formic acid buffer and acetonitrile used according the gradient from 90:10 to 10:90 at a flow rate of 0.200 mL/min. All MS experiments were performed using electrospray ionization (ESI) in positive ion mode.
[0214] All reactions were monitored by thin layer chromatography (TLC) carried out on Grace Resolv Davisil silica gel plates 250 μm thick, 60 F254, visualized by using UV (254 nm) or stains such as KMnO 4 , p-anisaldehyde, and ceric ammonium molybdate (CAM). Chromatographic purifications were carried out on silica gel columns with Grace Resolv Davisil silica 60. All organic solutions were dried over anhydrous Na 2 SO 4 or MgSO4 and concentrated on a rotary evaporator. All compounds used for biological assays are at least of 98% purity based on HPLC analytical results monitored with 220 and 254 nm wavelengths, unless otherwise noted.
General Procedure A
Example 1
Synthesis of 2-(4-chlorophenyl)-4-hydroxy-1,3-thiazole-5-carboxylic acid (1)
[0215] Ethyl-2-(4-chlorophenyl)-4-hydroxy-1,3-thiazole-5-carboxylate 8 (0.5 g, 1.8 mmol) (prepared according the general Procedure B, see below) was dissolved in dioxane (3 mL) and aqueous hydrochloric acid (37%) (0.3 mL) was added. The mixture was irradiated by microwave (250 W, 150° C.) for 10 min, whereupon the solvent was removed under vacuum. The crude product was purified by HPLC to yield the acid (0.34 g, 74%) as a white solid.
[0216] 1 H-NMR (CD 3 OD) δ (ppm): 8.01 (d, 2H, J=8.6), 7.50 (d, 2H, J=8.6).
Example 2
Synthesis of 4-hydroxy-2-(4-methylphenyl)-1,3-thiazole-5-carboxylic acid (2)
[0217] Following the procedure A and starting from ethyl 4-hydroxy-2-(4-methylphenyl)-1,3-thiazole-5-carboxylate 9 (0.25 g, 0.94 mmol) (prepared according the general Procedure B, see below), compound 2 was obtained as a white solid following HPLC purification (154 mg, 70%). 1 H-NMR (Acetone-d 6 ) δ (ppm): 7.94 (d, 2H, J=7.0), 7.33 (d, 2H, J=7.0), 2.42 (s, 3H).
Example 3
Synthesis of 2-(3-fluorophenyl)-4-hydroxy-1,3-thiazole-5-carboxylic acid (3)
[0218] Following the general procedure A and starting from ethyl 2-(3-fluorophenyl)-4-hydroxy-1,3-thiazole-5-carboxylate 10 (0.2 g, 0.738 mmol) (prepared according the general Procedure B, see below), compound 3 was obtained as a white solid following HPLC purification (120 mg, 68%). 1 H-NMR (CD 3 OD) δ (ppm): 13.29 (br s, 1H), 7.82-7.78 (m, 1H), 7.69-7.64 (m, 1H), 7.71-7.46 (m, 2H).
Example 4
Synthesis of 2-(4-fluorophenyl)-4-hydroxy-1,3-thiazole-5-carboxylic acid (4)
[0219] Following the general procedure A and starting from ethyl 2-(4-fluorophenyl)-4-hydroxy-1,3-thiazole-5-carboxylate 11 (123 mg, 0.46 mmol) (prepared according the general Procedure B, see below), compound 4 was obtained as yellow solid following HPLC purification (78 mg, 71%). 1 H-NMR (DMSO-d 6 ) δ (ppm): 7.93 (d, 2H, J=7.2), 7.59 (d, 2H, J=7.1), 2.62 (s, 3H).
General Procedure B
Example 5
Synthesis of methyl 4-hydroxy-2-phenyl-1,3-thiazole-5-carboxylate (5)
[0220] Benzenecarbothioamide (0.29 g, 2.09 mmol) and dimethyl 2-chloromalonate (447 μL, 3.5 mmol) were dissolved in dioxane (50 mL). The mixture was heated to 80° C. and stirred overnight, whereupon the solvent was removed under vacuum. 5 was obtained as a yellow solid after purification of the crude product by trituration in acetonitrile (345 mg, 70%). 1 H-NMR (dmso-d 6 ) δ (ppm): 12.3 (br s, 1H), 7.95-7.92 (m, 2H), 7.55-7.53 (m, 3H), 3.75 (s, 3H); MS (ES 1+ ) m/z: 236.53 (M+1).
Example 6
Synthesis of methyl 2-(2,4-difluorophenyl)-4-hydroxy-1,3-thiazole-5-carboxylate (6)
[0221] Following the general procedure B and starting from commercially available 2,4-difluorobenzenecarbothioamide (80 mg, 0.46 mmol) and dimethyl 2-chloromalonate (0.75 mL, 5.86 mmol), 6 was obtained as a pale yellow solid after purification of the crude product by trituration in acetonitrile (85 mg, 68%). 1 H-NMR (CDCl 3 , TMS) δ (ppm): 8.41-8.34 (m, 1H), 7.05-6.93 (m, 2H), 3.94 (s, 3H); MS (ES 1+ ) m/z: 272.69 (M+1).
Example 7
Synthesis of ethyl 4-hydroxy-2-phenyl-1,3-thiazole-5-carboxylate (7)
[0222] Following the general procedure B and starting from commercially available benzenecarbothioamide (0.2 g, 1.45 mmol) and diethyl chloropropanedioate (0.3 mL, 1.82 mmol), 7 was obtained as a yellow solid after purification of the crude product by trituration in acetonitrile (253 mg, 70%). 1 H-NMR (dmso-d 6 ) Δ (ppm): 12.3 (br s, 1H), 7.95-7.92 (m, 2H), 7.55-7.53 (m, 3H), 4.43 (q, 2H, J=7.03), 1.42 (t, 3H, J=7.03); MS (ES 1+ ) m/z: 250.53 (M+1); 222.42 (M−28).
Example 8
Synthesis of ethyl 2-(4-chlorophenyl)-4-hydroxy-1,3-thiazole-5-carboxylate (8)
[0223] Following the general procedure B and starting from commercially available 4-chlorobenzenecarbothioamide (2.04 g, 11.93 mmol) and the corresponding amount of diethyl chloropropanedioate, 8 was obtained as a yellow solid (2.42 g, 71%) by trituration in acetonitrile. 1 H-NMR (CDCl 3 , TMS) δ (ppm) 9.96 (brs, 1H), 7.94 (d, 2H, J=8.6), 7.45 (d, 2H, J=8.6), 4.43 (q, 2H, J=7.0), 1.42 (t, 3H, J=7.0); MS (ES 1+ ) m/z: 298.36 (M−28+41), 285.42 (M+1), 257.64 (M−28).
Example 9
Synthesis of ethyl 4-hydroxy-2-(4-methylphenyl)-1,3-thiazole-5-carboxylate (9)
[0224] Following the general procedure B and starting from commercially available 4-methylbenzenecarbothioamide (123 mg, 0.81 mmol) and the corresponding amount of diethyl chloropropanedioate, 9 was obtained as a yellow solid after purification of the crude product by trituration in acetonitrile (146 mg, 68%). 1 H-NMR (CDCl 3 , TMS) δ (ppm): 9.94 (brs, 1H), 7.88 (d, 2H, J=8.1), 7.26 (d, 2H, J=8.1), 4.62 (q, 2H, J=7.0), 2.41 (s, 3H), 1.39 (t, 3H, J=7.0); MS (ES 1+ ) m/z: 264.30 (M+1).
Example 10
Synthesis of ethyl 2-(3-fluorophenyl)-4-hydroxy-1,3-thiazole-5-carboxylate (10)
[0225] Following the general procedure B and starting from commercially available 3-fluorobenzenecarbothioamide (223 mg, 1.44 mmol) and the corresponding amount of diethyl chloropropanedioate, 10 was obtained as a white solid after purification of the crude product by trituration in acetonitrile (250 mg, 65%). 1 H-NMR (CDCl 3 , TMS) δ (ppm): 9.93 (br s), 7.76-7.69 (m, 2H), 7.46-7.39 (m, 1H), 7.22-7.17 (m, 1H), 4.40 (q, 2H, J=7.5),1.40 (t, 3H, J=7.5); MS (ES 1+ ) m/z: 240.13 (M−27), 282.66 (M−27+41).
Example 11
Synthesis of ethyl 2-(4-fluorophenyl)-4-hydroxy-1,3-thiazole-5-carboxylate (11)
[0226] Following the general procedure B and starting from commercially available 4-fluorobenzenecarbothioamide (243 mg, 1.57 mmol) and the corresponding amount of diethyl chloropropanedioate, 11 was obtained as a white solid after purification of the crude product by trituration in acetonitrile (280 mg, 67%). 1 H-NMR (CDCl 3 , TMS) δ (ppm): 9.94 (s, 1H), 8.01-7.96 (m, 2H), 7.17-7.12 (m, 2H), 4.39 (q, 2H, J=7.0), 1.40 (t, 3H, J=7.0); MS (ES 1+ ) m/z: 240.23 (M−27).
Example 12
Synthesis of ethyl 4-hydroxy-2-(pyridin-4-yl)-1,3-thiazole-5-carboxylate (12)
[0227] Following the general procedure B and starting from commercially available pyridine-4-carbothioamide (217 mg, 1.57 mmol) and the corresponding amount of diethyl chloropropanedioate, 12 was obtained as a yellow solid after purification of the crude product by trituration in acetonitrile (275 mg, 70%). 1 H-NMR (MeOD-d4) δ (ppm): 9.91 (br s, 1H), 8.70 (d, 2H, J=5.9), 7.81 (d, 2H, J=5.9), 4.36 (q, 2H, J=7.0), 1.35 (t, 3H, J=7.0); MS (ES 1+ ) m/z: 251.81 (M+1).
Example 13
Synthesis of ethyl 2-(4-(dimethylamino)phenyl)-4-hydroxythiazole-5-carboxylate (13)
[0228] Following the general procedure B and starting from commercially available 4-(dimethylamino)benzenecarbothioamide (88 mg, 0.48 mmol) and the corresponding amount of diethyl chloropropanedioate, 13 was obtained as a white solid after purification of the crude product by trituration in acetonitrile (117 mg, 82%). 1 H-NMR (DMSO-d 6 ) δ (ppm): 11.82 (br s, 1H), 7.76 (d, 2H, J=8.6), 6.77 (d, 2H, J=9.2), 4.28 (q, 2H, J=7.03), 3.02 (s, 6H), 1.26 (t, 3H, J=7.03); MS (ES 1+ ) m/z: 293.88 (M+1); 265.83 (M−28); 306.83 (M−28+41).
Example 14
Synthesis of ethyl 2-(3-chlorophenyl)-4-hydroxy-1,3-thiazole-5-carboxylate (14)
[0229] Following the general procedure B and starting from commercially available 3-chlorobenzenecarbothioamide (1.47 g, 8.54 mmol) and the corresponding amount of diethyl chloropropanedioate, 14 was obtained as a white solid after purification of the crude product by trituration in acetonitrile (1.7 g, 71%). 1 H-NMR (CDCl 3 , TMS) δ (ppm): 9.98 (br s, 1H), 8.01 (s, 1H), 7.87 (d, 1H, J=7.57), 7.49-7.33 (m, 2H), 4.43 (q, 2H, J=7.03), 1.42 (t, 3H, J=7.03); MS (ES 1+ ) m/z: 297.79 (M−28+41); 284.81 (M+1); 256.76 (M−28).
Example 15
Synthesis of ethyl 4-hydroxy-2-[2′-(trifluoromethyl)biphenyl-3-yl]-1,3-thiazole-5-carboxylate (15)
[0230] 3-Bromobenzenecarbothioamide (1.00 g, 4.62 mmol) and diethyl chloropropanedioate (1.0 mL, 6.0 mmol) were dissolved in dioxane (35 mL). The mixture was heated at 80° C. and stirred overnight, whereupon the solvent was removed under vacuum. Ethyl 2-(3-bromophenyl)-4-hydroxy-1,3-thiazole-5-carboxylate was obtained as a yellow solid (1.09 g, 72%) by trituration in acetonitrile. An oven-dried Schlenk tube equipped with a magnetic stir bar was charged with 1.5 mL of an aqueous solution of K 2 CO 3 (2M, 3.0 mmol), tetrakis(triphenylphosphine)palladium(0) (140 mg, 0.121 mmol) and toluene (3 mL). The tube was capped with a rubber septum and immersed in an oil bath at 80° C.for 30 min. Ethyl 2-(3′-bromophenyl)-4-hydroxy-1,3-thiazole-5-carboxylate (188 mg, 0.575 mmol) and 2-trifluoromethyl-phenylboronic acid (218 mg, 1.15 mmol) were then added, and the reaction mixture stirred at 80° C. Upon complete consumption of the starting material (12 h), as judged by thin-layer chromatography analysis, the reaction mixture was filtered on a celite pad. The filtrate was diluted with ethyl acetate, and extracted with water. The organic layers were further washed with brine and dried over sodium sulfate. The product was isolated by column chromatography (hexanes/EtOAc) as a yellow solid (56 mg, 25%). 1 H-NMR (DMSO-d 6 ) δ (ppm): 10.82 (brs, 1H), 7.96 (d, 2H, J=8.11), 7.86 (d, 2H, J=7.57), 7.78-7.73 (m, 1H), 7.67-7.62 (m, 1H), 7.47-7.41 (m, 2H), 4.16 (q, 2H, J=7.03), 1.24 (t, 3H, J=7.03).
Example 16
Synthesis of ethyl 2-(2′-fluorobiphenyl-3-yl)-4-hydroxy-1,3-thiazole-5-carboxylate (16)
[0231] The compound was prepared according to the experimental procedure described for compound 15 and starting from ethyl 2-(3′-bromophenyl)-4-hydroxy-1,3-thiazole-5-carboxylate (0.14 g, 0.43 mmol) and 2 fluorophenylboronic acid (0.12 g, 0.86 mmol). Compound 16 was obtained as a yellow oil after HPLC purification (106 mg, 72%). 1 H-NMR (CDCl 3 , TMS) δ (ppm): 10.98 (brs, 1H), 8.00 (d, 2H, J=7.58), 7.71 (d, 2H, J=7.58), 7.57-7.47 (m, 2H), 7.39-7.35 (m, 1H), 7.28-7.17 (m, 1H), 4.41 (q, 2H, J=6.49), 1.41 (t, 3H, J=6.49).
Example 17
Synthesis of ethyl 4-hydroxy-2-[2′-(trifluoromethyl)biphenyl-4-yl]-1,3-thiazole-5-carboxylate (17)
[0232] The compound was prepared according to the experimental procedure described for compound 15 and starting from ethyl 2-(4-bromophenyl)-4-hydroxy-1,3-thiazole-5-carboxylate (0.12 g, 0.36 mmol) and 2-trifluoromethylphenylboronic acid (136 mg, 0.72 mmol). Compound 17 was obtained as a yellow solid after purification of the crude product by trituration with acetonitrile (106 mg, 75%). 1 H-NMR (DMSO-d 6 ) δ (ppm): 10.23 (br s, 1H), 7.96 (d, 2H, J=8.11), 7.86 (d, 2H, J=7.57), 7.78-7.73 (m, 1H), 7.67-7.62 (m, 1H), 7.47-7.41 (m, 2H), 4.16 (q, 2H, J=7.03), 1.24 (t, 3H, J=7.03).
Example 18
Synthesis of ethyl 2-(2′-fluorobiphenyl-4-yl)-4-hydroxy-1,3-thiazole-5-carboxylate (18)
[0233] The compound was prepared according to the experimental procedure described for compound 15 and starting from ethyl 2-(4-bromophenyl)-4-hydroxy-1,3-thiazole-5-carboxylate (0.12 mg, 0.36 mmol) and 2-fluorophenylboronic acid (0.1 mg, 0.72 mmol). Compound 18 was obtained as a white solid after purification of the crude product by trituration with acetonitrile (105 mg, 85%). 1 H-NMR (DMSO-d 6 ) δ (ppm): 12.27 (brs, 1H), 8.06 (d, 2H, J=7.57), 7.74 (d, 2H, J=7.57), 7.66-7.60 (m, 1H), 7.52-7.46 (m, 1H), 7.40-7.33 (m, 2H), 4.25 (q, 2H, J=7.03), 1.28 (t, 3H, J=7.03).
Example 19
Synthesis of ethyl 2-{4-[(2-fluorobenzyl)oxy]phenyl}-4-hydroxy-1,3-thiazole-5-carboxylate (19)
[0234] Following the general procedure B and starting from 4-(2′-fluorobenzyloxy)phenyl)-benzenecarbothioamide (0.4 g, 1.53 mmol) and diethyl chloropropanedioate (0.45 g, 2.29 mmol), compound 19 was obtained as a white solid after purification of the crude product by trituration in acetonitrile (446 mg, 78%). 1 H-NMR (DMSO-d 6 ) δ (ppm): 12.10 (br s, 1H), 7.94 (d, 2H, J=8.70), 7.63-7.55 (m, 1H), 7.51-7.43 (m, 1H), 7.33-7.15 (m, 4H), 5.26 (s, 2H), 4.24 (q, 2H, J=7.05), 1.29 (t, 3H, J=7.05).
Example 20
Synthesis of ethyl 2-{4-[(4-fluorobenzyl)oxy]phenyl}-4-hydroxy-1,3-thiazole-5-carboxylate (20)
[0235] Following the general procedure B and starting from 4-(4′-fluorobenzyloxy)phenyl)-benzenecarbothioamide (0.31g, 1.19 mmol) and diethyl chloropropanedioate (0.35 g, 1.78 mmol), compound 20 was obtained as a white solid after purification of the crude product by trituration in acetonitrile (359 mg, 81%). 1 H-NMR (DMSO-d 6 ) δ (ppm): 12.06 (br s, 1H), 7.90 (d, 2H, J=8.65), 7.55-7.49 (m, 2H), 7.27-7.20 (m, 2H), 7.14 (d, 2H, J=8.65), 5.18 (s, 2H), 4.22 (q, 2H, J=7.03), 1.25 (t, 3H, J=7.03).
Example 21
Synthesis of ethyl 2-(4-fluorophenyl)-4-{[(trifluoromethyl)sulfonyl]oxy}-1,3-thiazole-5-carboxylate (21)
[0236] To a solution of ethyl 2-(4-fluorophenyl)-4-hydroxy-1,3-thiazole-5-carboxylate 11 (2.3 g, 8.6 mmol) in dry CH 2 Cl 2 (50 mL), Et 3 N (1.4 mL, 10.1 mmol) was added and the mixture was stirred for 40 min at room temperature. The reaction mixture was then cooled to −10° C. and trifluomethanesulfonic anhydride (1.7 mL, 10.1 mmol) was added dropwise, keeping the temperature under −5° C. The reaction mixture was stirred for 12 h at room temperature. Upon complete consumption of starting compound, the mixture was washed with a satured solution of NH 4 Cl (80 mL). The aqueous layer was then extracted with ethyl acetate (2×50 mL). The organic layers further washed with brine and dried over dry Na 2 SO 4 . Compound 21 was isolated by chromatography (hexane/EtOAc) as pale yellow solid (3.0 g, 87%). 1 H-NMR (CDCl 3 , TMS) δ (ppm): 7.97-7.92 (m, 2H), 7.21-7.15 (m, 2H), 4.43 (q, 2H, J=7.0), 1.41 (t, 3H, J=7.0).
Example 22
Synthesis of ethyl 4-methoxy-2-(4-methylphenyl)-1,3-thiazole-5-carboxylate (22)
[0237] Ethyl 4-hydroxy-2-(4-methylphenyl)-1,3-thiazole-5-carboxylate 9, (0.1 g, 0.379 mmol) was dissolved in DMF (4 mL). K 2 CO 3 (0.11 g, 0.802 mmol) was added and the mixture heated to 60° C. while stirring. After 15 min. iodomethane (59 μL, 0.95 mmol) was added and the mixture was stirred overnight at the same temperature. After cooling at room temperature, ethyl acetate (15 mL) was added and the mixture washed with water (2×15 mL). The organic phase was dried over dry Na 2 SO 4 and evaporated to dryness. The crude product was purified by HPLC to yield compound 22 as a white solid (0.080 g, 76%). 1 H-NMR (acetone-d6) δ (ppm): 7.90 (d, 2H, J=7.6), 7.35 (d, 2H, J=7.6), 4.30-4.19 (m, 2H), 3.89 (s, 3H), 2.40 (s, 3H), 1.36-1.24 (m, 3H); MS (ES 1+ ) m/z: 278.55 (M+1).
Example 23
Synthesis of ethyl 2-(4-methylphenyl)-4-(2-methylpropoxy)-1,3-thiazole-5-carboxylate (23)
[0238] Compound 23 was prepared according to the experimental procedure described for 22 and starting from ethyl 4-hydroxy-2-(4-methylphenyl)-1,3-thiazole-5-carboxylate 9 (85 mg, 0.32 mmol) and 1-iodo-2-methylpropane (147 mg, 0.80 mmol). Compound 23 was obtained as a white solid after HPLC purification (89 mg, 87%). 1 H-NMR (CDCl3, TMS) δ (ppm): 7.87 (d, 2H, J=8.1), 7.29 (d, 2H, J=8.1), 4.35 (m, 4H), 2.42 (s, 3H), 2.20 (m,1H), 1.80 (d, 6H, J=6.5), 1.38 (t, 3H, J=7.0); MS (ES 1+ ) m/z: 320.96 (M+1), 264.79 (M−57), 236.77 (M−57- 28).
General Procedure C
Example 24
Synthesis of ethyl 4-(benzyloxy)-2-phenyl-1,3-thiazole-5-carboxylate (24)
[0239] Ethyl 4-hydroxy-2-phenyl-1,3-thiazole-5-carboxylate 7, (0.2 g, 0.80 mmol) was dissolved in DMF (2 mL). K 2 CO 3 (0.22 g, 1.604 mmol) was added and the mixture was heated at 60° C. while stirring. After 15 min 1-(bromomethyl)benzene (164 mg, 0.96 mmol) was added and the mixture was stirred overnight at the same temperature. After cooling to room temperature, ethyl acetate (10 mL) was added and the mixture washed with water (2×15 mL). The organic phase was dried over dry Na 2 SO 4 and evaporated to dryness. The crude product was purified by HPLC to yield compound 24 as a white solid (241 mg, 89%). 1 H-NMR (CDCl 3 , TMS) δ (ppm): 8.0-7.9 (m, 4H), 7.87 (d, 1H, J=7.0), 7.48-7.28 (m, 5H), 5.37 (s, 2H), 4.37 (q, 2H, J=7.0), 1.42 (t, 3H, J=7.0); MS (ES 1+ ) m/z: 340.19 (M+1).
Example 25
Synthesis of ethyl 4-[(3-chlorobenzyl)oxy]-2-(4-chlorophenyl)-1,3-thiazole-5-carboxylate (25)
[0240] The title compound was prepared according to the general procedure C. starting from ethyl 2-(4-chlorophenyl)-4-hydroxy-1,3-thiazole-5-carboxylate 8 (111 mg, 0.39 mmol) and 1-(bromomethyl)-3-chlorobenzene (96 mg, 0.47 mmol). Compound 25 was obtained as pale yellow solid after HPLC purification (138 mg, 87%). 1 H-NMR (CDCl 3 , TMS) δ (ppm): 7.79 (d, 2H, J=7.1), 7.71 (d, 1H, J=7.0), 7.42-7.27 (m, 5H), 5.73 (s, 2H), 4.29 (q, 2H), 1.38 (t, 3H); MS (ES 1+ ) m/z: 409.03 (M+1).
Example 26
Synthesis of ethyl 4-[(3-chlorobenzyl)oxy]-2-(3-fluorophenyl)-1,3-thiazole-5-carboxylate (26)
[0241] The title compound was prepared according to the general procedure C and starting from ethyl 2-(3-fluorophenyl)-4-hydroxy-1,3-thiazole-5-carboxylate 10 (0.1 g, 0.37 mmol) and 1-(bromomethyl)-3-chlorobenzene (91 mg, 0.44 mmol). Compound 26 was obtained as white solid after HPLC purification (113 mg, 78%). 1 H-NMR (CDCl 3 , TMS) δ (ppm): 7.97 (m, 1H), 7.84-7.71 (m, 3H), 7.58-7.27 (m, 4H), 5.69 (s, 2H), 4.38 (q, 2H), 1.41 (t, 3H); MS (ES 1+ ) m/z: 392.71 (M+1).
Example 27
Synthesis of ethyl 4-(4-chlorobenzyloxy)-2-phenyl-1,3-thiazole-5-carboxylate (27)
[0242] Following the general procedure C and starting from ethyl 4-hydroxy-2-phenyl-1,3-thiazole-5-carboxylate 7, (58 mg, 0.23 mmol), 1-chloro-4-(chloromethyl)benzene (92.6 mg, 0.57 mmol), compound 27 was obtained as a white solid after HPLC purification (75 mg, 86%). 1 H-NMR (CDCl 3 , TMS) δ (ppm): 7.94-7.92 (m, 2H), 7.50-7.45 (m, 5H), 7.35-7.33 (m, 2H), 5.60 (s, 2H), 4.33 (q, 2H, J=7.0), 1.36 (t, 2H, J=7.0); MS (ES 1+ ) m/z: 374.89 (M+1).
Example 28
Synthesis of ethyl 4-(4-chlorobenzyloxy)-2-(3-chlorophenyl)-1,3-thiazole-5-carboxylate (28)
[0243] Following the general procedure C and starting from ethyl 2-(3-chlorophenyl)-4-hydroxy-1,3-thiazole-5-carboxylate 14 (0.3 g, 1.06 mmol) and 1-chloro-4-(chloromethyl)benzene (426.7 mg, 2.65 mmol), compound 28 was obtained as white solid after HPLC purification of the crude product (302 mg, 70%). 1 H-NMR (CDCl 3 , TMS) δ (ppm): 7.96 (s, 1H), 7.79 (d, 1H, J=7.5), 7.51-7.36 (m, 6H), 5.62 (s, 2H), 4.35 (q, 2H, J=5.6), 1.39 (t, 3H, J=5.6); MS (ES 1+ ) m/z: 409.03 (M+1).
Example 29
Synthesis of ethyl 4-[(4-chlorobenzyl)oxy]-2-(4-methylphenyl)-1,3-thiazole-5-carboxylate (29)
[0244] Following the general procedure C and starting from ethyl 4-hydroxy-2-(4-methylphenyl)-1,3-thiazole-5-carboxylate 9, (0.1 g, 0.401 mmol) and 1-chloro-4-(chloromethyl)benzene (0.161 g, 1.00 mmol), compound 29 was isolated as a white solid (0.112 g, 72%). 1 H-NMR (CDCl 3 , TMS) δ (ppm): 7.85 (d, 2H, J=8.1), 7.51 (d, 2H, J=8.6), 7.36 (d, 2H, J=8.1), 7.27 (d, 2H, J=7.6), 5.62 (s, 2H), 4.35 (q, 2H, J=7.03), 2.42 (s, 3H), 1.38 (t, 3H, J=7.03); MS (ES 1+ ) m/z: 389.02 (M+1).
Example 30
Synthesis of ethyl 4-[(4-chlorobenzyl)oxy]-2-(3-fluorophenyl)-1,3-thiazole-5-carboxylate (30)
[0245] The title compound was prepared according to the general procedure C and starting from ethyl 2-(3-fluorophenyl)-4-hydroxy-1,3-thiazole-5-carboxylate 10 (0.105 g, 0.39 mmol) and 1-(bromomethyl)-4-chlorobenzene (96 mg, 0.47 mmol. Compound 30 was obtained as yellow solid after HPLC purification (119 mg, 78%). 1 H-NMR (CDCl 3 , TMS) δ (ppm): 7.89 (s, 1H), 7.78 (d, 1 H, J=7.8), 7.62-7.59 (m, 3H), 7.55-7.41 (m, 3H), 5.62 (s, 2H), 4.35 (q, 2H, J=5.6), 1.39 (t, 3H, J=5.6); MS (ES 1+ ) m/z: 392.6 (M+1).
Example 31
Synthesis of ethyl 4-(2-chlorobenzyloxy)-2-phenyl-1,3-thiazole-5-carboxylate (31)
[0246] Following the general procedure C and starting from ethyl 2-phenyl-4-hydroxy-1,3-thiazole-5-carboxylate 7, (0.12 g, 0.48 mmol) and 1-chloro-2-(chloromethyl)benzene (0.2 g, 1.2 mmol), compound 31 was obtained as white solid after HPLC purification of the crude product (117 mg, 65%). 1 H-NMR (CDCl 3 , TMS) δ (ppm): 8.0-7.9 (m, 3H), 7.87 (d, 1H, J=7.0), 7.48-7.28 (m, 5H), 5.77 (s, 2H), 4.37 (q, 2H, J=7.0), 1.42 (t, 3H, J=7.0); MS (ES 1+ ) m/z: 374.99 (M+1).
Example 32
Synthesis of ethyl 4-(2-chlorobenzyloxy)-2-(4-fluorophenyl)-1,3-thiazole-5-carboxylate (32)
[0247] Following the general procedure C and starting from ethyl 2-(4-fluorophenyl)-4-hydroxy-1,3-thiazole-5-carboxylate 11, (0.27 g, 1.01 mmol) and 1-chloro-2-(chloromethyl)benzene (0.41 g, 2.52 mmol), compound 32 was obtained as white solid after HPLC purification of the crude product (261 mg, 66%). 1 H-NMR (CDCl 3 , TMS) δ (ppm): 7.99-7.95 (m, 2H), 7.78 (d, 1H, J=7.5), 7.41 (d, 1H, J=9.0), 7.35-7.25 (m, 2H), 7.20-7.12 (m, 2H), 5.74 (s, 2H), 4.37 (q, 2H, J=7.3), 1.42 (t, 3H, J=7.0); MS (ES 1+ ) m/z: 392.97 (M+1).
Example 33
Synthesis of ethyl 4-(2-chlorobenzyloxy)-2-(4-chlorophenyl)-1,3-thiazole-5-carboxylate (33)
[0248] Following the general procedure C and starting from ethyl 2-(4-chlorophenyl)-4-hydroxy-1,3-thiazole-5-carboxylate 8 (37 mg, 0.13 mmol) and 1-chloro-2-(chloromethyl)benzene (52 mg, 0.32 mmol), compound 33 was obtained as a white solid after HPLC purification (40 mg, 75%). 1 H-NMR (CDCl 3 , TMS) δ (ppm): 7.91 (d, 2H, J=8.6), 7.76 (d, 1H, J=7.0), 7.46-7.29 (m, 5H), 5.75 (s, 2H), 4.37 (q, 2H, J=5.6), 1.40 (t, 3H, J=5.6); MS (ES 1+ ) m/z: 409.03 (M+1).
Example 34
Synthesis of ethyl 4-(2-chlorobenzyloxy)-2-(3-chlorophenyl)-1,3-thiazole-5-carboxylate (34)
[0249] Following the general procedure C and starting from ethyl 2-(3-chlorophenyl)-4-hydroxy-1,3-thiazole-5-carboxylate 14, (0.18 g, 0.63 mmol) and 1-chloro-2-(chloromethyl)benzene (254 mg, 1.57 mmol), compound 34 was obtained as white solid after HPLC purification of the crude product (167 mg, 65%). 1 H-NMR (CDCl 3 , TMS) δ (ppm): 7.99 (s, 1H), 7.85-7.76 (m, 2H), 7.48-7.28 (m, 5H), 5.76 (s, 2H), 4.38 (q, 2H, J=5.6), 1.41 (t, 3H, J=5.6); MS (ES 1+ ) m/z: 409.31 (M+1).
Example 35
Synthesis of ethyl 4-[(2-chlorobenzyl)oxy]-2-(4-methylphenyl)-1,3-thiazole-5-carboxylate (35)
[0250] Following the general procedure C and starting from ethyl 2-p-tolyl-4-hydroxy-1,3-thiazole-5-carboxylate 9, (0.18 g, 0.68 mmol) and 1-chloro-2-(chloromethyl)benzene (273 mg, 1.69 mmol), compound 35 was obtained as white solid after HPLC purification of the crude product (181 mg, 74%). 1 H-NMR (CDCl 3 , TMS) δ (ppm): 7.87 (d, 2H, J=8.6), 7.78 (d, 1H, J=7.0), 7.45-7.32 (m, 5H), 5.75 (s, 2H), 4.37 (q, 2H, J=7.3), 2.42 (s, 3H), 1.42 (t, 3H, J=7.0); MS (ES 1+ ) m/z: 389.00 (M+H).
Example 36
Synthesis of ethyl 2-phenyl-4-{[4-(trifluoromethyl)benzoyl]oxy}-1,3-thiazole-5-carboxylate (36)
[0251] Ethyl 4-hydroxy-2-phenyl-1,3-thiazole-5-carboxylate 7 (0.1 g, 0.401 mmol) and pyridine (0.036 mL, 0.48 mmol) were dissolved in CH 2 Cl 2 (5 mL). 4-(Trifluoromethyl)benzoyl chloride (0.154 g, 0.802 mmol) was slowly added, and the mixture was stirred overnight at room temperature. After solvent removal under reduced pressure, the crude product was purified by HPLC yielding the title compound as a white solid (0.126 g, 74%). 1 H-NMR (CDCl 3 , TMS) δ (ppm): 8.37 (d, 2H, J=8.1), 7.99-7.96 (m, 2H), 7.81 (d, 2H, J=8.1), 7.52-7.45 (m, 3H), 4.26 (q, 2H, J=7.6), 1.21 (t, 3H, J=7.6); MS (ES 1+ ) m/z: 422.99 (M+1).
Example 37
Synthesis of ethyl 2-(3-fluorophenyl)-4-{[4-(trifluoromethyl)benzoyl]oxy}-1,3-thiazole-5-carboxylate (37)
[0252] The title compound was prepared according to the procedure described for compound 36 and starting from ethyl 2-(3-fluorophenyl)-4-hydroxy-1,3-thiazole-5-carboxylate 10 (83 mg, 0.31 mmol). Compound 37 was obtained as yellow solid after HPLC purification (110 mg, 81%).
[0253] 1 H-NMR (CDCl 3 , TMS) δ (ppm): 7.96-7.79 (m, 2H), 7.51-7.36 (m, 6H), 4.35 (q, 2H, J=6.8), 1.39 (t, 3H, J=6.6); MS (ES 1+ ) m/z: 440.33 (M+1).
Example 38
Synthesis of ethyl 2-(4-methylphenyl)-4-{[4-(trifluoromethyl)benzoyl]oxy}-1,3-thiazole-5-carboxylate (38)
[0254] The title compound was prepared according to the procedure described for compound 36 and stating from ethyl 4-hydroxy-2-(4-methylphenyl)-1,3-thiazole-5-carboxylate 9 (72 mg, 0.27 mmol). Compound 38 was obtained as red solid after HPLC purification (99 mg, 83%). 1 H-NMR (CDCl 3 , TMS) δ (ppm): 7.83 (d, 2H, J=8.1), 7.50 (d, 2H, J=8.1), 7.36 (d, 2H, J=8.1), 7.30 (d, 2H, J=7.6), 4.31 (q, 2H, J=7.03), 2.39 (s, 3H), 1.38 (t, 3H, J=7.03); MS (ES 1+ ) m/z: 436.4 (M+1).
Example 39
Synthesis of ethyl 4-(2-((1R,2S,5R)-2-isopropyl-5-methylcyclohexyloxy)acetoyloxy)-2-(4-methylphenyl)-1,3-thiazole-5-carboxylate (39)
[0255] Following the procedure adopted for the preparation of compound 36 and starting from ethyl 4-hydroxy-2-p-tolyl-1,3-thiazole-5-carboxylate 9 (0.15 g, 0.57 mmol) and 2-((1R,2S,5R)-2-isopropyl-5-methylcyclohexyloxy)acetyl chloride (265 mg, 1.14 mmol), compound 39 was obtained as white solid after purification by HPLC of the crude product (196 mg, 75%). 1 H-NMR (CDCl 3 , TMS) δ (ppm): 7.85 (d, 2H, J=8.1), 7.27 (d, 2H, J=7.0), 4.53 (s, 2H), 4.35 (q, 2H, J=7.0), 3.38 (m, 1H), 2.43 (s, 3H), 2.20-1.97 (m,1H), 1.90-1.81 (m, 2H), 1.75 (m, 3H), 1.67-1.57 (m, 2H), 1.43 (m, 1H) 1.40 (m, 3H), 1.38 (t, 3H, J=7.0), 1.09-1.07 (m, 6H); MS (ES 1+ ) m/z: 461.28 (M+1), 433.22 (M−28), 264.79 (M−196).
Example 40
Synthesis of ethyl 4-[(benzylcarbamoyl)oxy]-2-(4-chlorophenyl)-1,3-thiazole-5-carboxylate (40)
[0256] 1-(isocyanatomethyl)benzene (28.7 mg, 0.21 mmol) was added to a solution of ethyl 2-(4-chlorophenyl)-4-hydroxy-1,3-thiazole-5-carboxylate 8 (50 mg, 0.18 mmol) in toluene. The resulting mixture was stirred at 80° C. for 12 h and then concentrated under reduced pressure. The crude was triturated in ethyl acetate to give compound 40 as white solid (57 mg, 65%). 1 H-NMR (CDCl 3 , TMS) δ (ppm): 8.00-7.90 (m, 2H), 7.54-7.30 (m, 6H), 5.65 (br s,1H), 4.53 (m, 2H), 4.36 (m, 2H), 1.38 (t, 3H, J=7.03 Hz); MS (ES 1+ ) m/z: 418.09 (M+1), 325.91 (M−92); 284.75 (M−134).
Example 41
Synthesis of ethyl 4-(2-aminoethoxy)-2-(4-chlorophenyl)-1,3-thiazole-5-carboxylate (41)
[0257] Following the procedure adopted for the preparation of compound 36 and starting from ethyl 2-(4-chlorophenyl)-4-hydroxy-1,3-thiazole-5-carboxylate 8, (0.2 g, 0.704 mmol) and 2-bromoethanamine (218 mg, 1.76 mmol), compound 41 was obtained as a brownish solid (178 mg, 77%). 1 H-NMR (MeOD-d4) δ (ppm): 7.98 (d, 2H, J=8.1 Hz), 7.54 (d, 2H, J=8.1 Hz), 4.82 (m, 2H), 4.38 (q, 2H, J=7.0 Hz), 3.48 (m, 2H), 1.38 (t, 3H, J=7.0 Hz); MS (ES 1+ ) m/z: 327.90 (M+1), 368.96 (M+41), 297.78 (M−43); 284.77 (M−44); 256.73 (M−44-27).
Example 42
Synthesis of ethyl 2-(4-chlorophenyl)-4-{2-[(furan-2-ylmethyl)amino]ethoxy}-1,3-thiazole-5-carboxylate (42)
[0258] Ethyl 4-(2-aminoethoxy)-2-(4-chlorophenyl)-1,3-thiazole-5-carboxylate 41 (0.15 g, 0.46 mmol) and furan-2-carbaldehyde (48 mg, 0.51 mmol) were mixed in dry MeOH (15 mL) at room temperature under nitrogen atmosphere. The mixture was stirred at room temperature for 1 h, until the aldimine formation was completed (determined by analytic HPLC). The aldimine solution in MeOH was carefully treated with solid NaBH 4 (0.6 g, 16 mmol). The reaction mixture was stirred for further 2 h and quenched with a saturated aqueous solution of NH 4 Cl. The pH of the aqueous layer was adjusted to 7 with saturated aqueous NaHCO 3 . The reaction mixture was then diluted with ethyl acetate (20 mL) and extracted with diethyl ether. The organic extracts were washed with saturated aqueous NaCl and dried (MgSO 4 ). The solvent was evaporated to give compound 42 as a white solid (175 mg, 98%). 1 H-NMR (CDCl 3 , TMS) δ (ppm): 7.84 (d, 2H, J=8.6), 7.39 (d, 2H, J=8.6), 7.35 (s, 1H), 6.29-6.31 (m, 1H), 6.21-6.22 (m, 1H), 4.66 (t, 2H, J=5.4), 4.31 (q, 2H, J=7.0), 3.89 (s, 2H), 3.07 (t, 2H, J=5.4), 1.34 (t, 3H, J=7.0); MS (ES 1+ ) m/z: 407.96 (M+1).
General Procedure D
Example 43
Synthesis of 4-[(4-chlorobenzyl)oxy]-2-(4-methylphenyl)-1,3-thiazole-5-carboxylic acid (43)
[0259] Ethyl 4-[(4-chlorobenzyl)oxy]-2-(4-methylphenyl)-1,3-thiazole-5-carboxylate 29 (0.50 g, 1.3 mmol) was dissolved in dioxane (3 mL) and 1M NaOH (1.3 mL, 1.0 eq.) was added. The mixture was stirred at room temperature overnight. Upon complete consumption of starting material, as judged by thin-layer chromatography analysis, H 2 O (5 mL) was added to the reaction mixture. After extraction by CH 2 Cl 2 (3×5 mL), the aqueous phase was acidified with diluted HCl to pH 3-4, and extracted with EtOAc (3×5 mL). The organic layers were further washed with brine and dried over dry Na 2 SO 4 . The solvent was removed under vacuum to yield the acid 43 (0.43 g, 92%) as a white solid. 1 H-NMR (CD 3 OD) δ (ppm): 7.87 (d, 2H, J=7.0), 7.55 (d, 2H, J=7.6), 7.38 (d, 2H, J=7.0), 7.32 (d, 2H, J=7.6), 5.61 (s, 2H), 2.42 (s, 3H); MS (ES 1+ ) m/z: 360.90 (M+1).
Example 44
Synthesis of 4-(4-chlorobenzyloxy)-2-phenyl-1,3-thiazole-5-carboxylic acid (44)
[0260] Following the general procedure D and starting from ethyl 4-(4-chlorobenzyloxy)-2-phenyl-1,3-thiazole-5-carboxylate 27 (0.15 g, 0.40 mmol), compound 44 was obtained as a white solid (135 mg, 98%). 1 H-NMR (DMSO-d 6 ) δ (ppm): 12.95 (br s, 1H), 8.00-7.98 (m, 2H), 7.57-7.53 (m, 5H), 7.49-7.46 (m, 2H), 5.59 (s, 2H); MS (ES 1+ ) m/z: 346.59 (M+1), 302.66 (M−44).
Example 45
Synthesis of 4-(4-chlorobenzyloxy)-2-(4-chlorophenyl)-1,3-thiazole-5-carboxylic acid (45)
[0261] Following the general procedure D and starting from ethyl 4-(4-chlorobenzyloxy)-2-(4-chlorophenyl)-1,3-thiazole-5-carboxylate (0.11 g, 0.27 mmol), compound 45 was obtained as a white solid (99 mg, 96%). 1 H-NMR (DMSO-d 6 ) δ (ppm): 13.02 (br s, 1H), 8.06-8.00 (m, 2H), 7.67-7.47 (m, 6H), 5.60 (s, 2H); MS (ES 1+ ) m/z: absent.
Example 46
Synthesis of 4-(4-chlorobenzyloxy)-2-(3-chlorophenyl)-1,3-thiazole-5-carboxylic acid (46)
[0262] Following the general procedure D and starting from ethyl 4-(4-chlorobenzyloxy)-2-(3-chlorophenyl)-1,3-thiazole-5-carboxylate 28 (0.1 g, 0.24 mmol), compound 46 was obtained as a white solid (87 mg, 94%). 1 H-NMR (DMSO-d 6 ) δ (ppm): 13.04 (br s, 1H), 8.03 (s, 1H), 7.95 (d, 2H, J=7.57), 7.66-7.54 (m, 3H), 7.47 (d, 2H, J=7.57), 5.60 (s, 2H); MS (ES 1+ ) m/z: absent.
Example 47
Synthesis of 4-(benzyloxy)-2-phenyl-1,3-thiazole-5-carboxylic acid (47)
[0263] Following the procedure D and starting from ethyl 4-(benzyloxy)-2-phenyl-1,3-thiazole-5-carboxylate 24 (0.15 g, 048 mmol), compound 47 was obtained as a white solid (134 mg, 90%). 1 H-NMR (CDCl 3 , TMS) δ (ppm): 7.99-7-94 (m, 3H), 7.55-7.37 (m, 6H), 6.96 (brs, 1H), 5.65 (s, 2H); MS (ES 1+ ) m/z: 312.86 (M+1).
Example 48
Synthesis of 4-[(3-chlorobenzyl)oxy]-2-(3-fluorophenyl)-1,3-thiazole-5-carboxylic acid (48)
[0264] The title compound was prepared according to the general procedure D and starting from ethyl 4-[(3-chlorobenzyl)oxy]-2-(3-fluorophenyl)-1,3-thiazole-5-carboxylate 26 (58 mg, 0.14 mmol). Compound 48 was obtained as a whitish solid (46 mg, 91%). 1 H-NMR (DMSO-d 6 ) δ (ppm): 13.12 (br s, 1H), 8.02 (s, 1H), 7.96-7.93 (m, 1H), 7.68-7.49 (m, 4H), 7.41-7.38 (m, 2H), 5.66 (s, 2H); MS (ES 1+ ) m/z: 364.7 (M+1).
Example 49
Synthesis of 4-(2-chlorobenzyloxy)-2-phenyl-1,3-thiazole-5-carboxylic acid (49)
[0265] Following the general procedure D and starting from ethyl 4-(2-chlorobenzyloxy)-2-phenyl-1,3-thiazole-5-carboxylate 31 (90 mg, 0.24 mmol), compound 49 was obtained as a white solid (81 mg, 98%). 1 H-NMR (DMSO-d 6 ) δ (ppm): 12.97 (br s, 1H), 8.00-7.97 (m, 2H), 7.70-7.68 (m, 1H), 7.57-7.51 (m, 4H), 7.41-7.38 (m, 2H), 5.67 (s, 2H); MS (ES 1+ ) m/z: 346.6 (M+1), 263.5 (M−125+1+41), 222.5 (M−125+1).
Example 50
Synthesis of 4-(2-chlorobenzyloxy)-2-(4-fluorophenyl)-1,3-thiazole-5-carboxylic acid (50)
[0266] Following the general procedure D and starting from ethyl 4-(2-chlorobenzyloxy)-2-(4-fluorophenyl)-1,3-thiazole-5-carboxylate 32 (0.11 g, 0.28 mmol), compound 50 was obtained as a white solid (97 mg, 95%). 1 H-NMR (DMSO-d 6 ) δ (ppm): 12.97 (brs, 1H), 8.07-8.02 (m, 2H), 7.70-7.67 (m, 1H), 7.54-7.51 (m, 1H), 7.41-7.36 (m, 4H), 5.66 (s, 2H); MS (ES 1+ ) m/z: absent.
Example 51
Synthesis of 4-(2-chlorobenzyloxy)-2-(4-chlorophenyl)-1,3-thiazole-5-carboxylic acid (51)
[0267] Following the general procedure D and starting from ethyl 4-(2-chlorobenzyloxy)-2-(4-chlorophenyl)-1,3-thiazole-5-carboxylate 33 (50 mg, 0.12 mmol), compound 51 was obtained as a yellow solid (43 mg, 92%). 1 H-NMR (DMSO-d 6 ) δ (ppm): 13.00 (br s, 1H), 8.01 (d, 2H, J=8.1), 7.74-7.66 (m, 1H), 7.62 (d, 2H, J=8.1), 7.54-7.51 (m, 1H), 7.41-7.39 (m, 2H), 5.66 (s, 2H); MS (ES 1+ ) m/z: absent.
Example 52
Synthesis of 4-(2-chlorobenzyloxy)-2-(3-chlorophenyl)-1,3-thiazole-5-carboxylic acid (52)
[0268] Following the general procedure D and starting from ethyl 4-(2-chlorobenzyloxy)-2-(3-chlorophenyl)-1,3-thiazole-5-carboxylate 34 (105 mg, 0.26 mmol), compound 52 was obtained as a white solid (96 mg, 98%). 1 H-NMR (DMSO-d 6 ) δ (ppm): 13.02 (br s, 1H), 8.02 (s, 1H), 7.96-7.93 (m, 1H), 7.70-7.50 (m, 4H), 7.42-7.39 (m, 2H), 5.67 (s, 2H); MS (ES 1+ ) m/z: absent.
Example 53
Synthesis of 4-(2-chlorobenzyloxy)-2-(4-methylphenyl)-1,3-thiazole-5-carboxylic acid (53)
[0269] Following the general procedure D and starting from ethyl 4-(2-chlorobenzyloxy)-2-(4-methylphenyl)-1,3-thiazole-5-carboxylate 35 (80 mg, 0.21 mmol), compound 53 was obtained as a white solid (72 mg, 97%). 1 H-NMR (DMSO-d 6 ) δ (ppm): 12.92 (br s, 1H), 7.90-7.87 (m, 2H), 7.72-7.68 (m, 1H), 7.55-7.51 (m, 1H), 7.43-7.34 (m, 4H), 5.67 (s, 2H), 2.38 (s, 3H); MS (ES 1+ ) m/z: 360.73 (M+1).
Example 54
Synthesis of 4-[(2-chlorobenzyl)oxy]-2-(3-fluorophenyl)-1,3-thiazole-5-carboxylic acid (54)
[0270] Following the general procedure D and starting from ethyl 4-[(2-chlorobenzyl)oxy]-2-(3-fluorophenyl)-1,3-thiazole-5-carboxylate (89 mg, 0.22 mmol), compound 54 was obtained as a white solid (76 mg, 92%). 1 H-NMR (DMSO-d 6 ) δ (ppm): 12.11 (br s, 1H), 8.10 (m, 2H), 7.96-7.93 (m, 2H), 7.70-7.50 (m, 3H), 7.42-7.39 (m, 1H), 5.59 (s, 2H); MS (ES 1+ ) m/z: 364.7 (M+1).
Example 55
Synthesis of 2-phenyl-4-{[4-(trifluoromethyl)benzyl]oxy}-1,3-thiazole-5-carboxylic acid (55)
[0271] Following the general procedure D and starting from ethyl 2-phenyl-4-{[4-(trifluoromethyl)benzyl]oxy}-1,3-thiazole-5-carboxylate (91 mg, 0.22 mmol), compound 55 was obtained as brown solid (77 mg, 93%). 1 H-NMR (DMSO-d 6 ) δ (ppm): 12.93 (br s, 1H), 8.05-7.96 (m, 2H), 7.57-7.53 (m, 5H), 7.49-7.46 (m, 2H), 5.59 (s, 2H); MS (ES 1+ ) m/z: 380.49 (M+1).
Example 56
Synthesis of 2-(3-fluorophenyl)-4-{[4-(trifluoromethyl)benzyl]oxy}-1,3-thiazole-5-carboxylic acid (56)
[0272] Following the general procedure D and starting from ethyl 2-(3-fluorophenyl)-4-{[4-(trifluoromethyl)benzyl]oxy}-1,3-thiazole-5-carboxylate (101 mg, 0.23 mmol), compound 56 was obtained as pale yellow solid (82 mg, 90%). 1 H-NMR (DMSO-d 6 ) δ (ppm): 12.83 (br s, 1H), 8.05-7.96 (d, 2H, J=8.0), 7.76 (m, 1H), 7.57-7.53 (m, 3H), 7.49-7.46 (d, 2H, J=8.1), 5.59 (s, 2H); MS (ES 1+ ) m/z: 398.4 (M+1).
Example 57
Synthesis of 2-phenyl-4-{[4-(trifluoromethyl)benzoyl]oxy}-1,3-thiazole-5-carboxylic acid (57)
[0273] Following the general procedure described for compound 36 and starting from 4-hydroxy-2-phenyl-1,3-thiazole-5-carboxylic acid (89 mg, 0.40 mmol) and 4-(trifluoromethyl)benzoyl chloride (158 mg, 0.76 mmol), compound 57 was obtained as a white solid after HPLC purification (124 mg, 79%). 1 H-NMR (CDCl 3 , TMS) δ (ppm): 8.36 (d, 2H, J=8.1), 7.99-7.96 (m, 2H), 7.81 (d, 2H, J=8.1), 7.52-7.45 (m, 3H), MS (ES 1+ ) m/z: 394.11 (M+1).
Example 58
Synthesis of 2-(3-fluorophenyl)-4-{[4-(trifluoromethyl)benzoyl]oxy}-1,3-thiazole-5-carboxylic acid (58)
[0274] Following the procedure described for compound 57 and starting from 2-(3-fluorophenyl)-4-hydroxy-1,3-thiazole-5-carboxylic acid 3 (91 mg, 0.38 mmol), compound 58 was obtained as yellow solid after HPLC purification (136 mg, 87%). 1 H-NMR (CDCl 3 , TMS) δ (ppm): 8.29 (d, 2H, J=8.1), 7.91 (d, 2H, J=8.1), 7.88-7.96 (m, 3H), 7.52-7.45 (m, 1H), MS (ES 1+ ) m/z: 412.3 (M+1).
Example 59
Synthesis of 2-(4-methylphenyl)-4-{[4-(trifluoromethyl)benzoyl]oxy}-1,3-thiazole-5-carboxylic acid (59)
[0275] Following the general procedure described for compound 57 and starting from ethyl 4-hydroxy-2-(4-methylphenyl)-1,3-thiazole-5-carboxylate 2 (0.1 g, 0.42 mmol) and 4-(trifluoromethyl)benzoyl chloride (158 mg, 0.76 mmol), compound 59 was obtained as white solid after purification by HPLC of the crude product (110 mg, 71%). 1 H-NMR (CDCl 3 , TMS) δ (ppm): 8.28 (d, 2H, J=7.6), 8.03 (d, 2H, J=8.1), 7.80 (d, 2H, J=8.1), 7.34 (d, 2H, J=7.6), 2.47 (s, 3H); MS (ES 1+ ) m/z: absent.
Example 60
Synthesis of 4-methoxy-2-(4-methylphenyl)-1,3-thiazole-5-carboxylic acid (60)
[0276] Following the general procedure D and starting from ethyl 4-methoxy-2-(4-methylphenyl)-1,3-thiazole-5-carboxylate 22 (47 mg, 0.17 mmol), compound 60 was obtained as a white solid (40 mg, 94%). 1 H-NMR (DMSO-d 6 ): 6 (ppm): 12.81 (br s, 1H), 7.88 (d, 2H, J=7.8), 7.35 (d, 2H, J=7.8), 4.11 (s, 3H), 2.38 (s, 3H); MS (ES 1+ ) m/z: 250.71 (M+1), 291.84 (M+41), 232.76 (M−18).
Example 61
Synthesis of 2-(4-methylphenyl)-4-(2-methylpropoxy)-1,3-thiazole-5-carboxylic acid (61)
[0277] Following the general procedure D and starting from ethyl 2-(4-methylphenyl)-4-(2-methylpropoxy)-1,3-thiazole-5-carboxylate 23 (0.85 g, 2.67 mmol), compound 61 was obtained as a white solid (731 mg, 94%). 1 H-NMR (CDCl 3 , TMS) δ (ppm): 7.86 (d, 2H, J=7.6), 7.28 (d, 2H, J=7.6), 4.46 (d, 2H, J=6.5), 2.43 (s, 3H), 2.15-2.30 (m, 1H), 1.09 (d, 6H, J=6.5); MS (ES 1+ ) m/z: 292.86 (M+1), 277.83 (M−15), 236.76 (M−56).
General Procedure E
Example 62
Synthesis of ethyl 4-[(tert-butoxycarbonyl)amino]-2-(4-fluorophenyl)-1,3-thiazole-5-carboxylate (62)
[0278] Pd 2 (dba) 3 (15 mg, 0.015 mmol) and Xantphos (27 mg, 0.046 mmol) were dissolved in dry THF (6 mL) under N 2 atmosphere. The mixture was stirred at room temperature for 20 min. 0.100 g (0.240 mmol) of ethyl 2-(4-fluorophenyl)-4-{[(trifluoromethyl)sulfonyl]oxy}-1,3-thiazole-5-carboxylate 21 (0.2 g, 0.5 mmol) was then added, and after 5 minutes, tert-butyl carbamate (70.4 mg, 0.6 mmol) was added. The mixture was irradiated by microwave (250 W, 135° C.) for 1 h, whereupon the mixture was filtered on a celite pad and the solvent was removed under vacuum. The crude product was purified by flash column chromatography (eluent hexane/ethyl acetate mixture of increasing polarity) to yield the compound 62 as a yellow solid (157 mg, 86%). 1 H-NMR (CDCl 3 , TMS) δ (ppm): 9.26 (br s, 1H), 8.06-8.01 (m, 2H), 7.16-7.10 (m, 2H), 4.36 (q, 2H, J =7.0), 1.56 (s, 9H), 1.39 (t, 3H, J =7.0); MS (ES 1+ ) m/z: 311 (M−55).
Example 63
Synthesis of ethyl 4-amino-2-(4-fluorophenyl)-1,3-thiazole-5-carboxylate hydrochloride (63)
[0279] Ethyl 4-[(tert-butoxycarbonyl)amino]-2-(4-fluorophenyl)-1,3-thiazole-5-carboxylate 62 (157 mg, 0.43 mmol) was dissolved in a solution of 1.25 M HCl in CH 3 OH and stirred for 1 h at room temperature. The solvent was removed under vacuum and the compound 63 was obtained as an orange solid (121 mg, 93%). 1 H-NMR (DMSO-d 6 ): δ 8.01-7.96 (m, 2H), 7.39-7.33 (m, 2H), 7.08 (br s, 2H), 4.27 (q, 2H, J=7.0 Hz), 1.27 (t, 3H, J=7.0 Hz); MS (ES 1+ ) m/z: 267.82 (M+1), 308.91 (M+41).
Example 64
Synthesis of ethyl 4-acetamido-2-(4-methylphenyl)-1,3-thiazole-5-carboxylate (64)
[0280] Following the general procedure E and starting from ethyl 2-(4-methylphenyl)-4-{[(trifluoromethyl)sulfonyl]oxy}-1,3-thiazole-5-carboxylate (0.1 g, 0.25 mmol) and acetamide (18 mg, 0.30 mmol), compound 64 was obtained as white solid after purification by HPLC of the crude product (56 mg, 73%). 1 H-NMR (CDCl 3 , TMS) δ (ppm): 7.86 (d, 2H, J=8.1), 7.28 (d, 2H, J=8.1), 4.39 (q, 2H, J=7.0), 2.55 (br s, 3H), 2.43 (s, 3H), 1.40 (t, 3H, J=7.0); MS (ES 1+ ) m/z: 305.4 (M+1), 263.8 (M−42).
Example 65
Synthesis of ethyl 2-(4-methylphenyl)-4-{[4-(trifluoromethyl)benzoyl]amino}-1,3-thiazole-5-carboxylate (65)
[0281] Following the procedure described for compound 36 and starting from ethyl 4-amino-2-(4-methylphenyl)-1,3-thiazole-5-carboxylate (0.1 g, 0.38 mmol) and 4-(trifluoromethyl)benzoyl chloride (158 mg, 0.76 mmol), compound 65 was obtained as white solid after HPLC purification of the crude product (117 mg, 71%). 1 H-NMR (CDCl 3 , TMS) δ (ppm): 11.03 (br s, 1H), 8.19 (d, 2H, J=8.11 Hz), 8.03 (d, 2H, J=8.11 Hz), 7.84 (d, 2H, J=8.11 Hz), 7.28 (d, 2H, J=8.11 Hz), 4.39 (q, 1H, J=7.03 Hz), 2.44 (s, 3H), 1.40 (t, 3H, J=7.03 Hz); MS (ES 1+ ) m/z: 435.10 (M+1).
Example 66
Synthesis of ethyl 2-(4-methylphenyl)-4-[(phenylcarbamoyl)amino]-1,3-thiazole-5-carboxylate (66)
[0282] Following the procedure described for compound 40 and starting from ethyl 4-amino-2-(4-methylphenyl)-1,3-thiazole-5-carboxylate (1.23 g, 4.68 mmol) and phenylisocyanate (557 mg, 4.68 mmol), compound 66 was obtained as a white solid (1.63 g, 88%). 1 H-NMR (CDCl 3 , TMS) δ (ppm): 10.97 (br s, 1H), 9.11 (br s, 1H), 7.86 (d, 2H, J=8.1), 7.63 (d, 2H, J=8.1), 7.41-7.34 (m, 4H), 7.13 (t, 1H, J=7.0), 4.41 (q, 2H, J=7.0), 2.47 (s, 3H), 1.42 (t, 3H, J=7.0); MS (ES 1+ ) m/z: 382.44 (M+1).
Example 67
Synthesis of ethyl 4-[(2-aminoethyl)amino]-2-(4-methylphenyl)-1,3-thiazole-5-carboxylate (67)
[0283] Following the general procedure E and starting from ethyl 2-(4-methylphenyl)-4-{[(trifluoromethyl)sulfonyl]oxy}-1,3-thiazole-5-carboxylate (150 mg, 0.38 mmol) and ethane-1,2-diamine (27.4 mg, 0.45 mmol), compound 67 was obtained as pale yellow solid after purification by flash column cromatography (eluent hexane/ethyl acetate mixture of increasing polarity) of the crude product (84.7 mg, 73%). 1 H-NMR (CDCl 3 , TMS) δ (ppm): 7.83-7.78 (d, 2H, J=8.1), 7.25-7.19 (d, 2H, J=8.1), 4.25 (q, 2H, J=7.0), 3.70 (t, 2H, J=5.9), 2.39 (s, 3H), 1.90 (brs, 2H), 1.38 (t, 3H, J=7.0); MS (ES 1+ ) m/z: =306.2 (M+1).
Example 68
Synthesis of ethyl 2-(4-chlorophenyl)-4-{[2-(methylamino)ethyl]amino}-1,3-thiazole-5-carboxylate (68)
[0284] Following the general procedure E and starting from ethyl 2-(4-chlorophenyl)-4-{[(trifluoromethyl)sulfonyl]oxy}-1,3-thiazole-5-carboxylate (0.1 g, 0.240 mmol) and N-methylethane-1,2-diamine, compound 68 was obtained as a yellow powder (60 mg, 74%). 1 H-NMR (CDCl 3 , TMS) δ (ppm): 7.90 (d, 2H, J =8.6), 7.41 (d, 2H, J =8.6), 4.30 (q, 2H, J=7.3), 3.84 (q, 2H, J=5.9), 2.99 (t, 2H, J=2.9), 2.57 (s, 3H), 1.36 (t, 3H, J=7.0); MS (ES 1+ ) m/z: 381.96 (M+41), 340.92 (M+1), 309.81 (M−30), 294.73 (M−45).
Example 69
Synthesis of ethyl 2-(4-chlorophenyl)-4-{[2-(propylamino)ethyl]amino}-1,3-thiazole-5-carboxylate (69)
[0285] Following the general procedure E and starting from ethyl 2-(4-chlorobenzen)-4-{[(trifluoromethyl)sulfonyl]oxy}-1,3-thiazole-5-carboxylate, (0.12 g, 0.29 mmol) and N-ethylethane-1,2-diamine (25.4 mg, 0.35 mmol), compound 69 was obtained as pale yellow solid after purification by flash column cromatography (eluent hexane/ethyl acetate mixture of increasing polarity) of the crude product (75 mg, 70%). 1 H-NMR (CDCl 3 , TMS) δ (ppm): 7.90 (d, 2H, J =8.6), 7.41 (d, 2H, J =8.6), 5.08 (brs, 1H), 4.30 (q, 2H, J=7.0), 3.93 (q, 2H, J=5.9), 3.02 (t, 2H, J=5.9), 2.89 (t, 2H, J=7.3), 1.78-1.66 (m, 2H), 1.34 (t, 3H, J=7.0), 0.96 (t, 3H, J=7.0); MS (ES 1+ ) m/z: 368.95 (M+1).
Example 70
Synthesis of ethyl 4-[(2-aminoethyl)amino]-2-(4-chlorophenyl)-1,3-thiazole-5-carboxylate (70)
[0286] The title compound was prepared according to the general procedure E and starting from ethyl 2-(4-chlorophenyl)-4-{[(trifluoromethyl)sulfonyl]oxy}-1,3-thiazole-5-carboxylate (220 mg, 0.53 mmol). Compound 70 was obtained as a pale yellow oil after HPLC purification (124 mg, 72%). MS (ES 1+ ) m/z: 326.78 (M+1).
Example 71
Synthesis of ethyl 4-{[2-(methylamino)ethyl]amino}-2-(4-methylphenyl)-1,3-thiazole-5-carboxylate (71)
[0287] The title compound was prepared according to the general procedure E and starting from ethyl 2-(4-methylphenyl)-4-{[(trifluoromethyl)sulfonyl]oxy}-1,3-thiazole-5-carboxylate (203 mg, 0.51 mmol). Compound 71 was obtained as whitish solid after HPLC purification in 81% yield (132 mg). MS (ES 1+ ) m/z: 320.55 (M+1).
Example 72
Synthesis of ethyl 4-[(2-aminoethyl)amino]-2-[2′-(trifluoromethyl)biphenyl-4-yl]-1,3-thiazole-5-carboxylate (72)
[0288] The title compound was prepared according to the general procedure E and starting from ethyl 2-[2′-(trifluoromethyl)biphenyl-4-yl]-4-{[(trifluoromethyl)sulfonyl]oxy}-1,3-thiazole-5-carboxylate (188 mg, 0.35 mmol). Compound 72 was obtained as a white solid after HPLC purification in 61% yield (95 mg). MS (ES 1+ ) m/z: 436.41 (M+1).
Example 73
Synthesis of ethyl 4-[(2-aminoethyl)amino]-2-[2′-(trifluoromethyl)biphenyl-3-yl]-1,3-thiazole-5-carboxylate (73)
[0289] The title compound was prepared according to the general procedure E and starting from ethyl 2-[2′-(trifluoromethyl)biphenyl-3-yl]-4-{[(trifluoromethyl)sulfonyl]oxy}-1,3-thiazole-5-carboxylate (156 mg, 0.29 mmol). Compound 73 was obtained as dark yellow oil after HPLC purification (72 mg, 56%). MS (ES 1+ ) m/z: 436.37 (M+1).
Example 74
Synthesis of ethyl 2-(4-chlorophenyl)-4-{[2-(cyclopentylamino)ethyl]amino}-1,3-thiazole-5-carboxylate (74)
[0290] Following the general procedure described for compound 42 and starting from ethyl 4-(2-aminoethylamino)-2-(4-chlorophenyl)-1,3-thiazole-5-carboxylate (0.5 g, 1.53 mmol) and cyclopentanecarbaldehyde (166 mg, 1.69 mmol), compound 74 was obtained as a yellow oil (447 mg, 74%). 1 H-NMR (CDCl 3 , TMS) δ (ppm): 7.91 (d, 2H, J=8.12), 7.42 (d, 2H, J=8.12), 6.99 (br s, 1H), 4.31 (q, 2H, J=7.03), 3.84-3.79 (m, 2H), 3.25-3.17 (m, 2H), 3.01-2.97 (m,2H), 2.70 (br s, 1H), 1.93-1.86 (m, 2H), 1.76-1.66 (m, 2H), 1.61-1.31 (m, 2H), 1.37 (t, 3H, J=7.03); MS (ES 1+ ) m/z 394.95 (M+1).
Example 75
Synthesis of ethyl 2-phenyl-4-{[2-(pyrrolidin-1-yl)ethyl]amino}-1,3-thiazole-5-carboxylate (75)
[0291] Following the general procedure E and starting from 5-(ethoxycarbonyl)-2-phenylthiazol-4-yl trifluoromethanesulfonate (145 mg, 0.38 mmol) and 2-(pyrrolidin-1-yl)ethanamine (51.4 mg, 0.45 mmol), compound 75 was obtained as a yellow solid after purification by flash column cromatography (eluent hexane/ethyl acetate mixture of increasing polarity) of the crude product (83 mg, 63%). 1 H-NMR (CDCl 3 , TMS) δ (ppm): 7.72-7.64 (m, 2H), 7.45-7.38 (m, 1H), 7.20-7.13 (m, 1H), 6.98 (br s, 1H), 4.31 (q, 2H, J=7.03), 3.97-3.90 (m, 2H), 3.16-3.12 (m, 2H), 3.12-3.01 (m, 4H), 2.05-1.96 (m, 4H), 1.35 (t, 3H, J=7.03); MS (ES 1+ ) m/z: 346.41 (M+1).
Example 76
Synthesis of ethyl 4-(benzylamino)-2-(3-fluorophenyl)-1,3-thiazole-5-carboxylate (76)
[0292] Following the general procedure E and starting from 5-(ethoxycarbonyl)-2-(3-fluorophenyl)thiazol-4-yl trifluoromethanesulfonate (0.15 g, 0.33 mmol) and phenylmethanamine (43 mg, 0.40 mmol), compound 76 was obtained as a yellow solid after purification by flash column cromatography (eluent hexane/ethyl acetate mixture of increasing polarity) of the crude product (96 mg, 76%). 1 H-NMR (CDCl 3 , TMS) δ (ppm): 7.74-7.64 (m, 2H), 7.43-7.25 (m, 6H), 7.19-7.12 (m, 1H), 4.86 (s, 2H), 4.29 (q, 2H, J=7.03), 1.34 (t, 3H, J=7.03); MS (ES 1+ ) m/z: 357.41 (M+1).
Example 77
Synthesis of ethyl 4-[(1,3-benzodioxol-5-ylmethyl)amino]-2-(3-fluorophenyl)-1,3-thiazole-5-carboxylate (77)
[0293] Following the general procedure E and starting from 5-(ethoxycarbonyl)-2-(3-fluorophenyl)thiazol-4-yl trifluoromethanesulfonate (0.15 g, 0.33 mmol) and (benzo[d][1,3]dioxol-5-yl)methanamine (60 mg, 0.40 mmol), compound 77 was obtained as a yellow solid after purification by flash column cromatography (eluent hexane/ethyl acetate mixture of increasing polarity) of the crude product (82 mg, 62%). 1 H-NMR (CDCl 3 , TMS) δ (ppm): 7.75-7.70 (m, 2H), 7.46-7.39 (m, 1H), 7.21-7.11 (m, 2H), 6.91-6.78 (m, 2H), 5.96 (s, 2H), 4.77 (s, 2H), 4.31 (q, 2H, J=7.03), 1.46 (s, 1H), 1.38 (t, 3H, J=7.03); MS (ES 1+ ) m/z: 401.61 (M+1).
Example 78
Synthesis of ethyl 2-(3-fluorophenyl)-4-[(pyridin-3-ylmethyl)amino]-1,3-thiazole-5-carboxylate (78)
[0294] Following the general procedure E and starting from 5-(ethoxycarbonyl)-2-(3-fluorophenyl)thiazol-4-yl trifluoromethanesulfonate (0.15 g, 0.33 mmol) and (pyridin-3-yl)methanamine (43 mg, 0.40 mmol), compound 78 was obtained as a yellow solid after purification by flash column cromatography (eluent hexane/ethyl acetate mixture of increasing polarity) of the crude product (81 mg, 69%). 1 H-NMR (CDCl 3 , TMS) δ (ppm): 8.67 (s, 1H), 8.52 (s, 1H), 7.74-7.65 (m, 2H), 7.48-7.36 (m, 1H), 7.32-7.12 (m, 4H), 4.85 (s, 2H), 4.30 (q, 2H, J=7.03), 1.36 (t, 3H, J=7.03); MS (ES 1+ ) m/z: 358.53 (M+1).
Example 79
Synthesis of 4-[(2-aminoethyl)amino]-2-(4-methylphenyl)-1,3-thiazole-5-carboxylic acid (79)
[0295] The title compound was prepared following the general procedure D and starting from ethyl 4-[(2-aminoethyl)amino]-2-(4-methylphenyl)-1,3-thiazole-5-carboxylate 67 (93 mg, 0.30 mmol). Compound 79 was obtained as a white solid (68 mg, 81%). 1 H-NMR (CDCl 3 , TMS) δ (ppm): 7.83 (d, 2H, J=8.1), 7.22 (d, 2H, J=8.1), 3.20 (t, 2H, J=6.9), 2.80 (t, 2H, J=6.9), 2.39 (s, 3H). MS (ES 1+ ) m/z: 277.8 (M+1).
Example 80
Synthesis of 4-{[2-(methylamino)ethyl]amino}-2-(4-methylphenyl)-1,3-thiazole-5-carboxylic acid (80)
[0296] Following the general procedure D and starting from ethyl 4-{[2-(methylamino)ethyl]amino}-2-(4-methylphenyl)-1,3-thiazole-5-carboxylate 71 (89 mg, 0.27 mmol), compound 80 was obtained as white solid (74 mg, 91%). MS (ES 1+ ) m/z: 292.8 (M+1).
Example 81
Synthesis of 4-[(2-aminoethyl)amino]-2-(3-fluorophenyl)-1,3-thiazole-5-carboxylic acid (81)
[0297] Following the general procedure D and starting from ethyl 4-[(2-aminoethyl)amino]-2-(3-fluorophenyl)-1,3-thiazole-5-carboxylate (100 mg, 0.32 mmol), compound 81 was obtained as white solid (80 mg, 88%). MS (ES 1+ ) m/z: 282.4 (M+1).
General Procedure F
Example 82
Synthesis of sodium 4-[(3-chlorobenzyl)oxy]-2-(3-fluorophenyl)-1,3-thiazole-5-carboxylate (82)
[0298] 1 eq of NaOH was added to a 30 mM solution of 5-[(3-chlorobenzyl)oxy]-2-(3-fluorophenyl)-1,3-thiazole-4-carboxylic acid 48 and the mixture stirred for 30 min at room temperature. After evaporation under reduced pressure the compound 82 was isolated in form of sodium salt (19 mg, 95%). 1 H-NMR (DMSO-d 6 ) δ (ppm): 7.89-7.82 (m, 2H), 7.70-7.61 (m, 2H), 7.57-7.53 (m, 4H), 7.42 (m, 2H), 5.42 (s, 2H).
Example 83
Synthesis of sodium 4-[(4-chlorobenzyl)oxy]-2-(4-methylphenyl)-1,3-thiazole-5-carboxylate (83)
[0299] Following the procedure F and starting from 4-[(4-chlorobenzyl)oxy]-2-(4-methylphenyl)-1,3-thiazole-5-carboxylic acid 43, compound 83 was obtained as a white solid (54 mg, 95%). 1 H-NMR (CD 3 OD) δ (ppm): 7.83 (d, 2H, J=7.0), 7.52 (d, 2H, J=7.6), 7.41(d, 2H, J=7.0), 7.33 (d, 2H, J=7.6), 5.59 (s, 2H), 2.31 (s, 3H).
Example 84
Synthesis of sodium 4-(4-chlorobenzyloxy)-2-(4-chlorophenyl)-1,3-thiazole-5-carboxylate (84)
[0300] Following the general procedure F and starting from 4-(4-chlorobenzyloxy)-2-(4-chlorophenyl)-1,3-thiazole-5-carboxylic acid 45 (0.2 g, 0.526 mmol), compound 84 was obtained as a yellow solid (212 mg, 95%). 1 H-NMR (DMSO-d 6 ) δ (ppm): 7.89 (d, 2H, J=8.65), 7.57-7.53 (m, 4H), 7.42 (d, 2H, J=8.65), 5.47 (s, 2H).
Example 85
Synthesis of sodium 4-(2-chlorobenzyloxy)-2-(4-chlorophenyl)-1,3-thiazole-5-carboxylate (85)
[0301] Following the general procedure F and starting from 4-(2-chlorobenzyloxy)-2-(4-chlorophenyl)-1,3-thiazole-5-carboxylic acid 51 (0.16 g, 0.421 mmol), compound 85 was obtained as a yellow solid (170 mg, 96%). 1 H-NMR (DMSO-d 6 ) δ (ppm): 7.89-7.78 (m, 3H, J=8.65), 7.61 (d, 2H), 7.47-7.43 (m, 1H), 7.42 (d, 2H, J=8.65), 5.47 (s, 2H).
Example 86
Synthesis of sodium 4-(2-chlorobenzyloxy)-2-(4-methylphenyl)-1,3-thiazole-5-carboxylate (86)
[0302] Following the general procedure F and starting from 4-(2-chlorobenzyloxy)-2-(4-methylphenyl) -1,3-thiazole-5-carboxylic acid 53 (0.4 g, 1.11 mmol), compound 86 was obtained as a white solid (421 mg, 89%). 1 H-NMR (DMSO-d 6 ) δ (ppm): 7.85-7.82 (m, 1H), 7.74 (d, 2H, J=8.11), 7.49-7.46 (m, 1H), 7.37-7.33 (m, 2H), 7.28 (d, 2H, J=8.11), 5.55 (s, 2H), 2.34 (s, 3H).
Example 87
Synthesis of sodium 4-(2-chlorobenzyloxy)-2-(3-fluorophenyl)-1,3-thiazole-5-carboxylate (87)
[0303] Following the general procedure F and starting from ethyl 4-(2-chlorobenzyloxy)-2-(3-fluorophenyl)-1,3-thiazole-5-carboxylate 54 (70 mg, 0.179 mmol), compound 87 was obtained as a white solid (69 mg, 92%). 1 H-NMR (DMSO-d 6 ) δ (ppm): 7.80-7.67 (m, 3H), 7.58-7.47 (m, 2H), 7.41-7.30 (m, 3H), 5.59 (s, 2H).
Example 88
Synthesis of sodium 4-(4-chlorobenzyloxy)-2-(3-fluorophenyl)-1,3-thiazole-5-carboxylate (88)
[0304] Following the general procedure F and starting from ethyl 4-(4-chlorobenzyloxy)-2-(3-fluorophenyl)-1,3-thiazole-5-carboxylate (0.1 g, 0.255 mmol), compound 88 was obtained as a yellow solid (100 mg, 98%). 1 H-NMR (DMSO-d 6 ) δ (ppm): 7.69-7.40 (m, 7H), 7.31-7.24 (m, 1H), 5.44 (s, 2H).
Example 89
Synthesis of (1R,2S,5R)-2-isopropyl-5-methylcyclohexyl-4-(benzyloxy)-2-(4-methylphenyl)-1,3-thiazole-5-carboxylate (89)
[0305] Following the general procedure described for compound 36 and starting from (1R,2S,5R)-2-isopropyl-5-methylcyclohexanol (91 mg, 0.58 mmol) and 4-(benzyloxy)-2-(4-methylphenyl)-1,3-thiazole-5-carbonyl chloride (0.1 g, 0.29 mmol) (obtained by treatment of the corresponding acid with SOCl 2 , 3.0 eq., in toluene), compound 89 was obtained as transparent oil after purification by HPLC (116 mg, 87%). 1 H-NMR (acetone-d 6 ) δ (ppm): 7.94-7.91 (d, 2H, J=7.8), 7.61-7.58 (m, 2H), 7.44-7.31 (m, 5H), 5.69-5.58 (s, 2H), 4.84 (dt, 1H, J 1 =10.8, J 2 =4.3), 2.41 (s, 3H), 2.11-1.99 (m, 2H), 1.77-1.69 (m, 2H), 1.56-1.47 (m, 2H), 1.31-1.27 (m, 1H), 1.17-1.07 (m, 1H), 0.95-0.89 (m, 7H), 0.80 (d, 3H, J=7.0); MS (ES 1+ ) m/z: 465.34 (M+1).
Example 90
Synthesis of (1R,2S,5R)-2-isopropyl-5-methylcyclohexyl-4-hydroxy-2-(4-methylphenyl)-1,3-thiazole-5-carboxylate (90)
[0306] A solution of (1R,2S,5R)-2-isopropyl-5-methylcyclohexyl 4-(benzyloxy)-2-(4-methylphenyl)-1,3-thiazole-5-carboxylate 89 (0.1 g, 0.21 mmol) in dry THF was hydrogenated at atmospheric pressure in the presence of Pd/C for 1 h. The mixture was then filtered through celite and the filtrate concentrated under reduced pressure to give compound 90 as transparent oil (75 mg, 95%). 1 H-NMR (CDCl 3 , TMS) δ (ppm): 10.02 (bs, 1H), 7.90 (d, 2H, J=8.1), 7.34-7.26 (m, 2H), 5.02-4.87 (m, 1H), 2.42 (s, 3H), 1.95-1.87 (m, 2H), 1.78-1.69 (m, 2H), 1.65-1.44 (m, 2H), 1.31-1.28 (m, 1H), 1.22-1.09 (m, 1H), 0.97-0.82 (m, 10H); MS (ES 1+ ) m/z: 375.09 (M+1); 236.76 (M−136).
Example 91
Synthesis of ethyl 2-(4-chlorophenyl)-4-(methoxymethoxy)-1,3-thiazole-5-carboxylate (91)
[0307] Following the general procedure C and starting from ethyl 4-hydroxy-2-(4-chlorophenyl)-1,3-thiazole-5-carboxylate 8 (0.1 g, 0.35 mmol), and chloro(methoxy)methane (56 mg, 0.70 mmol), compound 91 was obtained as a white solid (110 mg, 96%). 1 H-NMR (CDCl 3 , TMS) δ (ppm): 7.94 (d, 2H, J=8.6), 7.45 (d, 2H, J=8.6), 5.67 (s, 2H), 4.43 (q, 2H, J=7.0), 3.6 (s, 3H), 1.42 (t, 3H, J=7.0); MS (ES 1+ ) m/z: 328.85 (M+1), 256.67 (M−72), 297.74 (M−72+41).
Example 92
Synthesis of 2-(4-chlorophenyl)-4-(methoxymethoxy)-1,3-thiazole-5-carboxylic acid (92)
[0308] Following the general procedure D starting from ethyl 2-(4-chlorophenyl)-4-(methoxymethoxy)-1,3-thiazole-5-carboxylate 91 (0.1 g, 0.3 mmol), compound 92 was obtained as a white solid (86 mg, 95%). 1 H-NMR (CDCl 3 , TMS) δ (ppm): 7.92 (d, 2H, J=8.6), 7.43 (d, 2H, J=8.6), 5.42 (s, 2H), 3.71 (s, 3H); MS (ES 1+ ) m/z: 299.74 (M+1).
Example 93
Synthesis of 2-(4-chlorophenyl)-4-(methoxymethoxy)-1,3-thiazole-5-carboxamide (93)
[0309] 2-(4-chlorophenyl)-4-(methoxymethoxy)-1,3-thiazole-5-carboxylic acid 92 (80 mg, 0.28 mmol) was dissolved in dry CH 2 Cl 2 (10 mL) at 0° C., under N 2 atmosphere, 1,1′-carbonyldiimidazole (0.41 mmol, 68 mg) was added at the same temperature. The mixture was warmed to room temperature and stirred for 40 min. Gaseous NH 3 was bubbled into the mixture and the course of the reaction was monitored by LC-MS analysis. At the end of the reaction the mixture was concentrated under reducer pressure and the crude product triturated with acetone. The resulting precipitate was collected by filtration, washed with diethyl ether and purified by flash column chromatography (eluent: dichloromethane/methanol mixture of increasing polarity). Compound 93 was obtained as white solid (77 mg, 78%). 1 H-NMR (CDCl 3 , TMS) δ (ppm): 7.86 (d, 2H, J=8.1), 7.41 (d, 2H, J=8.6), 6.98 (br s, 1H), 5.85 (br s, 1H), 5.70 (s,2H), 3.59 (s, 3H); MS (ES 1+ ) m/z: (ESI+)=300 (M+1), 282 (M−18), 252 (M−48).
Example 94
Synthesis of 2-(4-chlorophenyl)-4-(methoxymethoxy)-1,3-thiazole-5-carbonitrile (94)
[0310] A 250 mL three-necked round bottom flask was equipped with a thermometer, flame dried, and charged with N 2 and a solution 2-(4-chlorophenyl)-4-(methoxymethoxy)-1,3-thiazole-5-carboxamide 93 (450 mg, 1.5 mmol) in dry CH 2 Cl 2 (8 mL). To this solution DMSO (284 μL, 4.0 mmol) was added and the resulting pale yellow solution cooled to −78° C. A solution of (COCl) 2 (270 μL, 3.2 mmol) in dry CH 2 Cl 2 (2 mL) was then added dropwise. After 15 min. stirring at −78° C., Et 3 N (892 μL, 6.4 mmol) was added dropwise to the mixture. The following addition of DMSO (284 μL, 4.0 mmol), (COCl) 2 (270 μL, 3.2 mmol) and Et 3 N (500 μL, 3.5 mmol) at intervals of 1 h were necessary in order to complete the starting material consumption. The reaction was quenched by addition of water (20 mL), warming of the mixture to room temperature, and extraction of the aqueous layer with ethyl acetate (3×10 mL). The combined organic phases were washed with brine (30 mL), dried over dry Na 2 SO 4 and concentrated in vacuo. Purification by silica gel column chromatography (hexane/acetate 9/1 to 1/1) gave 94 as a pale yellow solid (270 mg, 74%). 1 H-NMR (CDCl 3 , TMS) δ (ppm): 7.86 (d, 2H, J=7.6), 7.45 (d, 2H, J=7.6), 5.59 (s, 2H), 3.58 (s, 3H).
Example 95
Synthesis of 2-(4-chlorophenyl)-5-(1H-tetrazol-5-yl)thiazol-4-ol (95)
[0311] 2-(4-chlorophenyl)-4-(methoxymethoxy)-1,3-thiazole-5-carbonitrile 94 (55 mg, 0.14 mmol), sodium azide (10 mg, 0.16 mmol), zinc chloride (19 mg, 0.14 mmol), and 8 mL of water were mixed in a 25 mL round-bottomed flask. The reaction mixture was vigorously stirred at 100° C. for 72 h. After consumption of the starting material, 6 N HCl (100 μL) and ethyl acetate (7 mL) were added, and stirring was continued until no solid was present and the aqueous layer reached pH 1. Additional ethyl acetate was added; the organic layer was separated and the aqueous one extracted again with ethyl acetate (2×10 mL). The combined organic layers were dried over dry Na 2 SO 4 and concentrated in vacuo. Compound 95 was obtained as pale yellow solid (28 mg, 75%) after preparative HPLC purification. 1 H-NMR (dmso-d 6 ) δ (ppm): 16.2 (br s, 1H), 13.0 (br s, 1H), 7.99 (d, 2H, J=8.6), 7.62 (d, 2H, J=8.6); MS (ES 1+ ) m/z: 278.8 (M+1), 231.8 (M+41), 235,6 (M−28).
Example 96
Synthesis of 2-(4-chlorophenyl)-5-(1-methyl-1H-tetrazol-5-yl)thiazol-4-ol (96)
[0312] A 25 mL three-necked round bottom flask was equipped with a thermometer, flame dried, and charged with N 2 and a solution of 2-(4-chlorophenyl)-5-(1H-tetrazol-5-yl)thiazol-4-ol 95 (40 mg, 0.14 mmol) in THF (10 mL). To this solution pyridine (12 μL, 0.14 mmol) were added by syringe. The resulting mixture was cooled to 0° C. and stirred for 30 min. Methyl iodide (34 μL, 0.17 mmol) was added dropwise by a syringe, while keeping the temperature below 5° C. After the addition, the ice bath was removed, and the solution stirred at room temperature until all starting material was consumed. The reaction mixture was diluted with ethyl acetate (15 mL) and the reaction was cautiously quenched with HCl 0.5 N (10 mL) at 0° C. The solution was allowed to warm to room temperature, the organic layer separated and the aqueous one extracted again with ethyl acetate (2×10 mL). The combined organic layers were dried over dry Mg 2 SO 4 and concentrated in vacuo. The resulting yellow solid was purified by preparative HPLC to afford the compound 96 as pale yellow solid (27 mg, 65%). 1 H-NMR (dmso-d 6 ) δ (ppm): 11.98 (br s, 1H), 7.99 (d, 2H, J=8.6), 7.62 (d, 2H, J=8.6), 3.91 (s, 3H); MS (ES 1+ ) m/z: 294.75 (M+1).
Example 97
Synthesis of 2-(3-fluorophenyl)-5-(1-methyl-1H-tetrazol-5-yl)-1,3-thiazol-4-ol (97)
[0313] Following the procedure described for compound 96 and starting from 2-(3-fluorophenyl)-5-(1H-tetrazol-5-yl)-1,3-thiazol-4-ol, the compound 97 was isolated as dark-yellow oil (73 mg, 47%). 1 H-NMR (dmso-d 6 ) δ (ppm): 11.79 (br s, 1H), 7.73-7.68 (m, 2H), 7.46-7.39 (m, 1H), 3.82 (s, 3H); MS (ES 1+ ) m/z: 278.18 (M+1).
Example 98
Synthesis of 2-(4-chlorophenyl)-5-(5-methyl-4H-1,2,4-triazol-3-yl)-1,3-thiazol-4-ol (98)
[0314] To a solution of 2-(4-chlorophenyl)-4-(methoxymethoxy)-1,3-thiazole-5-carbonitrile 94 (0.25 g, 0.890 mmol) in dry toluene (10 mL), a solution of Et 3 Al (122 μL, 0.89 mmol) in dry toluene was added dropwise and the resulting mixture stirred for 20 min at room temperature. Acetohydrazide (0.165 g, 2.22 mmol) was added and the mixture heated at 90° C. for 6 h until the starting materials had been completely consumed (as checked by TLC and LC-MS analysis). The mixture was diluted with toluene (10 mL) and transferred to a separatory funnel; the organic layer was washed with water, dried over Na 2 SO 4 , filtered, and concentrated in vacuo to afford a brown oil which was used in the next step without further purification. The oil was dissolved in toluene (10 mL), added to a microwave vial and irradiated by MW at 170° C. for 20 min. After consumption of the starting material, 2 mL of 6 N HCl were added and vigorous stirring continued for 1 h. The organic layer was isolated and the aqueous layer extracted with ethyl acetate (2×10 mL). The combined organic layers were evaporated and the crude product was purified by flash chromatography on silica gel (petroleum ether/ethyl acetate 90:10 to 70:30) to afford 98 as transparent oil (125 mg, 48%). 1 H-NMR (dmso-d 6 ) δ (ppm): 12.11 (br s, 1H), 12.98 (br s, 1H), 7.99 (d, 2H, J=7.6), 7.62 (d, 2H, J=7.6), 2.25 (s, 3H); MS (ES 1+ ) m/z: 293.74 (M+1).
Example 99
Synthesis of 2-(3-fluorophenyl)-5-(5-methyl-4H-1,2,4-triazol-3-yl)-1,3-thiazol-4-ol (99)
[0315] Following the procedure described for compound 98 and starting from 2-(3-fluorophenyl)-4-(methoxymethoxy)-1,3-thiazole-5-carbonitrile, the compound 99 was isolated following flash chromatography on silica gel (CH 2 Cl 2 /CH 3 OH 90:10) as slightly red oil (97 mg, 31%). 1 H-NMR (dmso-d 6 ) δ (ppm): 11.93 (br s, 1H), 12.80 (br s, 1H), 7.76-7.69 (m, 2H), 7.46-7.39 (m, 1H), 7.22-7.17 (m, 1H), 2.21 (s, 3H); MS (ES 1+ ) m/z: 277.27 (M+1).
Example 100
Synthesis of 2-(4-chlorophenyl)-5-(5-methyl-1,2,4-oxadiazol-3-yl)-1,3-thiazol-4-ol (100)
[0316] A microwave vial was charged with 2-(4-chlorophenyl)-4-(methoxymethoxy)-1,3-thiazole-5-carbonitrile 94 (250 mg, 0.89 mmol), acetic acid (5 mL), hydroxylamine (117 mg, 3.56 mmol) and 2,2-dimethyl-1,3-dioxane-4,6-dione (Meldrum's acid) (131 mg, 0.91 mmol). The mixture was irradiated by MW for 10 min at 130° C., then quenched with 10 mL of water and the precipitate was filtered and dried under vacuum at 50° C. The solid obtained was dissolved in a mixture of HCl 6N (5 mL) and ethyl acetate (10 mL) and stirred for 1 h. The two phases were separated into a separatory funnel; the organic layer was washed with water, dried over Na 2 SO 4 , filtered, and concentrated in vacuo to afford compound 100 as a dark yellow solid (107 mg, 41%). 1 H-NMR (dmso-d 6 ) δ (ppm): 11.98 (br s, 1H), 7.89 (d, 2H, J=7.5), 7.51 (d, 2H, J=7.6), 2.55 (s, 3H); MS (ES 1+ ) m/z: 294.50 (M+1), 316.7 (M+Na).
Example 101
Synthesis of 2-(3-fluorophenyl)-5-(5-methyl-1,2,4-oxadiazol-3-yl)-1,3-thiazol-4-ol (101)
[0317] Following the experimental procedure described for compound 100 and starting from 2-(3-fluorophenyl)-4-(methoxymethoxy)-1,3-thiazole-5-carbonitrile compound 101 was isolated as white solid (177 mg, 52%). 1 H-NMR (dmso-d 6 ) δ (ppm): 11.81 (br s, 1H), 7.76-7.69 (m, 3H), 7.22-7.17 (m, 1H), 2.33 (s, 3H); MS (ES 1+ ) m/z: 278.27 (M+1).
Example 102
Synthesis of 3-{4-[(4-chlorobenzyl)oxy]-2-(3-fluorophenyl)-1,3-thiazol-5-yl}-5-methyl-1,2,4-oxadiazole (102)
[0318] The title compound was prepared according to the general procedure C and starting from 2-(3-fluorophenyl)-5-(5-methyl-1,2,4-oxadiazol-3-yl)-1,3-thiazol-4-ol 101 (221 mg, 0.8 mmol) and 1-chloro-4-(chloromethyl)benzene (0.16 g, 1.00 mmol). Compound 102 was obtained as dark red oil (234 mg, 73%). 1 H-NMR (dmso-d 6 ) δ (ppm): 7.83-7-79 (d, 2H, J=7.6), 7.76-7.69 (m, 2H), 7.63-7.59 (m, 1H), 7.51 (d, 2H, J=7.4), 7.22-7.17 (m, 1H), 5.23 (s, 2H), 2.33 (s, 3H); MS (ES 1+ ) m/z: 402.8 (M+1).
Example 103
Synthesis of 2-(4-chlorophenyl)-5-(5-methyl-1,3,4-oxadiazol-2-yl)-1,3-thiazol-4-ol (103)
[0319] To a cooled solution (0° C.) of 2-(4-chlorophenyl)-4-hydroxy-1,3-thiazole-5-carboxylic acid 1 (0.43 g, 1.68 mmol) in CH 2 Cl 2 (15 mL), 1,1-carbonyldiimidazole (CDI, 275 mg, 1.70 mmol) was added. After stirring 1 h at 0° C., acetohydrazide (124 mg, 1.68 mmol) and diazobicyclo-[5.4.0]undec-7-ene (DBU, 260 μL, 1.68 mmol) were added, and the mixture was allowed stirring at room temperature for 4 h. Glacial AcOH (200 μL, 3.5 mmol) was added and the reaction mixture diluted with CH 2 Cl 2 (10 mL). The organic layer washed with saturated NH 4 Cl (2×10 mL) and water (2×10 mL), dried over Na 2 SO 4 , filtered and concentrated under reduced pressure to give a crude residue that, after purification by flash chromatography (CH 2 Cl 2 /CH 3 OH 95:5) afforded N′-acetyl-2-(4-chlorophenyl)-4-hydroxy-1,3-thiazole-5-carbohydrazide as pale yellow oil. The compound was dissolved in polyphosphoric acid (5 mL) in a microwave vial and irradiated by MW for 40 min at 150° C. The solution was added to an ice/water mixture and the precipitate filtered and washed with water. The solid precipitated was dried under vacuum at 50° C. to afford compound 103 as a whitish solid (182 mg, 37%). 1 H-NMR (dmso-d 6 ) δ (ppm): 11.89 (br s, 1H), 7.89 (d, 2H, J=7.6), 7.51 (d, 2H, J=7.4), 2.65 (s, 3H); MS (ES 1+ ) m/z: 294.50 (M+1), 316.7 (M+Na).
Example 104
Synthesis of 2-(3-fluorophenyl)-5-(5-methyl-1,3,4-oxadiazol-2-yl)-1,3-thiazol-4-ol (104)
[0320] The title compound was prepared according to the experimental procedure described for compound 103 and starting from 2-(3-fluorophenyl)-4-hydroxy-1,3-thiazole-5-carboxylic acid 3. Compound 104 was isolated as a yellow oil (109 mg, 59%). 1 H-NMR (dmso-d 6 ) δ (ppm): 11.79 (br s, 1H), 7.63-7.79 (m, 3H), 7.11-7.18 (m, 1H), 2.61 (s, 3H); MS (ES 1+ ) m/z: 278.27 (M+1).
Example 105
Synthesis of ethyl 4-hydroxy-2-phenyl-1,3-oxazole-5-carboxylate (105)
[0321] An oven-dried microwave vial was evacuated, backfilled with argon and finally charged with benzamide (0.3 g, 2.48 mmol), diethyl bromopropanedioate (1.27 μL, 7.44 mmol) and dry DMSO (3 mL). The reaction vial was sealed and placed in the microwave reactor and irradiated for 2 h at 250° C. until the complete consumption of the starting materials (as checked by TLC and GC analysis). The crude was diluted with ethyl acetate (20 mL) and washed with water (3×10 mL). The combined organic layers were dried over Na 2 SO 4 , filtered and the solvent was removed under reduced pressure. The residue was purified by flash chromatography on silica gel (CH 2 Cl 2 /CH 3 OH 95:5) to afford the compound 105 as colourless oil (83%). 1 H-NMR (dmso-d 6 ) δ (ppm): 12.3 (br s, 1H), 7.95-7.92 (m, 2H), 7.55-7.53 (m, 3H), 4.43 (q, 2H, J=7.03), 1.42 (t, 3H, J=7.03); MS (ES 1+ ) m/z: 234.33 (M+1).
Example 106
Synthesis of ethyl 2-(3-fluorophenyl)-4-hydroxy-1,3-oxazole-5-carboxylate (106)
[0322] The title compound was prepared according to the experimental procedure described for compound 105 and starting from 3-fluorobenzamide. Compound 106 was isolated as a yellow oil (99 mg, 59%). 1 H-NMR (CDCl 3 , TMS) δ (ppm): 11.98 (br s, 1H), 8.01 (s, 1H), 7.77 (d, 1H, J=7.57), 7.49-7.30 (m, 2H), 4.40 (q, 2H, J=7.03), 1.52 (t, 3H, J=7.03); MS (ES 1+ ) m/z: 252.18 (M+1).
Example 107
Synthesis of ethyl 4-hydroxy-2-(4-methylphenyl)-1,3-oxazole-5-carboxylate (107)
[0323] The title compound was prepared according to the experimental procedure described for compound 105 and starting from p-tolylbenzamide. Compound 107 was isolated as a whitish oil (39 mg, 79%). 1 H-NMR (CDCl 3 , TMS) δ (ppm): 11.94 (br s, 1H), 7.88 (d, 2H, J=7.6), 7.26 (d, 2H, J=7.6), 4.62 (q, 2H, J=7.0), 2.41 (s, 3H), 1.39 (t, 3H, J=7.0); MS (ES 1+ ) m/z: 248.25.
Example 108
Synthesis of ethyl 4-[(4-chlorobenzyl)oxy]-2-phenyl-1,3-oxazole-5-carboxylate (108)
[0324] Following the general procedure C and starting from ethyl 4-hydroxy-2-phenyl-1,3-oxazole-5-carboxylate 105 (055 g, 2.67 mmol) and 1-chloro-4-(chloromethyl)benzene (1.074 g, 6.67 mmol), compound 108 was obtained as a white solid (0.8 g, 81%). 1 H-NMR (CDCl 3 , TMS) δ (ppm): 7.83-7.48 (m, 5H), 7.35 (d, 2H, J=7.5), 7.27 (d, 2H, J=7.6), 5.31 (s, 2H), 4.35 (q, 2H, J=7.03), 1.38 (t, 3H, J=7.03); MS (ES 1+ ) m/z: 358.80 (M+1), 380.77 (M+Na).
Example 109
Synthesis of ethyl 4-[(4-chlorobenzyl)oxy]-2-(3-fluorophenyl)-1,3-oxazole-5-carboxylate (109)
[0325] Following the general procedure C and starting from ethyl 2-(3-fluorophenyl)-4-hydroxy-1,3-oxazole-5-carboxylate 106 (110 mg, 0.43 mmol), compound 109 was obtained as a white powder (114 mg, 71%). 1 H-NMR (CDCl 3 , TMS) δ (ppm): 7.85-7.51 (m, 3H), 7.47 (m, 1H), 7.36 (d, 2H, J=7.6), 7.26 (d, 2H, J=7.6), 5.53 (s, 2H), 4.33 (q, 2H, J=7.03), 1.38 (t, 3H, J=7.03); MS (ES 1+ ) m/z: 376.66 (M+1).
Example 110
Synthesis of ethyl 4-[(4-chlorobenzyl)oxy]-2-(4-methylphenyl)-1,3-oxazole-5-carboxylate (110)
[0326] Following the general procedure C and starting from ethyl 4-hydroxy-2-(4-methylphenyl)-1,3-oxazole-5-carboxylate 107 (98 mg, 0.39 mmol) compound 110 was obtained as a white powder (114 mg, 79%). 1 H-NMR (CDCl 3 , TMS) δ (ppm): 7.82 (d, 2H, J=7.6), 7.49 (d, 2H, J=7.6), 7.23 (d, 2H, J=7.6), 7.19 (d, 2H, J=7.6), 5.32 (s, 2H), 4.30 (q, 2H, J=7.03), 2.39 (s, 3H), 1.28 (t, 3H, J=7.03); MS (ES 1+ ) m/z: 372.72 (M+1).
Example 111
Synthesis of ethyl 2-phenyl-4-{[4-(trifluoromethyl)benzoyl]oxy}-1,3-oxazole-5-carboxylate (111)
[0327] Following the procedure described for compound 36 and starting from ethyl 4-hydroxy-2-phenyl-1,3-oxazole-5-carboxylate 105 (67 mg, 0.28 mmol) compound 111 was obtained as colorless oil (77 mg, 67%). 1 H-NMR (CDCl 3 , TMS) δ (ppm): 7.73-7.51 (m, 5H), 7.47 (d, 2H, J=7.5), 7.35 (d, 2H, J=7.6), 4.37 (q, 2H, J=7.13), 1.48 (t, 3H, J=7.11); MS (ES 1+ ) m/z: 406.28 (M+1).
Example 112
Synthesis of 4-[(4-chlorobenzyl)oxy]-2-phenyl-1,3-oxazole-5-carboxylic acid (112)
[0328] The title compound was prepared according to the general procedure D and starting from ethyl 4-[(4-chlorobenzyl)oxy]-2-phenyl-1,3-oxazole-5-carboxylate 108 (123 mg, 0.34 mmol). Compound 112 was obtained as slightly dark oil (99 mg, 88%). 1 H-NMR (dmso-d 6 ) δ (ppm): 12.12 (br s, 1H), 7.71-7.49 (m, 5H), 7.41 (d, 2H, J=8), 7.34 (d, 2H, J=7.6), 5.61 (s, 2H); MS (ES 1+ ) m/z: 330.68 (M+1).
Example 113
Synthesis of 4-[(4-chlorobenzyl)oxy]-2-(3-fluorophenyl)-1,3-oxazole-5-carboxylic acid (113)
[0329] The title compound was prepared according to the general procedure D and starting from ethyl 4-[(4-chlorobenzyl)oxy]-2-(3-fluorophenyl)-1,3-oxazole-5-carboxylate 109 (88 mg, 0.23 mmol). Compound 113 was obtained as white solid (70 mg, 86%). 1 H-NMR (dmso-d 6 ) δ (ppm): 11.91 (br s, 1H), 7.81-7.50 (m, 3H), 7.45 (m, 1H), 7.31 (d, 2H, J=7.6), 7.26 (d, 2H, J=7.6), 5.63 (s, 2H); MS (ES 1+ ) m/z: 348.62 (M+1).
Example 114
Synthesis of 4-[(4-chlorobenzyl)oxy]-2-(4-methylphenyl)-1,3-oxazole-5-carboxylic acid (114)
[0330] The title compound was prepared according to the general procedure D and starting from ethyl 4-[(4-chlorobenzyl)oxy]-2-(4-methylphenyl)-1,3-oxazole-5-carboxylate 110 (0.12 g, 0.32 mmol). Compound 114 was obtained as whitish solid (98 mg, 89%). 1 H-NMR (CD 3 OD) δ (ppm): 7.89 (d, 2H, J=7.6), 7.53 (d, 2H, J=7.6), 7.41 (d, 2H, J=7.5), 7.33 (d, 2H, J=7.6), 5.43 (s, 2H), 2.39 (s, 3H); MS (ES 1+ ) m/z: 344.66 (M+1).
Example 115
Synthesis of 2-(3-fluorophenyl)-5-(5-methyl-1,2,4-oxadiazol-3-yl)-1,3-oxazol-4-ol (115)
[0331] The title compound was prepared according to the experimental procedure described for compound 100 and starting from 2-(3-fluorophenyl)-4-hydroxy-1,3-oxazole-5-carbonitrile (76 mg, 0.25 mmol). Compound 115 was obtained as pale yellow oil (54 mg, 79%). 1 H-NMR (dmso-d 6 ) δ (ppm): 12.1 (br s, 1H), 7.83-7.74 (m, 3H), 7.11-7.18 (m, 1H), 2.51 (s, 3H); MS (ES 1+ ) m/z: 262.21 (M+1).
Example 116
Synthesis of 3-{4-[(4-chlorobenzyl)oxy]-2-(3-fluorophenyl)-1,3-oxazol-5-yl}-5-methyl-1,2,4-oxadiazole (116)
[0332] The title compound was prepared according to the experimental procedure B and starting from 2-(3-fluorophenyl)-5-(5-methyl-1,2,4-oxadiazol-3-yl)-1,3-oxazol-4-ol 115 (98 mg, 0.37 mmol). Compound 116 was obtained as yellow oil (88 mg, 61%). 1 H-NMR (CDCl 3 , TMS) δ (ppm): 7.77 (m, 1H), 7.61 (m, 1H), 7.60-7.55 (m, 3H), 7.50 (m, 1H), 7.35-7.29 (m, 2H), 5.40 (s, 2H), 2.45 (s, 3H); MS (ES 1+ ) m/z 386.78 (M+1).
Example 117
Synthesis of ethyl 2-(3-fluorophenyl)-5-hydroxy-1,3-thiazole-4-carboxylate (117)
[0333] Triethylamine (3.4 mL, 24 mmol) and 4-methylbenzoyl chloride (1.59 mL, 12.0 mmol) were added to a solution of diethyl 2-aminomalonate hydrochloride (2.28 g, 10.8 mmol in CH 2 Cl 2 (40 mL). and the resulting mixture was stirred overnight at room temperature. The mixture was washed with aqueous NaHCO 3 (20 mL), 1M HCl (20 mL), and water (20 mL); the organic layer was dried over anhydrous Na 2 SO 4 , filtered, and the solvent was evaporated under vacuum to yield the intermediate diethyl [(4-methylbenzoyl)amino]propanedioate as a yellow solid (96%).
[0334] Diethyl [(4-methylbenzoyl)amino]propanedioate (3.08 g, 10.5 mmol) was dissolved in THF (50 mL). Lawesson reagent (3.0 g, 7.4 mmol) was added and the mixture stirred overnight at room temperature. After solvent removal under reduced pressure, the crude product was purified by flash column chromatography (eluent:hexane/ethyl acetate mixture of increasing polarity) to give the intermediate diethyl {[(4-methyl phenyl)carbonothioyl]amino}propanedioate (85%).
[0335] Diethyl {[(4-methyl phenyl)carbonothioyl]amino}propanedioate (2.47 g, 8.00 mmol) was dissolved in dioxane (35 mL) and phosphoryl chloride (0.5 mL, 5 mmol) was added. The mixture was irradiated by microwave (250 W, 100° C.) for 15 min, whereupon the solvent was removed under vacuum. The compound 117 was obtained by trituration with acetonitrile (1.67 g, 84%). 1 H-NMR (CDCl 3 , TMS) δ (ppm): 9.93 (br s, 1H), 7.81 (d, 2H, J=7.3), 7.21 (d, 2H, J=7.3), 4.58 (q, 2H, J=7.0), 2.37 (s, 3H), 1.39 (t, 3H, J=7.0); MS (ES 1+ ) m/z: 264.30 (M+1).
Example 118
Synthesis of 2-(3-fluorophenyl)-5-(2-ethyl-2H-tetrazol-5-yl)-1,3-thiazol-4-ol (compound n. 118)
[0336] The compound was synthetised following the procedures described hereinbelow:
[0337] 1. Preparation of Ethyl 2-(3-fluorophenyl)-4-hydroxy-1,3-thiazole-5-carboxylate (intermediate 1) Commercial 3-fluorobenzenecarbothioamide (395 mg, 2.55 mmol) and diethyl bromopropanedioate (435 μL, 2.55 mmol) were dissolved in ethanol (8 mL) in a microwave vial. The mixture was irradiated at 100° C. for 30 min. The solvent was removed under reduce pressure ethyl 2-(3-fluorophenyl)-4-hydroxy-1,3-thiazole-5-carboxylate was obtained as a yellow solid after trituration in acetonitrile (476 mg, 70%). 1 H-NMR (CDCl 3 ) δ (ppm): 9.93 (br s), 7.76-7.69 (m, 2H), 7.46-7.39 (m, 1H), 7.22-7.17 (m, 1H), 4.40 (q, 2H, J=7.5), 1.40 (t, 3H, J=7.5); MS (ES 1+ ) m/z: 268 (M+1).
[0338] 2. Preparation of 2-(3-fluorophenyl)-4-hydroxy-1,3-thiazole-5-carboxylic acid (intermediate 2) The intermediate 1 (476 mg, 1.78 mmol) was dissolved in dioxane (5 mL) and 2 mL of aqueous hydrochloric acid (37%) were added. The mixture was heated at 80° C. for 16 h. After solvent removal under vacuum and the crude product was purified by HPLC to yield 2-(3-fluorophenyl)-4-hydroxy-1,3-thiazole-5-carboxylic acid as a white solid (0.315 g, 74%). 1 H-NMR (DMSO-d 6 ) δ (ppm): 12.2 (br s, 1H), 7.82-7.78 (m, 1H), 7.75-7.71 (m, 1H), 7.71-7.58 (m, 1H), 7.45-7.39 (m, 1H); MS (ES 1+ ) m/z: 238 (M−1).
[0339] 3. Preparation of 2-(3-fluorophenyl)-4-hydroxy-1,3-thiazole-5-carboxamide (intermediate 3) The intermediate 2 (130 mg, 0.54 mmol) was dissolved in dry CH 2 Cl 2 (10 mL) and 1,1′-carbonyldiimidazole (135 mg, 0.81 mmol) was added at 0° C. The mixture was stireed at room temperature and stirred for 30 min. Gaseous NH 3 was bubbled into the mixture and the course of the reaction was monitored by LC-MS analysis. At the end of the reaction the mixture was concentrated under reducer pressure and the crude product triturated with acetone. The resulting solid was purified by flash column chromatography (CH 2 Cl 2 /MeOH 95:5 as eluent). 2-(3-fluorophenyl)-4-hydroxy-1,3-thiazole-5-carboxamide was obtained as white solid (101 mg, 78%). 1 H-NMR (DMSO-d 6 ) δ (ppm): 12.25 (br s, 1H), 9.15 (br s, 2H), 7.80-7.78 (m, 1H), 7.73-7.70 (m, 1H), 7.69-7.60 (m, 1H), 7.45-7.41 (m, 1H); MS (ES 1+ ) m/z: 239 (M+1).
[0340] 4. Preparation of 2-(3-fluorophenyl)-4-hydroxy-1,3-thiazole-5-carbonitrile (intermediate 4) A 50 mL one-necked round bottom flask was charged with a solution of the intermediate 3 (101 mg, 0.42 mmol) in dry CH 2 Cl 2 (8 mL) and trichloroacetyl chloride (94 μL, 0.84 mmol) was added. After stirring 1 h at room temperature the reaction was quenched by water addition (8 mL) and extracted with CH 2 Cl 2 (3×10 mL). The collected organic phases were washed with brine (10 mL), dried over dry Na 2 SO 4 and concentrated in vacuo. Purification by silica gel chromatography (hexane/ethyl acetate 90:10 as eluent) gave intermediate 4 as a pale yellow solid (60 mg, 65%). 1 H-NMR (CDCl 3 , TMS) δ (ppm): 1H-NMR (CDC 3 ) δ (ppm): 10.05 (br s), 7.74-7.64 (m, 2H), 7.42-7.36 (m, 1H), 7.20-7.16 (m, 1H); MS (ES 1+ ) m/z: 221 (M+1).
[0341] 5. Preparation of 2-(3-fluorophenyl)-5-(1H-tetrazol-5-yl)-1,3-thiazol-4-ol (intermediate 5) A microwave vial was charged with intermediate 4 (60 mg, 0.27 mmol) and 2 mL of a solution of N-methyl pyrrolidone/AcOH 5:2 v/v. Then a 5.2 M solution of sodium azide (130 μL, 0.68 mmol) was added and the resulting mixture irradiated at 220° C. for 5 minutes. The reaction was quenched with 10 mL of water and extracted with ethyl acetate. The organic layer was separated and the aqueous one extracted again twice with ethyl acetate. The combined organic layers were dried over dry Na 2 SO 4 and concentrated in vacuo. 2-(3-fluorophenyl)-5-(1H-tetrazol-5-yl)-1,3-thiazol-4-ol was obtained as white solid (61 mg, 86%) after preparative HPLC purification. 1 H-NMR (DMSO-d 6 ) δ (ppm): 13.30 (br s, 1H), 12.10 (br s, 1H), 7.84-7.80 (m, 1H), 7.76-7.72 (m, 1H), 7.66-7.58 (m, 1H), 7.45-7.36 (m, 1H); MS (ES 1+ ) m/z: 264 (M+1).
[0342] 6. Preparation of 5-(2-ethyl-2H-tetrazol-5-yl)-2-(3-fluorophenyl)-1,3-thiazol-4-ol (compound 118) A 25 mL one-necked round bottom flask was charged with intermediate 5 (150 mg, 0.57 mmol) dissolved in 10 mL of acetonitrile. Triethylamine (79 μL, 0.56 mmol) and ethyl iodide (91 μL, 1.14 mmol) were added to the solution and the mixture was allowed to stir at room temperature overnight. The acetonitrile was evaporated and the crude diluted with water and washed with ethyl acetate (2×15 mL). The combined organic layers were dried over dry Mg 2 SO 4 and concentrated in vacuo. The two resulting N-ethyl regioisomers were separated by preparative HPLC. Compound 1 was obtained as pale yellow solid (66 mg, 40%). 1 H-NMR (DMSO-d 6 ) δ (ppm): 12.00 (br s, 1H), 7.84-7.78 (m, 1H), 7.76-7.72 (m, 1H), 7.66-7.58 (m, 1H), 7.45-7.36 (m, 1H), 4.75 (q, 2H, J=7.5), 1.50 (t, 3H, J=7.5); MS (ES 1+ ) m/z: 292 (M+1).
Example 119
Evaluation of In Vitro Activity
[0343] a. Cloning, Sequencing, Transfection and Selection of Positive Clones Expressing Human TRPM8
[0344] A functional cell-based assay for the identification of TRPM8 receptor antagonists, optimised to allow high throughput screening at FLIPR TETRA , was developed in HEK293 cells by stable pure clone selection and functional characterization with a fluorescent calcium sensitive dye.
[0345] TRPM8 was cloned into the multiple clonig site of pcDNA3 mammalian expression vector; the obtained construct pcDNA3/hTRPM8 was fully sequence verified and used for the transfection of HEK293 cell line. HEK293 cells stably transfected with TRPM8 gene were maintained in Minimum essential medium. The cells were transfected with the pcDNA3/hTRPM8 vector by electroporation and then selected with medium containing 0.8 mg/ml G418 for 10-15 days.
[0346] The following commercial compounds were used as TRPM8 channel reference compound to test HEK293/hTRPM8 cell line for both agonist and antagonist activity:
[0000] Activators: Menthol (SIGMA cat.# M2772) WS-3, (N-Ethyl-5-methyl-2-(1-methylethyl) cyclohexanecarboxamide) (SIGMA cat.# W345501)
Blocker: Capsazepine (SIGMA cat.# C191)
[0347] The experimental activities were performed using FLIPR instruments.
[0348] The functional clones were selected at FLIPR 384 on the basis of 1 mM menthol response. Two best responder clones were selected, diluted at a cell density of 1 cell/well and analysed at FLIPR 384 with 1 mM menthol.
[0349] The TRPM8 receptor was analysed for the response to reference agonist, menthol, using a calcium-dependent fluorescence signal.
[0350] Patch clamp recordings were also obtained in voltage-clamp configuration on HEK/TRPM8 clones in order to verify the receptor pharmacology and to determine the agonist dose-response curve and EC 50 value. HEK293 cells were maintained at room temperature on an fire-polished borosilicate glass pipettes having 1.5-2.5 MΩ resistance were used to record currents following drug application. Menthol application induced a dose-dependent inward current in a selected HEK/hTRPM8 clone (calculated EC 50 value=58μM). No menthol-induced currents were recorded in not transfected HEK293 cells.
[0351] In order to determine the capsazepine antagonist activity on menthol agonist response and to verify the antagonist response stability throughout different days of experiments, the selected clone of TRPM8 was analysed after 24 h at FLIPR 384 in presence of variable concentrations of antagonist (from 100 nM to 316 μM).
[0352] The selected clone showed very good stability and reproducibility of the antagonist activity (calculated IC 50 value=20μM).
[0353] Summarizing, the best clone was characterized for :1—pharmacology: agonist Ec 50 and antagonist IC 50 determination over different experiments;
[0000] 2—optimal cell density and seeding time;
3—DMSO sensitivity;
4—ligand stability;
5—patch clamp analysis.
b. Screening Set Up For the Identification of TRPM8 Antagonists
[0354] The following commercial compounds were used as ligands:
Activator: Cooling Agent 10 (Takasago CAS N. 87061-04-9)
Blocker: Capsazepine (SIGMA cat # D_5879)
[0355] The experimental activities were performed using FLIPR TETRA instruments.
[0356] HEK293 cells stably transfected with TRPM8 gene were maintained in Minimum essential medium.
[0357] The TRPM8 cell line was analysed for the response to a library of compounds using a Ca 2+ mobilization-dependent fluorescence signal in 384 wells microtiter plate format. The analysis was performed using the FLIPR TETRA (MDC) with the ICCD Camera.
[0358] The execution of the assay involved the use of three microtiter plates:
[0000] 1. Assay plate, containing cells loaded with dye and prepared as follows:
[0359] Cells were seeded at 15000 c/well in Poly-D-Lysine coated 384 wells Microtiter Plates in complete medium (25 μl/well).
[0360] 24 h after seeding, the cell plates were washed with Tyrode assay buffer by the Microplate Washer and 10 μL of Tyrode assay buffer was left in each well.
[0361] Cells were then loaded with 10 μL/well of the Fluo-4 NW dye solution by CyBi®-Well pipettor. Each bottle of Fluo4-NW dye (Molecular Probes cat. #F36206, component A) was re-suspended in 8 mL of Tyrode assay buffer and supplemented with 100 μL of water-soluble probenecid (MolecularProbes cat.#F36206, component B).
[0362] Dye loaded cell plates were incubated for 1 h at room temperature.
[0000] 2. Compound Dilution Plate ( FIG. 1 ), containing diluted test compounds, formulated as follows:
[0363] Column 1: wells containing Assay Buffer plus DMSO 0.5% final
[0364] Column 2: wells alternating Max Signal Control in first injection (Maximum Response: Cooling Agent 10 at EC 100 , 100 μM) and Min Signal Control in first injection (Assay buffer plus 0.5% DMSO final);
[0365] Columns 3-22: wells containing Assay Buffer plus 0.5% DMSO final. To these wells the compounds to be tested were added at 3× concentration.
[0366] Column 23: alternating wells of Max Signal Control in second injection (Assay buffer) and Min Signal Control in second injection (Antagonist Capsazepine IC 100 , 50 μM) in Assay buffer plus 0.5% DMSO final;
[0367] Column 24: wells containing Capsazepine (Antagonist) at 8 concentrations in duplicate at final concentrations of 50 μM, 25 μM, 6.25 μM, 3.15 μM, 1.56 μM, 780 nM, 309 nM in Assay buffer plus 0.5% DMSO final.
[0000] 3. Activator Plate ( FIG. 2 ), containing agonist Cooling Agent 10 at EC80, formulated as follows:
[0368] Column 1: Cooling Agent 10 (Agonist) at 8 concentrations dose response in duplicate at final concentrations of 100 μM, 31.6 μM, 10 μM, 3.16 μM, 1 μM, 316 nM, 100 nM, 31.6 nM in Assay buffer;
[0369] Columns 2-24: Cooling Agent 10 (Agonist) at EC 80 (3 fold concentrated, 20 μM final) in Assay buffer.
[0370] The test was carried out according to a procedure comprising the following steps:
[0371] 1. The samples contained in the wells of the Compound Plate were added to the corresponding wells of the Assay Plate by the FLIPR TETRA , thus resulting in the addition in Columns 3-22 of the test compounds at 3× concentration to the cells of the assay plates. No mixing was performed in the assay wells and the signal of the emitted fluorescence was recorded for 300 seconds.
[0372] 2. The samples contained in the wells of the Activator Plate were added to the corresponding wells of the Assay Plate by the FLIPR TETRA , thus resulting in the addition in Columns 3-22 of the Assay Plate of the agonist compound in addition to the test compounds. The signal of the emitted fluorescence was recorded for 180 seconds.
[0373] Columns 1, 2, 23 and 24 were used as control. In particular: the “Max Signal Control in first injection” indicates the Cooling Agent 10 agonist response at EC 100 , “Max Signal Control in the second injection” indicates the agonist at EC 80 (10 μM) in presence of pre-injected Assay buffer, the “Min Signal Control in first injection” corresponds to Assay buffer injection and “Min Signal Control in the second injection” indicates the agonist at EC 80 (20 μM) in presence of pre-injected reference antagonist Capazepine at IC 100 (50 μM).
[0374] FIG. 3 respresents a typical kinetic response graph obtained with all the compounds of Table IV.
[0375] During the Target Activation (TA) phase, the injection of the reference agonist at EC 80 gave an increase of fluorescent signal in MAX Signal control wells in which the assay buffer in CA was preinjected, while the response was completely inhibited in MIN Signal control wells due to the preinjection of the reference inhibitor Capsazepine.
[0376] The goal of the assay was to find antagonists of TRPM8 activity; to this aim the change of fluorescent signal during TA phase was measured.
[0377] Several parameters were computed and analyzed (Z′ factor, Interplate variability, Intraplate variability, Day to Day variability, Antagonist Dose response and IC 50 determination, Agonist Dose response and EC 50 determination).
[0378] As for the antagonist Dose response and IC 50 determination, capsazepine (reference antagonist) was included as control and the IC 50 values of all the assayed compounds were calculated.
[0379] Compounds 1-118 were tested and all showed an IC 50 value<30 μM; in particular, compounds n. 1, 2, 5, 8, 9, 27, 36, 41, 43, 67, 68, 70, 83, 84 were charaterized by an IC 50 value<10 μM; compounds n. 10 and 45 showed an IC 50 value=1 μM and 0.0002 μM, respectively.
[0000] c. Calcium Influx Assay
[0380] The ability of compounds n. 10 and 45 to act as TRPM8 antagonists was also evaluated with a calcium influx assay. The effects of 7 concentrations (0.00001, 0.0001, 0.001, 0.01, 0.1, 1, and 10 μM) of compounds 10, 45 and 118 were evaluated on TRPM8 using the following experimental procedure.
[0381] Channels were activated with menthol, as the positive control agonist, and the ability of test compound to inhibit this signal was examined and compared to the positive control antagonist, 2-APB (inserire dettagli composto). The signal elicited in the presence of the positive control agonist (10 μM menthol) was set to 100% and the signal in the presence of the positive control antagonist (200 μM 2-APB) was set to 0. The pIC 50 values of the compound 10 45 and 118 were 9.7, 6 and 7.7 respectively. Values were considered significant if the test compound mean was three or more standard deviations away from the positive control agonist mean.
Example 120
Evaluation of In Vivo Activity
[0382] a. Isovolumetric Bladder Model
[0383] Female rats were anesthetized with urethane. Ureters were ligated and sectioned. A catheter was inserted through the urinary meatus into the bladder before urethral ligature. The bladder was filled first 3 times every 5 min with 100 μL of a solution of solutol/NMP (2:1 w/w) containing 0.1 mg of compounds n. 10 or 45 or with 100 μL of vehicle, then with 100 μL of saline every 5 min until the occurrence of rhythmic bladder contraction (RBC). A maximal volume of 3 mL was infused. The intravesical pressure was followed during 1 h30 after RBC appearance. For each group, Threshold Volume (TV), Micturition Frequency (MF) and Amplitude of Micturition (AM) were measured during the whole period. In the group treated with compound 10 the threshold volume (TV) was significantly increased compared to the group treated with the solvent reaching 1.5 mL of volume whereas, in the vehicle group, RBC occurred in all rats with a mean volume of 0.7±0.09 mL. Compound 10 did not change AM. No effect on the total MF (measured during 90 min) was observed.
[0384] Both the molecules showed significant efficacy in the isovolumetric model in inhibiting rhythmic bladder contractions and micturition frequency. In particular, the systemic treatment with compound 10 (10 mg/kg i.v.) significantly reduced Micturition Frequency (MF) of about 36% in the first 30 min of the experiment. On the other hand, when administered by intravesical route at 2.3 mg/rat, compound 10 completely abolished the continuous RBC induced by the filling of the bladder with saline. In addition, compound 10 (2.3 mg/rat) and compound 45 (0.3 mg/rat) significantly increased the threshold volume (equivalent to the bladder capacity), reaching a higher volume of 1.5-3.0 mL if compared to that of 0.7±0.9 mL of the vehicle group. Both the compounds did not change Amplitude of Micturition (AM) when compared to basal values, suggesting that they are selective for the afferent arm of micturition reflex with no effect on the efferent pathway.
[0000] b. Chronic Constriction Model of Pain-compounds 10 and 45
[0385] Male Sprague-Dawley rats were used. Under pentobarbital anesthesia, the sciatic nerve was exposed at mid-thigh level (Bennett G J et al Pain. 33: 87-107, 1988). Four ligatures were loosely tied around the sciatic nerve of the left hind limb to induce enhancement of pain caused by nerve injury. Mechanical allodynia was evaluated by using a set of 8 manual von Frey monofilaments (0.4, 0.6, 1, 2, 4, 6, 8 and 15 g) 18 days after surgery and basal response was recorded.
[0386] On day 19 body weight was recorded and compounds 10 and 45 were administered by i.v. route at the dose of 10 mg/kg. 60, 120 and 180 min post dose, mechanical allodynia was tested by evaluation of the Paw Withdrawl Threshold (PWT) and % Maximum Possible Effect (MPE) was calculated according to the following formula:
[0000]
%
MPE
=
(
Log
PWT
of
test-Avg
Log
PWT
of
baseline
predrug
)
(
Log
(15)-Avg
log
PWT
of
baseline
predrug
)
*
100
[0387] The mechanical allodynia was tested 1 day before treatment and at 2 hours post-dosing. One-way ANOVA followed by Dunnett's test was applied for comparison between vehicle control and test compound treated groups. *p<0.05 is considered significant.
[0388] Compounds 10 and 45 showed a significant anti-allodynic activity at 2 hours post-dosing in CCI rats (see FIG. 4 ).
Example 121
Evaluation of In Vivo Activity For Compound 118
Chronic Constriction Model of Pain
Animals
[0389] Male Wistar rats (220-250 g, Harlan Italy) were used (n=60). Animals were housed in a room with controlled temperature (22±1° C.), humidity (60±10%) and light (12 h per day) for at least a week before being used. Rats were randomly divided into sham, control and treatment groups; ten animals per group were used. All animal experiments were complied with the Italian (D.L. no. 116 of Jan. 27, 1992) and associated guidelines in the European Communities Council (Directive of Nov. 24, 1986, 86/609/ECC).
Drug Treatment
[0390] Compound 118 (10 mg/kg; 5 mg/ml; 0.5 ml/iv/rat) was dissolved in 10% solutol-HS15 and N-Methylpyrrolidone (NMP) (SOLUTOL:NMP 2:1 w/v) and 90% Phosphate Buffered Saline (PBS) 1×, and was administered at day 3 rd , 7 th and 14 th following sciatic nerve ligation. Antiallodynic effects were assessed at 1 and 3 h post dose. Control animals received vehicle alone (0.5 ml/iv/rat; 10% solutol-NMP and 90% PBS).
Chronic Constriction Injury (CCI) Model of Neuropathic Pain
[0391] Neuropathic pain behavior was induced by ligation of the sciatic nerve according to the method described by Bennett and Xie [Bennett G. J. and Xie Y. K. A peripheral mononeuropathy in rat that produces disorders of pain sensation like those seen in man, Pain, (1988) 33:87-107]. Briefly, rats were anaesthetized (100 mg/kg ketamine and 10 mg/kg xylazine i.p.) and the left sciatic nerve was exposed at the level of the thigh by blunt dissection through the biceps femoris. Proximal to the sciatic's trifurcation, about 12 mm of nerve was freed of adhering tissue and four ligatures were loosely tied around it with about 1 mm spacing so that the epineural circulation was preserved. The length of nerve thus affected was 6-8 mm long. The animals were allowed to recover and used the day after the surgery. Sham animals represent rats operated but not ligated.
Mechanical Allodynia
[0392] To assess for changes in sensation or in the development of mechanical allodynia, sensitivity to tactile stimulation was measured using the Dynamic Plantar Aesthesiometer (DPA, Ugo Basile, Italy). Ligated animals were placed in a chamber with a mesh metal floor covered by a plastic dome that enabled the animal to walk freely, but not to jump. The mechanical stimulus was then delivered in the mid-plantar skin of the hind paw. The cut-off was fixed at 50 g, while the increasing force rate (ramp duration) was settled at 20 sec. The DPA automatically records the force at which the foot was withdrawn and the withdrawal latency. Each paw was tested twice per session. This test did not require any special pre-training, just an acclimation period to the environment and testing procedure. Testing was performed on both the ispsilateral (ligated) and contralateral (unligated) paw before ligation (day 0) and then on 3 rd , 7 th and 14 th days after ligation.
Cold Allodynia
[0393] Cold sensitivity was measured as the number of foot withdrawal responses after application of acetone to the dorsal surface of the paw. A drop of acetone (15-20° C.) was applied to the dorsal surface of the ligated paw with a syringe connected to a thin polyethylene tube while the rats were standing on a metal mesh. A brisk foot withdrawal response, after the spread of acetone over the dorsal surface of the paw, was considered as a sign of cold allodynia. Basal response was measured on the days before treatment (2 nd , 6 th and 13 th ). Data represents mean±SEM of 3 measurements performed at an interval of approximately 5 min.
Statistical Analysis
[0394] All data was presented as the mean±SEM. Analysis of data was conducted using GraphPad Prism 4.01. Statistical analysis was performed by two-way ANOVA followed by Bonferroni's test for multiple comparisons, as appropriate. Statistical significance was set at p<0.05.
Results
[0395] Intravenous administration of Compound 118 (10 mg/kg) on day 7 after nerve-induced injury significantly attenuated cold and mechanical allodynia at 1 hour post-dose. The results obtained reflected, as expected, a higher activity of Compound 1 to cold stimulus compared to mechanical stimulus (39% of inhibition and 26% of inhibition, respectively).
[0396] On day 14 after surgery, the inhibitory activity of Compound 118 was still statistically significant at 1 h post-dose on cold stimulus (52% of inhibition), even if no inhibition on mechanical stimulus could be observed; on the contrary, the reference compound maintained a statistically significant inhibitory effect both on cold and mechanical allodynia (51% and 26% respectively at 1 h after administration).
Example 122
Selectivity Analysis
[0397] The objective of this study was to evaluate the in vitro effects of compounds 10 and 45 on cloned human GPCRs (G-protein coupled receptors) expressed in HEK293 or CHO cells using radioligand binding assays (compound concentration=10 μM).
[0398] Three replicates were performed for each experiment.
[0399] For each assay a concentration-response curve of the appropriate reference compound was performed in each experiment. The sample radioactivity content was measured after the addition of the scintillation cocktail Microscint 20 (PerkinElmer), by a microplate scintillation Beta-counter TopCount NXT (PerkinElmer). The atomic disintegrations per minutes evaluated with the beta counter were about 15 times higher than those found using the gamma counter. Data are expressed as percentage of control binding value (% B) and test compound inhibition was considered significant when % AB was <75% at 10 μM.
[0000]
TABLE I
Receptor
Cmpd 10 (% B)
Cmpd 45 (% B)
human Muscarinic M 2 Receptor
90
96
human Muscarinic M 3 Receptor
98
95
human Adrenergic β 1 Receptor
82
90.53
human Adrenergic β 2 Receptor
88
93
human Adrenergic α 1A Receptor
100
96
human Adrenergic α 2A Receptor
100
100
human Serotoninergic 5-HT 1A
100
100
Receptor
human Histamine H 1 Receptor
99.3
100
human Histamine H 2 Receptor
90
93.2
human Cannabinoid CB 2 Receptor
102
86.7
human Bradykinin B 1 Receptor
91
99.6
human Dopamine D 2S Receptor
100
100
human Dopamine D 3 Receptor
87
97.2
[0400] As it is possible to note from Tab I, both compounds show no binding versus a wide range of selected GPCRs (including muscarinic M3, CB2, BK1, alpha e beta adrenergic) that are well know to be involved in the pain control. These data support that the observed in vivo efficacy of compounds 10, 45 and 118 and in general of all the compounds of the invention is strongly dependent on the TRPM8 blockage.
[0401] In order to address more specifically the potential selectivity issues, a counterassay was carried out for 10, 45 and 118 against TRPV1 and TRPV4 ion channels, both involved in the nociception (Jhaveri M D, et al 2005. Eur. J. Neurosci. 22 (2): 361-70, Brierley S M et al, 2008, Gastroenterology. 2008 Jun; 134(7):2059-69.).
[0402] The ability of each test compound to act as an antagonist of TRPV1 was evaluated with a calcium influx assay.
[0403] The signal elicited in the presence of the positive control agonist (0.1 μM capsaicin) was set to 100% and the signal in the presence of the antagonist (5 μM ruthenium red) was set to 0. The normalized % inhibition of the test articles is shown in Table below. Values were considered significant if the test article mean was three or more standard deviations away from the positive control agonist mean.
[0404] In parallel, the ability of each test compound to act as an antagonist of TRPV4 was evaluated with a calcium influx assay. The signal elicited in the presence of the positive control agonist (10 μM GSK1016790A) was set to 100% and the signal in the presence of the antagonist (5 μM ruthenium red) was set to 0. The normalized % inhibition of the test articles is shown in Table below. Values were considered significant if the test compound mean was three or more standard deviations away from the positive control agonist mean (i.e., greater than 31.70% inhibition for plate 1 and 24.60% inhibition for plate 2).
[0000]
TABLE II
Normalized
Cmpd
Test
Normalized
% inhibition
(10 and 1 uM)
Conc.
% inhibition (TRPV1)
(TRPV4)
10
1
1.2
2.0
10
2.3
8.9
45
1
3.1
5.1
10
6.3
3.1
118
1
1.2
2.0
10
2.3
8.9
[0405] The data strongly highlight the great selectivity of molecules 10, 45 and 118 towards both TRPV1 and TRPV4, thus confirming their selective mechanism of action.
Example 123
ADME Evaluation
[0406] The pharmacokinetic profiles of compounds 10 and 45 were evaluated. The result are summarised in Table III:
[0000]
TABLE III
Compound 10
Plasma
Microsome
Protein
CYP
hERG
stability
t 1/2
Binding
Log
(% inhibition)
binding
(% remaining)
i.v. rat
(% @10
D
@10 μM
@10 μM
@1 μM
(min)
μM)
1.59
1A2
<5
No effect
rat
45
50
rat
98
2C9
<5
2C19
<5
human
55
hu-
97
2D6
<5
man
3A4
<5
Compound 45
Plasma
Plasma
t 1/2
Protein
CYP
hERG
stability
i.v. rat
Binding
Log
(% inhibition)
binding
(% remaining)
(min),
(% @10
D
@10 μM
@10 μM
@10 μM
F(%)
μM)
2.7
1A2
<5
No effect
rat
95
240,
rat
99
2C9
<5
60
2C19
<5
human
100
hu-
99
2D6
<5
man
3A4
<5
[0407] All three molecules show no effect towards any human cytochrome isoform at the maximal concentration of 10 μM thus excluding potential drug drug interaction.
[0408] In addition, no effect was observed towards hERG channel thus excluding potential cardiotoxic effect during the clinical development.
[0409] The low logD values of compounds 10 and 118 make them particularly suitable when ip, iv and i ves applications are required, especially in the treatment of urological disorders. At the same time, the relatively high plasma half-life (4 h) and the high oral bioavailability (F=60%) could makes it the ideal candidate for the treatment of chronic diseases, like inflammatory and neuropathic pain.
[0000]
TABLE IV
Compound
X
R 1
R 2
R 3
R 4
1
S
OH
COOH
H
p-Cl
2
S
OH
COOH
H
p-CH 3
3
S
OH
COOH
H
m-F
4
S
OH
COOH
H
p-F
5
S
OH
COOCH 3
H
H
6
S
OH
COOCH 3
2-F
4-F
7
S
OH
COOCH 2 CH 3
H
H
8
S
OH
COOCH 2 CH 3
H
p-Cl
9
S
OH
COOCH 2 CH 3
H
p-CH 3
10
S
OH
COOCH 2 CH 3
H
m-F
11
S
OH
COOCH 2 CH 3
H
p-F
12
S
OH
COOCH 2 CH 3
H
13
S
OH
COOCH 2 CH 3
H
p-N(CH 3 ) 2
14
S
OH
COOCH 2 CH 3
H
m-Cl
15
S
OH
COOCH 2 CH 3
H
m-(2-CF 3 —C 6 H 5 )
16
S
OH
COOCH 2 CH 3
H
m-(2-F—C 6 H 5 )
17
S
OH
COOCH 2 CH 3
H
p-(2-CF 3 —C 6 H 5 )
18
S
OH
COOCH 2 CH 3
H
p-(2-F—C 6 H 5 )
19
S
OH
COOCH 2 CH 3
H
p-(2-F—OCH 2 C 6 H 5 )
20
S
OH
COOCH 2 CH 3
H
p-(4-F—OCH 2 C 6 H 5 )
21
S
F 3 CSO 2 O
COOCH 2 CH 3
H
p-F
22
S
OCH 3
COOCH 2 CH 3
H
p-CH 3
23
S
COOCH 2 CH 3
H
p-CH 3
24
S
COOCH 2 CH 3
H
H
25
S
COOCH 2 CH 3
H
p-Cl
26
S
COOCH 2 CH 3
H
m-F
27
S
COOCH 2 CH 3
H
H
28
S
COOCH 2 CH 3
H
m-Cl
29
S
COOCH 2 CH 3
H
p-CH 3
30
S
COOCH 2 CH 3
H
m-F
31
S
COOCH 2 CH 3
H
H
32
S
COOCH 2 CH 3
H
p-F
33
S
COOCH 2 CH 3
H
p-Cl
34
S
COOCH 2 CH 3
H
m-Cl
35
S
COOCH 2 CH 3
H
p-CH 3
36
S
COOCH 2 CH 3
H
H
37
S
COOCH 2 CH 3
H
m-F
38
S
COOCH 2 CH 3
H
p-CH 3
39
S
COOCH 2 CH 3
H
p-CH 3
40
S
COOCH 2 CH 3
H
p-Cl
41
S
COOCH 2 CH 3
H
p-Cl
42
S
COOCH 2 CH 3
H
p-Cl
43
S
COOH
H
p-CH 3
44
S
COOH
H
H
45
S
COOH
H
p-Cl
46
S
COOH
H
m-Cl
47
S
COOH
H
H
48
S
COOH
H
m-F
49
S
COOH
H
H
50
S
COOH
H
p-F
51
S
COOH
H
p-Cl
52
S
COOH
H
m-Cl
53
S
COOH
H
p-CH 3
54
S
COOH
H
m-F
55
S
COOH
H
H
56
S
COOH
H
m-F
57
S
COOH
H
H
58
S
COOH
H
m-F
59
S
COOH
H
p-CH 3
60
S
OCH 3
COOH
H
p-CH 3
61
S
COOH
H
p-CH 3
62
S
COOCH 2 CH 3
H
p-F
63
S
NH 2
COOCH 2 CH 3
H
p-F
64
S
COOCH 2 CH 3
H
p-CH 3
65
S
COOCH 2 CH 3
H
p-CH 3
66
S
COOCH 2 CH 3
H
p-CH 3
67
S
COOCH 2 CH 3
H
p-CH 3
68
S
COOCH 2 CH 3
H
p-Cl
69
S
COOCH 2 CH 3
H
p-Cl
70
S
COOCH 2 CH 3
H
p-Cl
71
S
COOCH 2 CH 3
H
p-CH 3
72
S
COOCH 2 CH 3
H
p-(2-CF 3 —C 6 H 5 )
73
S
COOCH 2 CH 3
H
m-(2-CF 3 —C 6 H 5 )
74
S
COOCH 2 CH 3
H
p-Cl
75
S
COOCH 2 CH 3
H
H
76
S
COOCH 2 CH 3
H
m-F
77
S
COOCH 2 CH 3
H
m-F
78
S
COOCH 2 CH 3
H
m-F
79
S
COOH
H
p-CH 3
80
S
COOH
H
p-CH 3
81
S
COOH
H
m-F
82
S
COONa
H
m-F
83
S
COONa
H
p-CH 3
84
S
COONa
H
p-Cl
85
S
COONa
H
p-Cl
86
S
COONa
H
p-CH 3
87
S
COONa
H
m-F
88
S
COONa
H
m-F
89
S
H
p-CH 3
90
S
OH
H
p-cH 3
91
S
COOCH 2 CH 3
H
p-Cl
92
S
COOH
H
p-Cl
93
S
C(O)NH 2
H
p-Cl
94
S
CN
H
p-Cl
95
S
OH
H
p-Cl
96
S
OH
H
p-Cl
97
S
OH
H
m-F
98
S
OH
H
p-Cl
99
S
OH
H
m-F
100
S
OH
H
p-Cl
101
S
OH
H
m-F
102
S
H
m-F
103
S
OH
H
p-Cl
104
S
OH
H
m-F
105
O
OH
COOCH 2 CH 3
H
H
106
O
OH
COOCH 2 CH 3
H
m-F
107
O
OH
COOCH 2 CH 3
H
p-CH 3
108
O
COOCH 2 CH 3
H
H
109
O
COOCH 2 CH 3
H
m-F
110
O
COOCH 2 CH 3
H
p-CH 3
111
O
COOCH 2 CH 3
H
H
112
O
COOH
H
H
113
O
COOH
H
m-F
114
O
COOH
H
p-CH 3
115
O
OH
H
m-F
116
O
H
m-F
117
S
OCOCH 2 CH 3
OH
H
p-CH 3
118
S
OH
H
m-F
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The invention relates to compounds acting as selective antagonists of Transient Receptor Potential cation channel subfamily M member 8 (TRPM8), and having formula:
Said compounds are useful in the treatment of diseases associated with activity of TRPM8 such as pain, inflammation, ischaemia, neurodegeneration, stroke, psychiatric disorders, itch, irritable bowel diseases, cold induced and/or exacerbated respiratory disorders and urological disorders.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. provisional patent application No. 61/107,248 entitled “Fuel Tank System and Related Method of Assembly” filed on Oct. 21, 2008, which is hereby incorporated by reference herein.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Field of the Invention
[0002] The present invention relates to internal combustion engines and, more particularly, to fuel tanks and related components implemented on (or in conjunction with) such engines and/or systems and methods for mounting such fuel tanks and related components upon (or as part of) such engines.
BACKGROUND OF THE INVENTION
[0003] Internal combustion engines include or operate in conjunction with fuel tanks that store gasoline, diesel fuel, biofuels or other fuels prior to their consumption by the engines. A variety of different types of fuel tanks and methods of coupling/integrating those fuel tanks with internal combustion engines are known in the art. At least some conventional internal combustion engines employ plastic fuel tanks. In some such embodiments, the plastic fuel tank includes a boss feature molded into the plastic fuel tank that allows a fastening screw extending from the remainder of the engine (e.g., from the engine crankcase) to thread directly into the fuel tank body, thereby allowing direct fastening of the fuel tank to the remainder of the engine.
[0004] Notwithstanding the common usage of this type of design, there are at least two disadvantages with such a design. First, during factory assembly or field service of an engine employing such a configuration, it is possible that an improper screw may be threaded into the fuel tank boss. The fuel tank is then at risk from cracking and leaking if the screw diameter is too large or at risk from puncture and leakage if the screw is too long. Additionally, such a conventional design can risk cracking of the fuel tank due to fatigue experienced over time. In particular, forming the screw boss feature on the fuel tank can create an irregular wall thickness. When exposed to various types of stresses over time, particularly stresses associated with exposure of the fuel tank to fuel chemicals and various environmental effects including variations in the temperature to which the fuel tank is exposed, it is possible that the fuel tank may crack and begin to leak fuel. This situation can be exacerbated by material deformation of the screw.
[0005] At least some conventional plastic fuel tanks are manufactured via a blow-molding process. Although blow-molding is a useful process for manufacturing components such as fuel tanks, it is especially difficult to create detailed features such as bosses using this process. Consequently, with respect to blow-molded fuel tanks, other methods have often been used to constrain and mount fuel tanks, such as clamping of external web-sections. While such methods can avoid direct impregnation of the fuel tanks by fastening screws, such methods often involve extra cost burdens, for example, those associated with the use of additional clamping materials and the additional assembly time required to manufacture such fuel tank assemblies.
[0006] For at least these reasons, therefore, it would be advantageous if an improved fuel tank system and/or method of assembling fuel tanks to internal combustion engines could be developed. More particularly, it would be advantageous if, in at least some embodiments, the risk that portion(s) of the fuel tank and/or mounting component(s) allowing for the fuel tank to be fastened to the remainder of an internal combustion engine might result in damage to the fuel tank was reduced by comparison with conventional fuel tank systems. Additionally, it would be advantageous if, in at least some embodiments, advantage(s) associated with manufacturing a fuel tank by way of a blow-molding process could be achieved without incurring one or more of the constraints faced when implementing blow-molded fuel tanks in conventional engines.
BRIEF SUMMARY OF THE INVENTION
[0007] In at least some embodiments, the present invention relates to a fuel tank system that includes a fuel tank, a first mounting bracket, first and second fastening devices, and at least one additional fastening device by which the mounting bracket is capable of being secured to another engine component. The fuel tank includes an outer wall that defines an internal cavity, an input orifice by which fuel can be added to the fuel tank, and first and second channels extending between first and second opposed outer surfaces of the wall through the cavity. The first mounting bracket has first and second protrusions, where a first surface of the mounting bracket is positioned proximate the first opposed outer surface of the fuel tank, and where the first and second protrusions respectively extend into the first and second channels. The first and second fastening devices are positioned proximate the second opposed outer surface of the fuel tank and are respectively fastened to the first and second protrusions, respectively, so as to prevent movement of the first and second protrusions out of the first and second channels, thereby securing the mounting bracket to the fuel tank.
[0008] Additionally, in at least some embodiments, the present invention relates to a method of assembling a fuel tank to another component of an internal combustion engine. The method includes assembling a first mounting bracket to one of the fuel tank and the other component, and assembling the first mounting bracket to the other of the fuel tank and the other component. The assembling of the first mounting bracket to the fuel tank includes inserting first and second protrusions of the first mounting bracket into first and second complementary holes extending through the fuel tank from a first opposed outer surface of the fuel tank to a second opposed outer surface of the fuel tank, thereby extending through a cavity formed within the fuel tank, where a main body of the first mounting bracket is positioned along the first opposed outer surface of the fuel tank. The assembling of the first mounting bracket to the fuel tank additionally includes affixing at least one fastening device to the first and second protrusions proximate the second opposed outer surface of the fuel tank, whereby the first mounting bracket is thereby assembled to the fuel tank.
[0009] Further, in at least some embodiments, the present invention relates to an internal combustion engine. The engine includes a crankcase, and a fuel tank including an outer wall that defines an internal cavity and first and second channels extending between first and second opposed outer surfaces of the wall through the cavity. The engine further includes a plurality of mounting components by which the fuel tank is assembled to the crankcase. The mounting components include a first mounting bracket having first and second protrusions, where the first and second protrusions respectively extend into the first and second channels, respectively. The mounting components also include first, second and third fastening devices, where the first and second fastening devices are respectively fastened to the first and second protrusions, respectively, so as to prevent movement of the first and second protrusions out of the first and second channels, and where the third fastening device secures the mounting bracket at least indirectly to the crankcase.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is an exploded, front perspective view of an engine assembly including, among other components, a fuel tank and mounting assembly components employed to secure the fuel tank to other portion(s) of the engine assembly;
[0011] FIG. 2 is an additional exploded, rear perspective view of the engine assembly of FIG. 1 ;
[0012] FIG. 3 is a further, unexploded front perspective view of the engine assembly of FIGS. 1-2 ; and
[0013] FIG. 4 is a further, unexploded rear perspective view of the engine assembly of FIGS. 1-3 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0014] Referring to FIGS. 1 and 2 , two exploded views are provided of portions of an exemplary engine assembly 2 that, in the present embodiment, can be implemented in (or as part of) a single-cylinder, vertical crankshaft internal combustion engine. Although other portions of such an engine, such as a crankshaft, are not shown in FIGS. 1 and 2 , it will be understood that such an engine will nevertheless typically include one or more such additional portions when fully assembled. As shown, the engine assembly 2 in particular includes a crankcase 4 including a cylinder 6 configured to receive a piston (not shown), as well as a fuel tank 8 and mounting assembly components 10 that allow the fuel tank 8 to be assembled to the crankcase 4 . Although in the present embodiment the engine assembly 2 is for use in a single cylinder, vertical crankshaft engine, other embodiments of the present invention can encompass or relate to engine assemblies for use in other types of internal combustion engines, including for example multi-cylinder engines and/or horizontal crankshaft engines.
[0015] Referring additionally to FIGS. 3 and 4 , two additional views of the engine assembly 2 of FIGS. 1 and 2 are provided in which the fuel tank 8 is shown to be assembled to the crankcase 4 by way of the mounting assembly components 10 , that is, where the engine assembly is no longer shown to be exploded but rather is shown to be assembled. More particularly, FIG. 3 provides a front view of the engine assembly 2 corresponding to the orientation illustrated in FIG. 1 , while FIG. 4 provides a rear view of the engine assembly corresponding to the orientation illustrated in FIG. 2 . Although the description provided below primarily relates to FIGS. 1 and 2 insofar as the exploded views of FIGS. 1 and 2 make visible in more detail a number of the components of the engine assembly 2 , it should be remembered that the same engine assembly 2 shown in FIGS. 1 and 2 is also shown in FIGS. 3 and 4 .
[0016] In the present embodiment, the fuel tank 8 is a blow-molded plastic structure manufactured using high density polyethylene, although in alternate embodiments the fuel tank can be manufactured using other plastic materials or other materials and by way of other manufacturing processes. For example, in at least some other embodiments, the fuel tank can be manufactured by way of injection molding, twin sheet hot forming (or vacuum forming), or welding. The structure of the fuel tank is a wall (or multiple integrally-formed walls) that defines an interior cavity within which fuel can be contained. In the present embodiment, the fuel tank 8 is configured to have an arched ceiling portion 33 , within which air/fuel vapors collect when the fuel tank is otherwise filled with fuel, and which accommodates pressure changes due to expansion/contraction accompanying temperature changes.
[0017] As shown, the fuel tank 8 also has a fuel tank neck 9 defining an orifice by which fuel can be provided into the tank, and also includes a fuel tank cap 11 that is used to close off the orifice once fuel has been added to the tank. The fuel tank cap 11 can be provided with any of a variety of features that allow fuel vapors to exit the fuel tank 8 to the outside atmosphere, or so that fuel vapors are absorbed in a carbon canister or the like. The fuel tank cap 11 can also be shaped/formed/molded in a variety of manners depending upon the embodiment to allow for the fuel tank cap to be coupled to the fuel tank neck 9 in various ways. For example, in one embodiment, the fuel tank cap 11 is molded to include threads that are complementary with respect to threads 17 formed on the fuel tank neck 9 . Also for example, in other embodiments the fuel tank cap 11 is formed to include “quarter turn” or “quick turn” features allowing for the fuel tank cap to be locked to the fuel tank neck by way of only a quarter-turn (or other small amount of rotation) by the cap relative to the neck.
[0018] In addition to the fuel tank neck and cap 9 , 11 , the fuel tank 8 also has first and second tapered holes or channels (or tubes) 12 , 14 extending through a width of the tank as illustrated by a width dimension arrow 16 , and that are respectively located near opposite ends of a length of the tank as illustrated by a length dimension arrow 18 . In the present embodiment, the tapered holes 12 , 14 extend completely through the fuel tank 8 between opposed outer surfaces of the fuel tank wall, more particularly, between an inboard outer surface 15 (see FIG. 1 ) and an outboard outer surface 25 (see FIG. 2 ) that are opposed to one another, and thus the tapered holes 12 , 14 extend completely through the internal cavity of the fuel tank. As illustrated, the tapered holes 12 , 14 are tubular with walls that extend internally within the fuel tank 8 between the surfaces 15 , 25 and that effectively constitute internal extensions of the wall of the fuel tank 8 , and the presence of the tapered holes does not create any breach in the integrity of the internal storage cavity of the fuel tank 8 by which fuel stored within the fuel tank might escape from the fuel tank. Thus, the tapered holes 12 , 14 add significantly to the structural strength of the body of the fuel tank 8 .
[0019] In addition to the tapered holes 12 , 14 , the fuel tank 8 also has two additional holes 13 (one of which is visible in FIG. 1 ) along its underside, that is, located below the tapered holes 12 , 14 . The additional holes 13 , unlike the tapered holes 12 , 14 , do not extend through the cavity defined by the fuel tank 8 , but rather are formed in a web surface extending from the main body of the fuel tank along the underside of the fuel tank.
[0020] The mounting assembly components 10 include an upper fuel tank mounting bracket 20 that in the present embodiment is molded from die-cast aluminum or injection molded thermoplastic plastic, although in alternate embodiments the bracket can be manufactured from other materials or by way of other processes. The upper fuel tank mounting bracket 20 includes first and second tapered protrusions or posts 22 and 24 that are connected to one another by way of a primary bracket portion 26 , and that extend outward away from the primary bracket portion from a fuel tank side 23 of the mounting bracket. The taper angle of the tapered posts 22 , 24 matches that of the tapered holes 12 , 14 of the fuel tank 8 . In each case, the thickness (e.g., the diameter) of the posts/holes decreases as one proceeds away from the primary bracket portion 26 .
[0021] When the upper fuel tank mounting bracket 20 is mounted to the fuel tank 8 , the first and second tapered posts 22 and 24 respectively extend through the first and second tapered holes 12 and 14 , respectively, such that the tapered posts extend through the width of the fuel tank parallel to the width dimension arrow 16 . Additionally, when so mounted, the primary bracket portion 26 of the upper fuel tank mounting bracket 20 extends along the length of the fuel tank generally parallel to the length dimension arrow 18 . In the present embodiment, the fuel tank side 23 of the upper fuel tank mounting bracket 20 has a convex shape and the inboard surface of the fuel tank 8 has a complementary concave groove 19 extending generally between the tapered holes 12 , 14 , into which the fuel tank side of the mounting bracket fits. In other embodiments, the upper fuel tank mounting bracket 20 and fuel tank 8 can have other shapes and take other forms.
[0022] The fuel tank 8 is secured to the upper fuel tank mounting bracket 20 by way of mounting assembly components 10 as follows. In particular, the fuel tank 8 is positioned onto the tapered posts 22 , 24 of the upper fuel tank mounting bracket 20 , such that the tapered posts respectively extend through the tapered holes 12 , 14 , respectively. The tapered posts 22 , 24 additionally extend through respective rubberized grommets 28 that are positioned along the inboard side of the fuel tank 8 , and that fit within pockets/eyelet cavities 29 (see FIG. 1 ) along the inboard ends of the tapered holes 12 , 14 of the fuel tank 8 . When the tapered posts 22 , 24 are fully inserted into the tapered holes 12 , 14 (as shown in additional FIG. 4 discussed further below), the rubberized grommets 28 are sandwiched between the inboard outer surface 15 of the fuel tank 8 and the inboard ends of the tapered posts 22 , 24 (that is, the ends of the tapered posts that are closer to the primary bracket portion 26 ). Depending upon the embodiment, the rubberized material making up the grommets 28 can range from rubber to any of a variety of other materials having properties similar to those of rubber.
[0023] Once the tapered posts 22 , 24 are positioned in this manner relative to the tapered holes 12 , 14 , respective bolt assemblies 30 are assembled to the respective outboard edges of the respective tapered posts (that is, the ends of the tapered posts that arc farther from the primary bracket portion 26 ). Each of the bolt assemblies 30 more particularly includes a respective plastic washer 32 , a respective metal back-up washer 34 and a respective retaining bolt 36 with a respective head 37 (see FIG. 2 ). The plastic washers 32 fit within pockets/eyelet cavities 39 at the respective outboard ends of the tapered holes 12 , 14 of the fuel tank 8 . The plastic washers 32 are typically made from a plastic material having material properties similar to those of the fuel tank 8 , so as to eliminate or at least reduce any abrasion or wear that might occur due to the contact between the washers and the fuel tank. The respective bolts 36 are screwed into complementary threaded holes 57 (one of which is shown in FIG. 2 ) formed within the tapered posts 22 , 24 , such that the bolts are affixed to the posts with the plastic washers 32 and metal back-up washers 34 being sandwiched between the outboard side of the fuel tank 8 and the respective heads 37 of the respective bolts (the metal back-up washers being between the heads and the plastic washers).
[0024] With respect to fastening the upper fuel tank mounting bracket 20 to the crankcase 4 , the mounting assembly components 10 additionally include two bolts 27 that arc respectively inserted through two orifices 47 positioned at opposite ends of the primary bracket portion 26 along a crankcase side 49 of the mounting bracket opposite the fuel tank side 23 from which the tapered posts 22 , 24 extend. As shown, the orifices 47 are configured so that central axes of the orifices are substantially perpendicular to each of the width and length dimensions of the fuel tank as represented by the width dimension arrow 16 and length dimension arrow 18 (e.g., in the present embodiment, substantially vertical). The orifices 47 are aligned with threaded receiving orifices 50 formed along the crankcase 4 (particularly within extensions 52 of the crankcase). Following passage of the bolts through the orifices 47 , the bolts enter the receiving orifices 50 and, upon appropriate rotation, the bolts are secured to the crankcase 4 , thus resulting in the securing of the upper fuel tank mounting bracket 20 and the fuel tank 8 to the crankcase as well.
[0025] In addition to the components already described above, the mounting assembly components 10 additionally include a lower fuel tank mounting bracket 42 (see FIG. 1 ), which in the present embodiment is a steel stamping (as shown, the stamping is substantially symmetrical about a vertical axis) and provides addition support of the fuel tank 8 relative to the crankcase 4 . In the present embodiment, the lower fuel tank mounting bracket 42 is fastened to the fuel tank 8 with two screws 44 (see FIG. 2 ) that respectively extend through two orifices 43 in the mounting bracket (one of which is shown in FIG. 1 ) and into the two additional holes 13 along the underside of the fuel tank 8 , such that the mounting bracket is securely sandwiched between heads of the two screws and the fuel tank. Additionally, the lower fuel tank mounting bracket 42 is fastened to the crankcase 4 by way of an additional bolt 45 (see FIG. 1 ) that extends through an additional orifice 47 in the mounting bracket and into a corresponding hole 51 (see FIG. 2 ) in the crankcase.
[0026] The overall manner of assembly of the fuel tank 8 relative to the crankcase 4 by way of the mounting assembly components 10 serves both to fasten the fuel tank to the crankcase as well as to constrain their relative motion. In particular, the upper fuel tank mounting bracket 20 serves to constrain two axes of linear motion and rotation in one plane. Additionally, the lower fuel tank mounting bracket 42 serves to constrain the location of the fuel tank 8 relative to the engine crankcase 4 (particularly by preventing rotation on a plane parallel to that defined by the axes of the tapered posts 22 , 24 ), so as to avoid interference with other engine components such as decorative covers, linkages, etc., which among other things could be exacerbated or exaggerated by engine shaking forces.
[0027] The mounting assembly components 10 and fuel tank 8 are engineered to limit total crush of the fuel tank when assembled together. The rubber grommets 28 are never fully collapsed nor are they free from interference with the tank, such that they are always in contact with the tank and are a dampening mechanism to engine vibration (generating shaking forces). The primary bracket portion 26 also defines a functional open area or space 40 in the middle area of its span between the tapered posts 22 , 24 . The open area 40 serves to provide a vent path for cool air to flow from the engine cooling fan (which is not shown, but which is typically located on the crankshaft above the crankcase 4 ) through the bracket and to and along the engine crankcase 4 .
[0028] The fuel tank 8 in the present embodiment is blow-molded, and in particular is blow-molded to include compression limiting features to prevent the tank from being crushed and damaged. While it is typical for injection-molded fuel tanks to have fuel filtration screens that are welded directly onto the fuel tank well surface, this is not typically the case with blow-molded fuel tanks, which instead typically use external fuel filters that are spliced into the fuel hose that feeds the carburetor. In the present embodiment, rather than employ such a spliced external fuel filter, the fuel tank 8 is designed to include a fuel tank outlet spud or nipple 54 (see FIG. 2 ) that is large enough to utilize a long and slim cylindrical filter 56 to fit inside the outlet spud. Since this filter is inserted into the spud from the outside of the fuel tank, the filter is a serviceable, replaceable fuel tank component that can be implemented without a two-piece fuel hose and two-additional hose clamps that are typical of in-line fuel hose filtration methods.
[0029] Embodiments of the present invention can provide one or more of a variety of advantages. In particular, in at least some embodiments, the present invention provides a fuel tank system assembly with high structural integrity that is capable of supporting four times the weight of the overall engine (e.g., up to 128 lb-force). This allows for optimization of the packaging of engines on shipping pallets, which often requires that the engines rest on and be supported by the fuel tank (rather than vice-versa). Use of a single-piece, blow-molded design for the fuel tank in particular is advantageous relative to the use of a fuel tank formed from multiple pieces that are welded together. Indeed, not only does the absence of a weld seam serve to strengthen the fuel tank, but also it enhances the durability of the fuel tank from the standpoint of avoiding possible leakage along the weld seam that could possibly occur over time due to chemical attack from the fuel (e.g., due to alcohol found in gasoline).
[0030] Also, in the embodiment described above, the fuel tank 8 and mounting assembly components 10 allow for the fuel tank to be attached to the crankcase 4 without modification, and allow for the fuel tank to be used to replace previously designed fuel tanks (e.g., as an aftermarket component). Further, the fuel tank 8 and major mounting assembly components (e.g., the upper and lower fuel tank mounting brackets 20 , 42 ) are engineered so as to allow assembly of the fuel tank relative to the crankcase 4 without any specific order of assembly being required, thus, providing flexibility in terms of engine manufacturing process. That is, the mounting brackets 20 , 42 can be assembled to the crankcase 4 first and then subsequently to the fuel tank 8 , or vice-versa (or even potentially by assembling the mounting brackets to both the crankcase and the fuel tank substantially simultaneously). Also, it is possible that one of the mounting brackets 20 , 42 can be affixed first to the fuel tank while the other is affixed first to the engine crankcase, and subsequently that each respective mounting bracket can then be affixed to the other of the fuel tank/engine crankcase to which it still needs to be connected.
[0031] The fuel tank 8 and mounting assembly components 10 in the present embodiment are also engineered such that the frequencies at which the fuel tank can vibrate (e.g., the modal frequencies) are substantially above those generated by the engine during operation. For example, assuming a standard maximum engine operational frequency of 60 Hz (corresponding to 3600 rpm), the fuel tank 8 can be designed to have a first modal frequency at a minimum of about two times that frequency or 150 Hz. Thus, vibrations caused by engine operation are unlikely to produce undesirable vibrations of the fuel tank 8 and mounting assembly components 10 at their natural frequencies. Further, in the present embodiment, the fuel tank 8 is engineered to provide finger protection with respect to rotating engine components without the need for any additional components to provide this function, as is often the case with conventional fuel tank assemblies. As noted above, in the present embodiment, the upper fuel tank mounting bracket 20 is configured to provide a pathway for cooling air generated by the engine fan to communicate with the crankcase 4 .
[0032] A variety of additional embodiments of the present invention are also intended to be encompassed herein in addition to those described above. For example, in at least one additional embodiment, it is possible for the number of tapered holes/tapered posts to be other than two as shown above (e.g., only one of each can be present, or more than two can be present). Also, the number and types of fastening components used can vary considerably depending upon the embodiment. Also, in at least some embodiments, the tapered posts need not extend all of the way through the fuel tank (that is, need not extend the entire length or substantially the entire length of the tapered holes), but rather only need extend part of the way.
[0033] Further, in at least some embodiments, it is possible that posts (or, indeed, the bolts) extending into the fuel tank from the outboard side of the fuel tank (opposite the inboard side along which the mounting bracket(s) are positioned) can be the components that extend partly, substantially or entirely through the fuel tank. In at least some such embodiments, such posts or other structures also could be tapered (albeit the tapering would typically proceed in a manner opposite to that described above). Additionally, depending upon the type of engine with respect to which the fuel tank is to be mounted, the arrangement and characteristics of the fuel tank can vary in other manners. For example, in at least some embodiments where the fuel tank is to be mounted upon a horizontal crankshaft engine, the tapered holes/channels can pass vertically through the fuel tank rather than horizontally as shown in FIG. 1 (albeit depending upon the embodiment, tapered holes/channels can proceed in any given direction, and any number of tapered holes/channels can be employed).
[0034] Although the above description occasionally utilizes terms suggestive of a physical orientation of components relative to the ground or some other reference point (e.g., horizontal/vertical), the present invention is intended to encompass a wide variety of embodiments of engines and fuel tank systems having fuel tanks, mounting assembly components, and/or other components arranged in any of a variety of manners and the use of these terms is not intended to restrict applicability of the invention to embodiments having particular physical orientations relative to ground or any other reference.
[0035] It is specifically intended that the present invention not be limited to the embodiments and illustrations contained herein, but include modified forms of those embodiments including portions of the embodiments and combinations of elements of different embodiments as come within the scope of the following claims.
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A fuel tank system, engine employing such a system, and related method of assembly are disclosed. In at least one embodiment, the fuel tank system includes a fuel tank, a mounting bracket, and at least three fastening devices. The tank includes an outer wall that defines an internal cavity, and first and second channels extending between first and second opposed outer surfaces of the wall through the cavity. The bracket has first and second protrusions, where the first and second protrusions respectively extend into the first and second channels, respectively. First and second ones of the fastening devices are respectively fastened to the first and second protrusions, respectively, so as to prevent movement of the protrusions out of the channels, thereby securing the bracket to the tank. A third of the fastening devices allows the bracket to be secured to another engine component.
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STATEMENT OF GOVERNMENT INTEREST
The invention described herein may be manufactured and used by or for the Government of the United States of America for governmental purposes without the payment of any royalties thereon or therefor.
BACKGROUND OF THE INVENTION
The launching of air or undersea vessels requires that a nonvaried sequence be rigidly adhered to; particularly, in the case of systems relying upon pressurized gas as the motivating force for a catapult or launching ram the high pressure of the working fluid presents formidable potential for failure, damage or, even worse injury. Heretofore, a combination of three way valves, lead valves and several tapped pressure fittings have been employed in an undersea launcher of torpedo-like vehicles. In case of a malfunction a pressure fitting needed to be uncapped, a pressure source connected and pressure applied. Next, the pressure needed to be released, the pressure source removed and the fitting recapped. This sequence was time consuming and, because the valves were individually operated in this pressurization sequence with no interlocking among them, the untimely operation of the launcher might occur with the attendant hazardous exposure of personnel and the vessel itself. The launcher was modified by introducing a tank for bleeding-off the pressurized working fluid in the lines and other elements of the launcher. This modification called for an additional valve which had to be operated in conjunction with the three way valve. In the case where more than one operator initiated the launching or resetting sequence, the number of valves and pressure fittings were likely to create problems if operated out of sequence.
There is a continuing need in the state-of-the-art for a single control manifold which has only a single pair of valves operated by handles having specific configurations to allow the venting of gases and the readying of the launcher in a predetermined sequence.
SUMMARY OF THE INVENTION
The present invention is directed to providing an apparatus for controlling the venting of pressurized gas from a launcher. A manifold block is provided with a high pressurized gas passage, a receiver passage, a piston return passage, a snubber passage and a vent passage. The block is further provided with a vent recess communicating with all of the aforestated passages and a high pressure gas recess communicating with the high pressure gas passage. The high pressure gas valve is rotatably mounted in the high pressure gas recess and has a lateral bore selectively rotated to be in communication with the high pressure gas passage. A venting valve is rotatably mounted in the vent recess and has a port selectively rotated to communicate the vent passage with the high pressure gas passage, snubber passage, piston return passage, and the receiver passage. A high pressure gas valve handle is mounted on the high pressure gas valve for imparting rotational motion to the valve and selectively aligning its bore with the high pressure gas passage. A venting valve handle is mounted on the venting valve for imparting rotational motion to the valve to align its port with a selective one of the passages and for blocking rotational motion of the high pressure gas valve handle at predetermined positions to assure that the predetermined sequence is followed. Further assurance of following the predetermined sequence is attributed to a one way rotational permitting means mounted on the manifold block and engaging the valve handle which allows only one way rotation of the venting valve.
A primary object of the invention is to provide a control manifold which assures a following of a predetermined sequence.
Another object is to provide a control manifold which reduces the hazards associated with launching an undersea missile.
Still another object is to provide a control manifold employing a pair of rotatable valves for alignment of a number of passages which has handles configured to assure a predetermined sequence of operation.
Still another object is to provide a control manifold with a pair of rotatable valves which rotate in only one direction or between preestablished limits.
A further object is to provide a control manifold ideally suited for readying a launcher of ordnance for a subsequent shot.
Still another object of the invention is to provide a control manifold that is compact and sized for actuation by a single operator.
These and other objects of the invention will become more readily apparent from the ensuing specification when taken together with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 schematically depicts the invention operatively connected in a typical launching system.
FIG. 1a is an isometric view of the invention.
FIG. 2a is a cross-sectional view of the invention along lines 2a--2a in FIG. 1a.
FIG. 2b is a representation of the back of the handles as well as the ratchet on the backside of the venting valve taken along lines 2b--2b in FIG. 1a.
FIG. 2c is a representation of a portion of the invention taken along lines 2c--2c in FIG. 1a.
FIG. 3 is the manifold in the ready to fire position.
FIG. 4 is the vent valve in the vent receiver tank position.
FIG. 5 shows the manifold in the vent drive piston position.
FIG. 6 depicts the vent valve in the drive piston return pressure assist position.
FIG. 7 shows the arrangement of the valves as the manifold vents the snubber.
FIG. 8 shows the manifold as it vents the gas reservoir.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIG. 1 of the drawings a schematic depiction of a control manifold 10 is operatively connected to a representative launching system. The launching system in this case is for the launching of a torpedo-like vehicle and, most assuredly, launchers for flying missiles have a good deal in common with the one shown.
This typical system has an air reservoir 11 which feeds pressurized gas to a drive piston rod assembly 12. As gas is vented into the drive piston rod assembly, a catapult assembly connected to the missile ejects the missile from its launch tube. A drive/snubber tube 13 prevents the piston rod from being damaged during the launching sequence by trapping a cushioning volume of gas on the other side of the piston. After the torpedo or missile has been launched the gas used to eject the missile is vented to a receiver tank 14 in a manner to be elaborated on below. Lastly, after the vehicle or missile has been launched the elements, thusly referred to, are depressurized through a vent 15. After this sequence has been followed the launching system is once again in the ready to fire position for another missile or vehicle.
Control manifold 10 is fashioned from a block of stainless steel. Stainless steel was chosen because of its demonstrated capability to resist corrosion and its toughness. Obviously, other materials could be selected to adapt to a variety of applications.
A pair of recesses 16 and 17 are bored in the control manifold block to receive appropriately sized valves, a high pressure gas valve 18 in recess 16 and a venting valve 19 in recess 17.
Both valves are cylindrical in shape and are sized to rotatably fit within the two recesses. They are sealed and secured in the recesses according to techniques well established in the art and each have an axial pin which extends upwardly from the face of the control manifold.
High pressure gas valve 18 is provided with a lateral bore 20 and venting valve 19 is provided with an essentially L-shaped port 21. The L-shaped port is arranged so that one portion of it radially extends from the center of the venting valve while the other portion extends coaxially toward the back of the control manifold.
A high pressure gas passage 22 is provided in the control manifold so that when the high pressure gas valve 18 is rotated to align its lateral bore with the passage, high pressure gas is free to flow into the manifold. At the venting valve end of the manifold a receiver tank passage 23, a drive piston return passage 24 and a snubber passage 25 are provided in the manifold to communicate with recess 17 in essentially the same lateral plane. This same lateral plane is the lateral plane with which the radially extending portion of the L-shaped port 21 communicates as the venting valve 19 is rotated in the recess.
A vent passage 26 is in communication with the coaxial portion of the L-shaped port so that as venting valve 19 is rotated to communicate the port with the high pressure gas passage, the receiver tank passage, the drive piston return passage and the snubber passage, they vent gas through passage 26 and to vent 15. At this point it should be noted that the high pressure gas passage 22 is effectively coupled to vent 15 when the venting valve is switched to communicate with snubber passage 25 since the high pressure gas passage is in communication with the snubber passage.
The coaxial pins provided on both the high pressure gas valve 18 and the venting valve 19 extend through the manifold face and, if desired, a cover plate 27 secured to the face of the manifold (appropriate legends may be included on the plate to provide an operator with a visual representation of the valve's position). The pins reaching from the valves are secured by means of a set screw in the venting valve handle 28 and the high pressure gas valve handle 29 when the pins are inserted in a hole 28a or 29a in the respective valves.
Venting valve 19 is provided with a pair of projections 30 and 31 orthogonally disposed with respect to one another and a pair of arms 32 and 33 similarly orthogonally disposed from one another. The arms are sized to be larger than the projections to restrict the rotation of high pressure gas handle 29 when it is in certain positions. As will become more apparent from the following, this feature helps assure that a predetermined sequence of operation is followed.
A pair of pins 34 and 35, see FIGS. 1a, 2c and FIG. 3 through B, contain the high pressure gas handle within a bidirectional ninety degree arc of travel. This amount of travel is sufficient to align the lateral bore of the high pressure gas valve with the high pressure gas passage or to block it. The ninety degree arc of travel will place an extension 36 of the high pressure gas handle abutting either projection 30 or 31 of the venting valve handle 28 when it is suitably rotated.
Further reliable operation is provided for by including a spring biased pawl 37 on the face of the control manifold which engages a ratchet 38 consisting of four orthogonally disposed machined inclines on the inside of venting valve handle 28. Thus, the venting valve handle can rotate the venting valve in only one direction due to the mechanical coaction between the pawl 37 and the ratchet 38.
The foregoing structure possesses the capability for ensuring that an operator follows a preestablished sequence of operation. Referring to FIGS. 1 and 3 in the drawings, a control manifold is depicted in the "ready to fire" position. High pressure gas valve 18 and venting valve 19 are positioned so that their respective lateral bore and L-shaped port switch all but venting passage 26 out of the launcher system.
After pressurized gas is released from high pressure gas reservoir 11 and displaces the drive piston rod to actuate the catapult assembly, a portion of the pressurized gas is fed through a pilot valve assembly to receiver tank 14. Consequently, after the missile has been launched, the first step is to bleed the gas from receiver tank 14.
Noting FIG. 4, venting valve handle 28 is rotated 90 degrees clockwise to align L-shaped port 21 of venting valve 19 with receiver tank passage 23. Any pressurized gas in the tank is vented through vent 15 via receiver tank passage 23, L-shaped port 21 and venting passage 26. The high pressure gas handle cannot be rotated to feed high pressure gas from reservoir 11 through the launching system since arm 32 abuts the high pressure gas handle and prevents it from rotating.
The next step in preparing the launcher system for refiring is to vent the pressurized gas now contained on the right side of the piston of drive piston rod assembly 12. Venting the drive piston assembly calls for rotating venting valve handle another ninety degrees clockwise to align L-shaped port 21 with drive piston return passage 24 in the control manifold, see FIG. 5. Thus, the complete passageway from piston assembly 12 to vent 15 takes the path of drive piston return passage 24, L-shaped port 21 and venting passage 26.
If a drive piston rod pressure assist is needed, that is to say, if there need be the introduction of pressurized gas through the snubber to return the piston to the far right end of the drive/snubber tube, then high pressure gas reservoir 11 is switched through the control manifold. Note FIG. 6 which shows that high pressure gas handle 29 is rotated ninety degrees counter clockwise so that its extension 36 rests on projection 30. Gas is fed to the back of the piston through the drive snubber to displace the piston to the right.
Next, the snubber is vented by rotating venting valve handle ninety degrees clockwise to couple L-shaped port 21 with snubber passage 25 and venting passage 26. The high pressure gas handle 29 has since been rotated ninety degrees clockwise to take its lateral bore 20 out of alignment with high pressure gas passage 22.
From time to time maintenance or equipment failure in some portion of the launching system may require that the high pressure gas reservoir be vented. In this situation the manifold is actuated to assume the representation of FIG. 8. The high pressure gas handle is rotated 90 degrees counter clock wise so that its extension rests on projection 31. Pressurized gas passes easily from reservoir 11 through high pressure gas passage 22, through lateral bore 20 and once again through another portion of high pressure gas passage 22 to snubber passage 25, through L shaped port 21 and out to vent 15 via the venting passage 26.
Obviously, many modifications and variations of the present invention are possible in the light of the above teachings, and, it is therefore understood that within the scope of the disclosed inventive concept, the invention may be practiced otherwise than specifically described.
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A manifold controls the venting of pressurized gas from an ordnance launc. A manifold block is provided with a number of passageways which communicate with a pair of recesses machined in the block. A high pressure gas valve is disposed in one of the recesses while a venting valve is rotatably positioned in the other recess. Ports are included in both of the valves so that when they are rotated a venting sequence of the launcher is effected. A specifically configured handle is secured to each of the valves and a spring biased pawl engages a number of teeth on the venting valve handle to allow only one direction of rotation. The configurations of the handles, the ratchet and pawl ensure a preestablished venting sequence and readying of the launcher for another shot.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application Ser. No. 60/756,847, filed Jan. 6, 2006, which is incorporated herein in its entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The invention relates to a rotary latch.
[0004] 2. Description of Related Art
[0005] Rotary latches are well known in the art, providing a strong, compact latching mechanism for many applications. A rotary latch generally includes a housing portion fixed to a first structure having a U-shaped slot configured to receive a post fixed to an opposing structure. A C-shaped latch is pivotally attached within the housing and arranged to rotate from a latched position within and perpendicular to the U-shaped slot to an unlatched position. In the latched position, the C-shaped latch and the U-shaped notch overlap to define a central opening configured to hold the post. In the unlatched position, the C-shaped latch is rotated toward the opening of the U-shaped slot, allowing the post to move into or out of the U-shaped slot. The C-shaped latch usually includes a catch on its body in an opposing position to the opening of the “C” relative to the pivot point of the latch. The catch is configured to act in concert with a trip lever pivotally mounted within the housing. The C-shaped latch and the trip lever are generally spring-biased. The C-shaped latch is biased in an open position and the trip lever is biased in a locked position. When the C-shaped latch is moved into the closed position, the trip lever is biased to engage the catch, holding the C-shaped latch in the closed position. The C-shaped latch is released by rotating the trip lever until it disengages from the catch. A stud is usually mounted to the trip lever for attachment of a release cable. Because of the configuration of the trip lever having a fixed pivot axle, it is necessary to arrange the release cable in a very narrow approach angle to the stud, in order to be able to pivot the trip lever with a minimal force exerted on and by the release cable. In the known arrangement, the release cable is generally aligned parallel to the housing of the rotary latch. Deviations from the optimal attachment of the release cable to the stud, with a tangential positioning of the cable relative to the pivot axis of the trip lever, unnecessarily increase the force required to release the rotary latch. The mechanical advantage available in the trip lever can therefore be lost by suboptimal positioning of the cable. Also, in different applications, it becomes necessary to modify the configuration of the trip lever and the stud so that the release cable can even access the stud. This necessitates the manufacture and stocking of multiple configurations of rotary latch assemblies, dependent upon the variety of applications used in a particular assembly.
[0006] It would be advantageous to provide a rotary latch system that provides the maximum available mechanical advantage regardless of the exact alignment of the release cable relative to the pivot axis of the trip lever. It would further be advantageous to provide a rotary latch system that improves the accessibility of a release mechanism in different applications without requiring the physical modification of the rotary latch.
BRIEF SUMMARY OF THE INVENTION
[0007] A rotary latch for selectively locking a closure, such as a tonneau cover on a pickup truck bed or the swing-up window on a pickup truck cap, is provided with a spring loaded toggle release lever, or joystick. The joystick enables the rotary latch to be installed in any position with respect to a remote actuating handle because the joystick can be pushed or pulled in almost any direction to release the rotary latch.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0008] The present invention will become more fully understood from the following detailed description and the accompanying drawings, wherein:
[0009] FIG. 1 is a side view of a pickup truck with a tonneau cover and a rotary latch with joystick according to the invention.
[0010] FIG. 2 is a partially broken sectional view of the rotary latch according to the invention, mounted on FIG. 1 pickup truck tailgate and tonneau cover, and substantially as taken on the line 2 - 2 of FIG. 3 .
[0011] FIG. 3 is a front view of the rotary latch of FIG. 2 .
[0012] FIG. 3A shows various means for actuating connection to the joystick of FIG. 3 and schematically illustrates the possibility of linking two (or more) latch mechanisms by means of their joysticks.
[0013] FIG. 3B shows a power actuator to joystick connector according to FIG. 3 .
[0014] FIG. 3C shows an unlatched position of parts of the FIG. 3 apparatus.
[0015] FIG. 4 is a pictorial view of the rotary latch of FIG. 3 .
[0016] FIG. 5 is a bottom view of the rotary latch of FIG. 3 .
[0017] FIG. 6 is a rear view of the rotary latch of FIG. 3 .
[0018] FIG. 6A is a fragment of FIG. 3 showing the joystick in central cross section.
[0019] FIG. 6B is a sectional view substantially taken on the line 6 B- 6 B of FIG. 6 .
[0020] FIG. 7 is an end view of the rotary latch of FIG. 3 .
[0021] FIG. 8 is an opposite end view of the rotary latch of FIG. 3 .
[0022] FIG. 8A is an exploded pictorial of a bracket for mounting the latch mechanism of FIGS. 1-8 .
[0023] FIG. 9 is an exploded pictorial view of the housing of the rotary latch of FIG. 3 .
[0024] FIG. 9A is a pictorial view of the latch member and latch release member of the rotary latch of FIG. 3 .
[0025] FIG. 10 is a side view similar to FIG. 6 , but with the rear housing portion mostly removed.
[0026] FIGS. 11A-11H depict the release sequence the main parts (only) of the rotary latch of FIG. 3 .
[0027] FIG. 12 is an end view of the free end of the joystick of the rotary latch of FIG. 3 .
DETAILED DESCRIPTION OF THE INVENTION
[0028] Certain terminology will be used in the following description for convenience in reference only and will not be limiting. The words “up”, “down”, “right” and left” will designate directions in the drawings to which reference is made. The words “in” and “out” will refer to directions toward and away from, respectively, the geometric center of the device and designated parts thereof. The words “proximal” and “distal” will refer to the orientation of an element with respect to the device. Such terminology will include derivatives and words of similar import.
[0029] FIG. 1 shows an application by way of example and not limitation, for the present invention. The invention is applicable in any enclosure requiring selective latching, and wherein the release of said latching can be accomplished by powered or manual actuation, electronically or mechanically, or by direct or remote control. In a motor vehicle 50 , e.g. a pickup truck, the present invention is applied for latching a door on a pickup truck cap or, as here shown, a tonneau cover 55 over a pickup truck bed cargo area 60 having a tailgate 65 . The tonneau cover 55 is movable between an open position (shown) and a closed position (shown in phantom). In the closed position, the tonneau cover 55 can be secured by a latch mechanism 100 releasably engaging a pin, or strike, 110 ( FIG. 2 ). The latch mechanism 100 is here indicated as being mounted on the tonneau cover 55 and the pin 110 on the tailgate 65 , respectively, but could on the tailgate 65 and tonneau cover 55 , respectively instead.
[0030] The latch mechanism 100 is attached to the inside of the tonneau cover 55 by a bracket 105 . A cooperating pin 110 is mounted to the tailgate 65 .
[0031] Referring further to FIGS. 3A-3C , the latch mechanism 100 includes a joystick 130 . The joystick 130 is spring biased into a rest position (vertical as shown in the drawings), and as will be further disclosed, displacement of the joystick 130 from such vertical position triggers unlatching of the latch mechanism 100 .
[0032] Referring now to FIGS. 5-10 , the latch mechanism 100 has a housing 140 formed of a left (in FIGS. 7-9 ) housing portion 145 and a right housing portion 150 .
[0033] The left ( FIG. 9 ) housing portion 145 comprises an elongate longitudinally extending sidewall 145 A having a laterally and endwardly facing notch 145 B, an elongate longitudinal flange 145 C extending widthwise perpendicularly from and following one length edge of the sidewall, a perpendicular first end flange 145 D at the notched end of the sidewall and adjacent one end of the elongate flange 145 C, a narrow step-like end wall 145 E extending widthwise perpendicularly from the other end of the sidewall to about half the width of the adjacent end of the elongate flange 145 C, an extension wall 145 F extending longitudinally from the free edge of the end wall 145 E in a plane parallel to the sidewall 145 A, and a narrow end flange 145 G extending from the free end of the extension wall generally parallel to and spaced from the step-like end wall 145 E.
[0034] The housing portion 150 is preferably substantially a mirror image of the housing portion 145 except as follows. The housing portion 150 comprises a longitudinally and widthwise extending flange 150 H at the longitudinally extending edge 150 J of its notch 150 B, but omits parts comparable to the longitudinal flange 145 C, first end flange 145 D and narrow end flange 145 G of the housing portion 145 .
[0035] The left and right housing portions are joined by a pair of swaged bushings 175 , 180 whose ends are fixedly received in respective apertures 155 , 165 and 160 , 170 in recessed portions of the sidewalls 145 A and 150 A. The swaged bushings 175 , 180 each have a threaded interior passage 185 for receiving a threaded fastener (e.g. screw) 190 , for securing the latch mechanism 100 to the bracket 105 and to an alignment plate 195 . In FIG. 3 , the bracket 105 is fixed to the tonneau cover 55 by bolt and nut units 194 . The left (in FIGS. 5 , 6 and 10 - 11 ) end 196 of housing 140 defines a U-shaped channel, or notch, 198 for receiving the pin 110 .
[0036] The housing narrow end walls 145 E and 150 E space the housing extension walls 145 F and 150 F laterally inboard of the housing sidewalls 145 A and 150 A, at the width of the end flange 145 G. The extension walls 145 F and 150 F and end flange 145 G define the left (in FIGS. 5 and 6 ) end portion 196 of the housing as a narrow (compared to the width of the housing at the sidewalls 145 and 150 ) nose 196 . The narrowed nose 196 allows mounting of the housing very close (e.g. almost abutting as in FIG. 5 ) the structure 65 (e.g. the truck tailgate) carrying the cooperating conventional pin 110 , even if the latter incorporates a radially projecting mounting flange, or the like, as indicated in the dotted line at 111 in FIG. 5 . Moreover, and as will be noted in FIG. 5 , since the narrowed nose 196 is spaced laterally inboard from both sidewalls 145 A and 150 A of the housing 140 , the housing 140 can be placed close to the pin supporting structure 65 , even with its orientation reversed, e.g. with its sidewall 150 A adjacent the pin supporting structure 65 , rather than its sidewall 145 A as in FIG. 5 . Thus, not only can the latch mechanism 100 be mounted in any desired orientation (e.g. joystick up, joystick down, joystick left, joystick right, housing length axis vertical or horizontal or sloped, but in any of those orientations, the housing 140 can be placed close to or spaced from the pin support structure 65 with which the latch mechanism 100 latchingly cooperates.
[0037] The mounting bracket 105 here includes a main body and a mounting flange 106 perpendicular thereto. Slots 107 and 108 in the main of the bracket 105 and in the flange 106 , respectively, allow adjustment of the location of the bracket 105 with respect to the adjacent side of the housing 140 and structure (e.g. the tonneau cover 55 of FIG. 1 ) on which the bracket is fixed.
[0038] To allow mounting of the housing 140 , in its contents, in any desired orientation, the bracket 105 may be fixed on either side of the housing 140 , e.g. either adjacent to the sidewall 150 A as seen in FIG. 8 , or to the opposite side wall 145 A. Moreover, with the mounting bracket 105 fixed to supporting structure (e.g. the FIG. 1 tonneau cover 55 ) by means of its mounting flange 106 ( FIG. 8 ), the housing 140 can be fixed in its joystick down orientation of FIG. 8 or reoriented with the joystick 130 up.
[0039] The alignment plate 195 ( FIG. 8A ) has through holes 195 A spaced from each other widthwise of the plate 195 at the same spacing as the slots 107 and the bracket and bushing holes 155 and 160 in the housing portion 145 and holes 165 and 170 in the housing portion 150 so as to coaxially align therewith. Aligned with the holes 195 A are a pair of upper lugs 195 B and a pair of lower lugs 195 C adjacent the top and bottom (in FIG. 8A ) edges of the alignment plate 195 . The lugs 195 B and 195 C protrude toward and are of width be snuggly received in the bracket slots 107 , as indicated in FIG. 8 . With the screws 190 loosened to adjust the position of the housing 140 along the length of the slots 107 , the adjustment plate 195 positively prevents one of the screws 195 from rising above the other and so prevents tilting of the housing 140 in a plane parallel to the adjustment plate 195 and main portion of the bracket 105 , i.e. maintains the top and bottom plates of the housing 140 perpendicular to the length axis of the slots 107 of the bracket 105 .
[0040] The latch mechanism 100 ( FIGS. 9A and 10 ) includes a rotating latch member 200 and a rotating latch release member 205 .
[0041] As shown in FIG. 10 , the latch member 200 and latch release member 205 are plate-like and pivotally mounted on the bushings 180 and 175 , respectively, which extend through corresponding holes 201 and 206 ( FIG. 9A ) therein.
[0042] The latch member 200 includes a C-shaped portion 235 to the left (in FIG. 10 ) of the bushing 180 and a tail portion 255 on the opposite side of the bushing 180 . The C-shaped portion 235 includes an inner arm 240 and an outer arm 245 . The inner arm 240 and the outer arm 245 define a U-shaped channel, or notch, 250 therebetween. The tail portion 255 has a shallow notch 215 in its lower ( FIG. 10 ) edge.
[0043] The close flanking of the C-shaped portion 235 ( FIG. 10 ) of the latch member 200 by the extension walls 145 F and 150 F of the housing portions 145 and 150 helps prevent the C-shaped portion 235 from bending or cocking out of its intended operating plane. Further, the bearing of the end flange 145 G on the extension wall 150 F (as seen in FIG. 5 ) helps rigidify the housing nose 196 .
[0044] The latch release member 205 includes a catch portion 260 . The catch portion 260 includes a step-like catch 265 and a shallow notch 230 . The catch 265 , as shown in FIGS. 9A-11 , is configured to engage the tail portion 255 of the latch member 200 . The latch release member 205 further includes a lever portion 270 . The lever portion 270 and catch portion 260 are on opposite sides of the bushing 180 . The lever portion 270 is formed as a flange perpendicular to the remainder of the latch release member 205 and comprises a leg 271 extending substantially tangentially beyond the bushing and terminating in a foot 272 extending parallel to the axis of the bushing hole 206 . The foot 272 here includes an aperture 275 .
[0045] A torsion-type latch spring 210 is also concentrically mounted on the bushing 180 , and at one end engages the notch 215 in the latch member 200 . The spring 210 at its other end bears against the end wall 220 of the housing 140 , thereby biasing the latch member 200 in a counterclockwise direction (as seen in FIG. 10 ). A second torsion-type spring 225 is mounted concentrically on the bushing 175 . The second spring 225 at one end engages the notch 230 in the latch release member 205 . The second spring 225 has its other end trapped behind the bushing 180 to bias the latch release 205 in a clockwise direction.
[0046] As shown in FIG. 6A , a rivet 280 protrudes through the longitudinal flange 145 C in alignment with the aperture 275 and thus secures a first end 285 of a coil compression spring 290 . The compression spring 290 passes through the aperture 275 and is received within a cavity 295 in the joystick 130 .
[0047] The joystick 130 includes a flat circular base portion, or annular flange, 300 ( FIG. 10 ), a necked-down (here convex or substantially frusto-conical) central portion 305 , and an elongate cylindrical arm portion 310 . The joystick 130 ( FIGS. 6A , 9 and 10 ) passes through a round aperture 315 in the flange 150 H of the right housing portion 150 . The flat circular base portion 300 of the joystick 130 is larger than the aperture 315 , so that the joystick 130 is retained within the housing 140 , with the base portion 300 bearing against an inner surface 316 of the flange 150 H of the housing 140 . The joystick 130 is biased into the aperture 315 by the compression spring 290 bearing between the base portion 300 of the joystick 130 and the longitudinal flange 145 C of the left housing portion 145 . The joystick central portion 305 tapers, from a diameter closely conforming to the aperture 315 , to the diameter of the cylindrical arm portion 310 . The profile of the outer wall 317 of the tapered central portion 305 can be linear or arcuate.
[0048] The compression spring 290 is partially compressed between the longitudinal flange 145 C ( FIG. 6A ) and the inboard end of the recess, or cavity, 295 in the inboard end of the joystick 130 , even in the relaxed (unactuated) position of the joystick shown. The rivet 280 is received in the first end 285 of the spring 290 to prevent the spring 290 from sliding sideways along the flange 145 C. The function of the rivet 280 can also be provided by forcible upsetting of the material of the flange 145 C in a position to retain the first end 285 of the spring 290 .
[0049] The joystick cylindrical arm portion 310 is hollow, having a threaded internal recess 320 . A pair of openings 322 , 325 pass transversely through the cylindrical arm portion 310 and the internal recess 320 . The threaded internal recess 320 is configured for receiving a connecting screw 330 ( FIG. 6A ). The cylindrical arm portion 310 further includes a pair of longitudinally spaced annular flanges 335 , 340 adjacent at its distal end 345 .
[0050] A given latch mechanism 100 may be used with one or more devices for unlatching same. As shown for example in FIG. 3 , the latch mechanism 100 is operable by a conventional power actuator 115 . As shown, the power actuator 115 is mounted in line with the latch mechanism 100 by a bracket 116 fixed to the tonneau cover 55 by nut and bolt units 117 (or by a bracket not shown carried by the latch mechanism 100 ). The power actuator 115 conventionally is electrically connected to a power source 120 (e.g. the vehicle battery not shown) and operated by a switch 125 . The switch 125 is conventionally capable of direct manual actuation or actuation by a conventional wireless remote control (not shown). The joystick 130 is connected to the power actuator 115 by a substantially rigid spring wire, push/pull connector, or “spring pull”, 135 ( FIG. 4 ). Due to the construction of the joystick 130 , displacement of the joystick 130 in any direction will actuate the latch mechanism 100 . Therefore, the actuator 130 need not be aligned with the latch mechanism 100 as shown. The power actuator 115 can be any type of mechanical or electrical actuator, or a hydraulic, magnetic, or pneumatic actuator. Furthermore, the actuator 115 need not be fixedly attached to the joystick 130 , but need only be positioned so as to displace the joystick 130 upon activation.
[0051] As shown in FIG. 3A , the spring pull 135 grips the cylindrical arm portion 310 of the joystick 130 between the flanges 335 , 340 . As a further example one or more conventional pullable release cables 350 , 355 ( FIG. 3A ) can be received through the openings 322 , 325 , and maintained therein by distal end plugs 360 , 365 fixed thereon. As a further example, a similar release cable, or a push rod 370 , having an eye 371 ( FIG. 6A ) can be fixed to the joystick 130 by a screw 330 .
[0052] In some instances, it may be desirable to provide more than one latch mechanism in a single installation of (e.g. tonneau cover pickup truck bed as in FIG. 1 ). For example, two could be located and spaced apart along the tailgate, or one might be provided on each side of the pickup truck bed. In such a dual installation, it may be desired to use a single powered or manual actuator to unlatch both latch mechanisms 100 . This can be done without any modification to the joysticks 130 of the dual latch mechanisms 100 . As seen for example in FIG. 3A , two joysticks 130 are spaced apart and linked by the cable 350 ,) the left (in FIG. 3A ) joystick 130 being connected through the wire member 135 to the power actuator 115 ( FIG. 3 ), and the other joystick being connected by a further cable 355 to another (e.g. manual) actuator of conventional type, not shown. In this way, actuation of one joystick 130 actuates the other so that both of the corresponding latch mechanisms 100 unlatch simultaneously.
[0053] Since axial pushing on the exposed end of the at rest joystick will also pivot the latch release member 205 and open the latch mechanism 100 , it is contemplated that screw 330 ( FIG. 6A ) may in some instances be substituted by a manually engageable push button, not shown, with the latch mechanism 100 being located so that such push button is reachable by a user either inside or outside the protected cavity (e.g. truck bed in FIG. 1 ).
Operation
[0054] The latch mechanism 100 has a latched position ( FIGS. 3 and 10 ), e.g. for latching the tonneau cover 55 in its closed, dotted line position on the pickup truck 50 .
[0055] As shown in FIG. 10 , the latch member 200 is held in a latched position against the bias of the spring 210 by the interference of the latch release member 205 , wherein the tail portion 255 of the latch member 200 is received within the catch 265 of the latch release member 205 .
[0056] Referring sequentially to FIGS. 11A-11H , the latched latch mechanism 100 is unlatched by axially depressing or pivotally deflecting the joystick 130 from its rest (here vertical) position shown in FIG. 11A . In this position, the latch member 200 is positioned such that the outer arm 245 of the C-shaped portion 235 appears perpendicular to the left end 196 of the housing 140 . The latch member 200 and the housing 140 thereby close the channel 198 and trap the pin 110 therein, such that the tonneaus cover (for example) is closed and latched.
[0057] The joystick 130 is then pivotally deflected e.g. by the power actuator 115 drawing on the spring pull 135 , by a manual actuator (not shown) pulling on a cable 350 , 355 , or in any other convenient way.
[0058] In FIG. 11B , the joystick 130 has been slightly pivotally deflected (to the right in FIG. 11B , though to the left or into or out of the page, or even axial deflection upward into the housing 140 would serve as well), forceably rotating the latch release member 205 slightly counterclockwise without yet releasing the latch member 200 . The joystick flat circular base portion 300 is slightly tilted away from the inner surface 316 of the housing 140 , while the frusto-conical portion 305 of the joystick 130 rides in the aperture 315 in the housing 140 .
[0059] In FIGS. 11C-11D , the joystick 130 is further deflected. The latch release member 205 is rotated further counterclockwise still without releasing the latch member 200 .
[0060] In FIG. 11E , the joystick 130 is fully deflected so that the latch release member 205 has been rotated sufficiently counterclockwise to clear the tail portion 255 of the latch member 200 . The latch member 200 is now free to rotate counterclockwise under the biasing force of the spring 210 .
[0061] In FIGS. 11F-11H , the latch member 200 , freed from latch release member 205 , sequentially rotates counterclockwise towards its unlatched position. In FIG. 11H , the latch member 200 has rotated to its fully counterclockwise, fully open position. At any time in the FIG. 11F-11H sequence the joystick 130 can be released, so that the latch release member 205 is allowed to rotate clockwise under the bias of the spring 225 , to return both to their FIG. 11A rest position. As the latch member 200 rotates counterclockwise under the bias of its spring 210 , the inner arm 240 of latch member 200 effectively pushes the latch mechanism 100 and pin 110 away from each other. The user is thus free to open the tonneau cover 55 to its FIG. 1 solid line position.
[0062] In the preferred embodiment shown, and as seen for example in FIG. 10 , during actuation the joystick base portion 300 bears at diametrically opposed points on the housing flange 150 H and on the foot 272 of the latch release member 205 to define a driven lever arm. On the other hand, the free end of the joystick, as at a point between the flanges 335 and 340 , may be connected to an actuator (for example the power actuator 115 or one of the release cables 350 , 355 , or the like). The distance, between that connection point on the free end of the joystick and the mentioned point on the joystick base 300 bearing on the housing flange 150 H, defines a driving lever arm. The ratio of these two lever arms (e.g. 2 to 1) defines the mechanical advantage provided by the joystick.
[0063] Similarly, the distances from the rotative center of the latch release lever 205 (the axis of swaged bushing 175 ) to the point of contact of the foot 272 with the joystick base 300 above mentioned and to the point of engagement of the step-like catch 265 with the portion 255 of the latch member 200 , define corresponding driving and driven lever arms of the latch release member 205 . For example in the embodiment shown, the ratio of such lever arms is approximately 2 to 1, the latch release member 205 thus providing a mechanical advantage of approximately 2 to 1.
[0064] Thus, the joystick and catch release member, taken together would, in this example, thus provide a combined mechanical advantage of approximately 4 to 1.
[0065] Moreover, the distances from the pivot axis of the latch member 200 (the central axis of its swaged bushing 180 ) to the point of contact of its tail portion 255 with the step-like catch 265 of the latch release member 205 and to the point of contact of the spring 210 with the shallow notch 215 , again defines driving and driven lever arms, which in the embodiment shown are the length ratio of about 3 / 2 .
[0066] Thus, in this particular example, there is a total mechanical advantage of about 6 to 1 from the joystick free end to pin 110 . The FIG. 1 tonneau cover 55 may have substantial weight. To release the latch mechanism 100 requires the tonneau cover mounted inner arm 240 to push downward on the pin 110 with sufficient force to cause the bushing 180 and housing 140 and bracket 105 to lift the tonneau cover 55 out of its normally closed, latched position shown in dotted line in FIG. 1 . Thus, the latch member spring 210 has to be strong enough to forcibly pivot the latch lever 200 , from its FIG. 11F position through its FIG. 11G position and into its fully opened FIG. 11H position, to lift the heavy tonneau cover 55 . However, that same strong spring 210 , in the latch mechanism closed position of FIGS. 10 and 11 A strongly holds the tail portion 255 against the step-like catch 265 , so as to strongly resist the opening rotation of the latch release lever 205 above discussed as to FIGS. 11B-11D . Again, the distance, from the point of contact of the tail portion 255 of the latch member 200 with the step-like catch 265 of the latch release member 205 , ( FIGS. 10 and 11A ) to the point of contact of the spring 210 with the edge of the spring 210 with the edge of the notch 215 in the latch member 200 , is here in the approximate ratio of 1 to 1. Accordingly, the combined mechanical advantage available to overcome the force of the spring 210 by actuation of the joystick 130 is hereabout 6 to 1. Accordingly, if a 40 pound force is required to lift the tonneau cover 55 to complete the laterally sequence from FIG. 11F through 11H , only about ⅙ that force (e.g. 7 pounds) need be applied to the end of the free end of the joystick 130 to open the latch mechanism 100 . Accordingly, it becomes possible to actuate the joystick 130 by relatively low force means, for example a conventional low cost power actuator 115 , even with a relatively heavy tonneau cover, and without need for the user to attempt to assist the unlatching process by manually lifting the tonneau cover. In short, even a relatively heavy tonneau cover 55 will pop open as the end result of the unlatching process shown in the FIG. 11A-11H sequence.
[0067] Vehicle users will occasionally load their pickup beds high enough that the user must exert downward pressure on the tonneau cover 55 to enable the pin 110 and latch lever 200 to assume their FIG. 10 latched positions. In that instance, after latching, the user stops pressing downward on the tonneau cover 55 and moves away to other activity, but the overweight load in the pickup bed is still pressing the tonneau cover upward away from the pickup truck bed, and hence urges the latch mechanism 100 upward with respect to the pin 110 , i.e. adding to the counterclockwise (in FIG. 10 ) force of the spring 210 and hence pushing the tail portion 255 even harder against the step-like catch 265 to further resist counterclockwise, unlatching rotation of the latch release member 205 . Thus, the substantial mechanical advantage provided by the inventive joystick 130 and latch release 205 allows this added resistance to latching to be overcome with a relatively light force applied to the joystick 130 manually, by cables, or by the power actuator 115 .
[0068] The power actuator 115 and other means (e.g. cables 350 / 365 of FIG. 3B actuate the joystick independently of each other, i.e. the power actuator actuates the joystick when the cables are slack and the cables actuate the joystick when the actuator is not powered. The latch mechanism 100 can be initially installed without the power actuator and, at some later time, the user can add a power actuator.
[0069] Should a person accidentally become trapped in the FIG. 1 pickup truck bed with the tonneau cover 55 latch closed, the inventive latch mechanism 100 provides a safety advantage in that it enables relatively easy escape. More particularly, the joystick 130 stands proud from the housing 140 to a substantial extent and so is relatively easy to find, even in the dark. Also, the joystick 130 requires only a very low activating force (in view of the substantial mechanical advantage of the latch mechanism 100 ), and pushing or pulling the joystick in a wide range of directions causes the latch mechanism 100 to unlatch.
[0070] The joystick 130 is free to rotate about its length (vertical in FIGS. 6 and 6A ) axis to orient the diametral through holes 322 and 325 in any desired direction on a plane perpendicular to the longitudinal axis of the joystick, so as to accommodate the actuators (e.g. cables 350 and/or 355 ( FIG. 3B )) approaching the joystick from virtually any direction.
[0071] While the invention has been described in the specification and illustrated in the drawings with reference to preferred embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention as defined in the claims. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to particular embodiments illustrated by the drawings and described in the specification as the best mode presently contemplated for carrying out this invention, but that the invention will include any embodiments falling within the scope of the appended claims.
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A rotary latch for selectively locking a closure, such as a tonneau cover, is provided with a joystick or toggle release lever. The joystick release lever enables the rotary latch to be installed in any position with respect to a remote handle because the joystick can be pulled in any direction, 360 degrees, to release the rotary latch. The joystick includes a trapped base supporting a spherical portion that is nested in a circular opening in the housing of the latch. The joystick is spring loaded, and is movable about its central axis in any direction, causing the base to pivot against the inside of the housing. The base of the joystick is positioned over a spring-loaded catch locking the rotary latch. As the base of the joystick rotates against the inside of the housing, it depresses the spring-loaded catch, releasing the rotary latch.
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BACKGROUND OF THE INVENTION
The present invention relates to novel N-carbamoyl-oxadiazolidin-5-ones and thiones which are active as insecticides.
The cyclization of thio- and dithiocarbazic acid ester derivatives which are acylated in position 3 by the radical of a carboxylic, sulfonic, carbamic, phosphoric, thiophosphoric or thiophosphonic acid with phosgene to give compounds of the formula: ##STR2## where y is O or S, Acyl is ##STR3## is disclosed by Rufenacht in Helvetica Chimica Acta 56, 162-175 (1973). The compounds where Acyl is phosphoryl or thiophosphoryl ##STR4## are disclosed as having an "insecticidal, acaricidal, and nematicidal effect"; however, the compounds where X is O are disclosed as unstable.
Rufenacht, supra, also discloses the preparation of compounds of the formulae: ##STR5## The compounds of formula (B) are disclosed as "having an insecticidal and acaricidal effect" but also as "not stable enough under the conditions of practical pesticide use".
U.S. Pat. No. 3,661,926 issued to Van den Bos et al. discloses 2-oxo-3-dialkoxyphosphoro-5-alkyl (or cycloalkyl of 5 to 7 carbons)-1,3,4-oxadiazolines as insecticidal.
U.S. Pat. No. 3,523,951 issued to Rufenacht teaches derivatives of 1,3,4-thiadiazole as possessing insecticidal activity.
My commonly assigned patent application, "Insecticidal 2-Oxo-3-Dialkoxyphosphoro-5-Cyclopropyl-1,3,4-Oxadiazoline," Ser. No. 343,088, filed Jan. 27, 1982 now U.S. Pat. No. 4,426,379, discloses compounds of the formula: ##STR6## wherein R is hydrogen, lower alkyl or lower alkoxy; R 1 and R 2 are independently lower alkyl; and Y is either oxygen or sulfur.
My commonly assigned U.S. patent application, "Insecticidal 5-Thiocarbamoyl-1,3,4-Oxadiazoles", Ser. No. 514,067, filed July 15, 1983, discloses insecticidal compounds of the formula: ##STR7## wherein R 1 and R 2 are independently lower alkyl having from 1 to 4 carbon atoms; and R 3 is lower alkyl having 1 to 6 carbon atoms, lower cycloalkyl having 3 to 6 carbon atoms optionally substituted with methyl or ethyl, lower alkoxyalkyl having up to a total of 8 carbon atoms or lower alkylthioalkyl having up to a total of 8 carbon atoms.
SUMMARY OF THE INVENTION
The present invention relates to insecticidal N-carbamoyl-oxadiazolidin-5-ones and thiones of the formula: ##STR8## wherein X is oxygen or sulfur; R 1 and R 2 are independently lower alkyl having from 1 to 4 carbon atoms; and R 3 is lower alkyl having from 1 to 6 carbon atoms, lower cycloalkyl having from 3 to 6 carbon atoms optionally substituted with methyl or ethyl, lower alkoxyalkyl having up to a total of 8 carbon atoms or lower alkylthioalkyl having up to a total of 8 carbon atoms.
Among other factors, the present invention is based on my surprising finding that the compounds of this invention are effective insecticides, and are particularly effective against certain economically important pests such as aphids.
Preferred compounds include those which have R 3 groups in which the carbon atom attached to the oxadiazolidine ring is a tertiary carbon.
Definitions
As used herein, the following terms have the following meanings, unless expressly stated to the contrary.
The term "alkyl" refers to both straight- and branched-chain alkyl groups. The term "lower alkyl" refers to both straight- and branched-chain alkyl groups having a total of from 1 to 6 carbon atoms and includes primary, secondary and tertiary alkyl groups. Typical lower alkyls include, for example, methyl, ethyl, n-propyl, isopropyl, n-butyl, isobutyl, t-butyl, n-pentyl, n-hexyl, and the like.
The term "alkylene" refers to the group --(CH 2 ) m -- wherein m is an integer greater than zero. Typical alkylene groups include methylene, ethylene, propylene, and the like.
The term "alkoxy" refers to the group --OR' wherein R' is an alkyl group. The term "lower alkoxy" refers to alkoxy groups having from 1 to 6 carbon atoms; examples include methoxy, ethoxy, n-hexoxy, n-propoxy, isopropoxy, isobutoxy, and the like.
The term "alkoxyalkyl" refers to an alkyl group substituted with an alkoxy group. The term "lower alkoxyalkyl" refers to groups having up to a total of 8 carbon atoms and includes, for example, ethoxymethyl, methoxymethyl, 2-methoxypropyl, and the like.
The term "alkylthio" refers to the group --SR' wherein R' is an alkyl group. The term "lower alkylthio" refers to alkylthio groups having from 1 to 6 carbon atoms; examples include methylthio, ethylthio, n-hexylthio, n-propylthio, isopropylthio, isobutylthio, and the like.
The term "alkylthioalkyl" refers to an alkyl group substituted with an alkylthio group. The term "lower alkylthioalkyl" refers to groups having up to a total of 8 carbon atoms and includes, for example, ethylthiomethyl, methylthiomethyl, 2-methylthiopropyl, and the like.
The term "cycloalkyl" refers to cyclic alkyl groups. The term "lower cycloalkyl" refers to groups having from 3 to 6 carbon atoms in the ring, and includes cyclopropyl, cyclobutyl, cyclopentyl, and cyclohexyl.
The term "tertiary carbon" refers to the group ##STR9## wherein R', R'" and R"" are independently lower alkyl, or R'" is an alkoxy or alkylthio group, or R'" and R"" taken together are an alkylene group, thus forming a cycloalkyl group.
The term "oxadiazolidine" refers to the ##STR10## The conventional numbering system for this group is shown below: ##STR11##
DETAILED DESCRIPTION OF THE INVENTION
(a) The compounds of the present invention where X is oxygen may be prepared according to the following reaction scheme: ##STR12## wherein R 1 , R 2 and R 3 are as previously defined in conjunction with formula I.
Reaction (1) is conducted by combining approximately equimolar amounts of the acid chloride II and thiol III. The acid chloride II is prepared from the corresponding carboxylic acid by techniques well known to the art, such as treatment with thionyl chloride. Although the reactants may be combined in any order, it is preferred to add III to II. The reaction is conducted at a temperature from about 0° C. to about 50° C., preferably from about 0° C. to about 25° C., and is generally complete within about 8 to about 12 hours. The product, IV, is isolated by conventional procedures such as extraction, stripping, chromatography, distillation, and the like.
Reaction (2) is conducted by combining IV in solvent, V, and VI. Although approximately equimolar amounts of IV and V may be used, in excess of V relative to IV may be used. Suitable solvents include protic solvents such as methanol, ethanol, other low molecular weight alcohols, water, and the like. If desired, a hydrazine hydrate, such as hydrazine monohydrate, may be used instead of anhydrous hydrazine, V and water, VI. It is preferred to drop a mixture of IV in solvent into a stirred solution of V and VI. The reaction is conducted at a temperature from about 0° C. to about 50° C., preferably from about 0° C. to about 25° C., and is generally complete within about 6 to about 8 hours. It may be desirable to cool the reaction mixture during the addition, maintaining the temperature at about 0° C. to about 5° C. The product, VII, is isolated by conventional procedures such as extraction, drying, stripping, filtration, crystallization, distillation, and the like.
Reaction (3) is conducted by combining approximately equimolar amounts of VII and VIII in solvent. The reaction is conducted at a temperature from about 0° C. to about 50° C., preferably about 0° C. to about 25° C., and is generally complete within about 8 to about 12 hours. It is preferred to add VIII slowly to a stirred mixture of VII in solvent. It is preferred to cool the reaction system during the addition, maintaining the temperature in the range of about 0° C. to about 15° C. Suitable solvents include inert organic solvents such as methylene chloride, ethyl acetate, toluene, and the like. The product, IX, is isolated by conventional procedures such as stripping, washing, extraction, filtration, drying, crystallization, distillation, and the like.
Reaction (4) is conducted by first combining approximately equimolar amounts of IX and X in solvent. The addition is conducted at a temperature from about 0° C. to about 50° C., preferably from about 0° C. to about 25° C., or, for convenience, at ambient temperature. After the addition is complete, the reaction mixture is stirred from about 6 to about 8 hours and/or refluxed about 2 to about 3 hours. Then, XI is slowly added to the reaction mixture. This addition is conducted at a temperature from about 0° C. to about 25° C., preferably from about 0° C. to about 5° C. Then, the reaction mixture may be allowed to come to ambient temperature. The reaction is conducted at a temperature from about 25° C. to about 65° C., preferably from about 25° C. to about 50° C., and is generally complete within about 3 to about 6 hours. Suitable solvents include organic solvents such as dimethoxyethane, tetrahydrofuran, and the like. The product, Ia, is isolated by conventional procedures such as washing, extraction, drying, stripping, chromatography, distillation, and the like.
Reaction (4) may also be conducted using phosgene and the appropriate dialkylamine (HNR 1 R 2 ) replacing XI.
(b) The compounds of this invention where X is sulfur are conveniently prepared by starting with the appropriate reagent II, following Reactions (1) and (2), and then proceeding according to the following synthetic scheme: ##STR13## wherein R 1 , R 2 and R 3 are as previously defined.
Reaction (5) is conducted by combining VII and XII in solvent. It is preferred to use an excess of XII relative to VII, on the order of from about 1 to 2 equivalents XII per equivalent VII due to the volatility of the carbon disulfide. It is preferred to add XII to a stirred mixture of VII in solvent. Suitable solvents include polar organic solvents such as dimethylformamide, dimethylsulfoxide, and the like. The reaction is conducted at a temperature from about 0° C. to about 50° C., preferably from about 0° C. to about 25° C., and is generally complete within about 8 to about 12 hours. The product, XIII, is isolated by conventional procedures such as filtration, stripping, extraction, and the like.
Intermediate XIII is then converted to product Ib according to Reaction (6) which is conducted in the same manner as Reaction (4).
Utility
The compounds of this invention are useful for controlling insects, particularly insects such as aphids. However, some insecticidal compounds of this invention may be more insecticidally active than others against particular pests.
Like most insecticides, they are not usually applied full strength, but are generally incorporated with conventional biologically inert extenders or carriers normally employed for facilitating dispersion of active ingredients for agricultural chemical application, recognizing the accepted fact that the formulation and mode of application may affect the activity of a material. The toxicants of this invention may be applied as sprays, dusts, or granules to the insects, their environment or hosts susceptible to insect attack. They may be formulated as granules of large particle size, powdery dusts, wettable powders, emulsifiable concentrates, solutions, or as any of several other known types of formulations, depending on the desired mode of application.
Wettable powders are in the form of finely divided particles which disperse readily in water or other dispersants. These compositions normally contain from 5-80% toxicant and the rest inert material which includes dispersing agents, emulsifying agents, and wetting agents. The powder may be applied to the soil as a dry dust or preferably as a suspension in water. Typical carriers include fuller's earth, kaolin clays, silicas, and other highly absorbent, readily wet, inorganic diluents. Typical wetting, dispersing or emulsifying agents used in insecticidal formulations include, for example, the alkyl and alkylaryl sulfonates and sulfonates and their sodium salts; alkylamide sulfonates, including fatty methyl taurides; alkylaryl polyether alcohols, sulfated higher alcohols, and polyvinyl alcohols; polyethylene oxides; sulfonated animal and vegetable oils; sulfonated petroleum oils; fatty acid esters of polyhydric alcohols and the ethylene oxide addition products of such esters; and the addition products of long-chain mercaptans and ethylene oxide. Many other types of useful surface-active agents are available in commerce. The surface-active agent, when used, normally comprises from 1-15% by weight of the pesticidal composition.
Dusts are freely flowing admixtures of the active ingredient with finely divided solids such as talc, natural clays, kieselguhr, pyrophyllite, chalk, diatomaceous earths, calcium phosphates, calcium and magnesium carbonates, sulfur, lime, flours, and other organic and inorganic solids which act as dispersants and carriers for the toxicant. These finely divided solids have an average particle size of less than about 50 microns. A typical dust formulation useful herein contains 75% silica and 25% of the toxicant.
Useful liquid concentrates include the emulsifiable concentrates, which are homogeneous liquid or paste compositions which are readily dispersed in water or other dispersants, and may consist entirely of the toxicant with a liquid or solid emulsifying agent, or may also contain a liquid carrier such as xylene, heavy aromatic naphthas, isophorone, and other nonvolatile organic solvents. For application, these concentrates are dispersed in water or other liquid carriers, and are normally applied as a spray to the area to be treated.
Other useful formulations for insecticidal applications include simple solutions of the active ingredient in a dispersant in which it is completely soluble at the desired concentration such as acetone, alkylated naphthalenes, xylene, or other organic solvents. Granular formulations, wherein the toxicant is carried on relatively coarse particles, are of particular utility for aerial distribution or for penetration of cover-crop canopy. Baits, prepared by mixing solid or liquid concentrates of the toxicant with a suitable food such as a mixture of cornmeal and sugar, are useful formulations for control of insect pests. Pressurized sprays, typically aerosols wherein the active ingredient is dispersed in finely divided form as a result of vaporization of a low-boiling dispersant solvent carrier such as the Freons, may also be used. All of these techniques for formulating and applying the active ingredient are well known in the art.
The percentages by weight of the toxicant may vary according to the manner in which the composition is to be applied and the particular type of formulation, but in general comprise 0.1-95% of the toxicant by weight of the insecticidal composition.
The insecticidal compositions may be formulated and applied with other active ingredients, including nematocides, insecticides, fungicides, bactericides, plant-growth regulators, fertilizers, etc. In applying the chemical, an effective amount and concentration of the toxicant of this invention is, of course, employed.
The terms "insecticide" and "insect" as used herein refer to their broad and commonly understood usage rather than to those creatures which, in the strict biological sense, are classified as insects. Thus, the term "insect" is used not only to include small invertebrate animals belonging to the class "Insecta", but also to other related classes of arthropods, whose members are segmented invertebrates having more or fewer than six legs, such as spiders, mites, ticks, centipedes, worms, and the like.
A further understanding of the invention can be had in the following non-limiting Examples. Wherein, unless expressly stated to the contrary, all temperatures and temperature ranges refer to the Centigrade system and the term "ambient" or "room temperature" refers to about 20°-25° C. The term "percent" refers to weight percent and the term "mol" or "mols" refers to gram mols. The term "equivalent" refers to a quantity of reagent equal in mols, to the mols of the preceding or succeeding reactant recited in that example in terms of finite mols or finite weight or volume. Also, unless expressly stated to the contrary, geometric isomer and racemic mixtures are used as starting materials and correspondingly, isomer mixtures are obtained as products.
EXAMPLES
EXAMPLE 1 ##STR14##
Ethyl Trimethylacetylthioate
Trimethylacetyl chloride, 100 g (0.83 mole), was stirred at 0° C. Then 51.5 g (0.83 mole) ethylthiol was added and stirring was continued until the mixture returned to room temperature. The reaction mixture was then heated a total of 10 hours until no more HCl evolved. The mixture was evacuated to remove any HCl; the above-identified product was then used in Example 2 without further isolation.
EXAMPLE 2 ##STR15##
Trimethylacetyl Hydrazide
A mixture of 101.5 g (0.7 mole) of ethyl trimethylacetylthioate (the product of Example 1) in 75 ml methanol was stirred. This methanol mixture was added dropwise to a stirred solution of 24.5 g (0.7 mole) hydrazine in 120 ml water. The reaction mixture was stirred over the weekend. Stripping of the solvent gave 78.1 g of the above-identified product.
EXAMPLE 3 ##STR16##
2-Tert-Butyl-1,3,4-Δ 2 -Oxadiazolidin-5-one
In a flask equipped with a thermometer, dropping funnel and mechanical stirrer, 147.8 g (0.186 mole) phosgene (about 12.5% in benzene) was placed. The reaction vessel was cooled to 15° C.; then 20 g (0.166 mole) trimethylacetyl hydrazide (the product of Example 2) in ethyl acetate (about 100 ml) was dropped in. The reaction mixture was stirred overnight. The reaction mixture was washed with a dilute sodium bicarbonate solution and then extracted with methylene chloride. The organic phase was dried and stripped to give the above-identified product.
EXAMPLE 4 ##STR17##
2-Tert-Butyl-4-Dimethylcarbamoyl-1,3,4-Δ 2 -Oxadiazolidin-5-one
To a stirred mixture of 10.5 g (0.074 mole) 2-tert-butyl-1,3,4-Δ 2 -oxadiazolidin-5-one (the product of Example 3) in 100 ml dimethoxyethane, 24.0 g of 60% sodium hydride (0.074 mole) were added slowly. After the sodium hydride reaction appeared complete, 8.0 g (0.074 mole) N,N-dimethylcarbamoyl chloride were added. The reaction mixture was refluxed 3 hours. The mixture was then washed with water and extracted with methylene chloride. The organic phase was then dried, stripped and chromatographed on silica gel, eluting with ether, to give the above-identified product as a white solid, melting point 71°-73° C.
Elemental analysis for C 9 H 15 N 3 O 3 showed: calculated %C 50.69%, %H 7.09, and %N 19.71; found %C 50.89, %H 7.24, and %N 20.11.
EXAMPLE 5 ##STR18##
2-(1-Methylcyclopropyl)-1,3,4- 2 -Oxadiazolidin-5-one
(a) A stirred mixture of 100 g (1 mole) ##STR19## 1-methylcyclopropane carboxylic acid and 150 ml ethyl ether was cooled to 5° C.; then 119 g (1 mole) thionyl chloride was added dropwise. The resulting mixture was refluxed 8 hours. The reaction mixture was cooled to 5° C.; then 62 g (1 mole) ethylthiol was added. The resulting mixture was refluxed 6 hours and then stirred over the weekend. The solvent was stripped and the product (residue) used in Step (b) without further isolation.
(b) A stirred mixture of 48 g (1.5 mole) hydrazine and 12 ml water was cooled to 5° C.; the product of Step (a) in 80 ml methanol was dropped into that mixture. The resulting mixture was stirred overnight and then stripped. Methylene chloride (about 300 ml) was added to the residue. The methylene chloride mixture was dried and stripped to give 85 g of a dark oil which crystallized upon cooling. The product, 1-methylcyclopropane carboxylic acid hydrazide, was used in Step (c) without further isolation.
(c) The crystals obtained in Step (b) were placed in a 2-liter, three-neck, round-bottom flask. Methylene chloride (about 150 ml) was added and the resulting mixture stirred until the crystals dissolved. The methylene chloride solution was cooled to 5° C.; then 590.5 g of 12.5% phosgene (0.75 mole) were dropped in. The resulting mixture was refluxed 7 hours and then stripped to give the above-identified product as a crystalline solid. The residue was washed with petroleum ether and filtered. The product was obtained as 66.6 g of light brown crystals, melting point 68°-70° C.
Elemental analysis for C 6 H 8 N 2 O 2 showed: calculated %C 51.36%, %H 5.75, and %N 20.08; found %C 51.96, %H 6.01, and %N 21.52.
EXAMPLE 6 ##STR20##
2-(1-Methylcyclopropyl)-4-Dimethylcarbamoyl-1,3,4-Δ 2 -Oxadiazolidin-5-one
To a stirred mixture of 10 g (0.07 mole) of 2-(1-methylcyclopropyl)-1,3,4-Δ 2 -oxadiazolidin-5-one (the product of Example 5) in 80 ml dimethoxyethane, 2.4 g of 60% sodium hydride (0.07 mole) were added slowly. After the reaction appeared complete, 7.5 g (0.07 mole) N,N-dimethylcarbamoyl chloride were added and the resulting mixture refluxed about 6 hours. Additional sodium hydride (about 0.5 g) was added and the mixture refluxed for about 6 hours. The reaction mixture was washed with water (300 ml) containing 1.9 g ammonium chloride) and then extracted with methylene chloride. The methylene chloride phase was dried and stripped. Chromatography on silica gel, eluting with ether, gave the product as a yellow oil.
Elemental analysis for C 9 H 13 N 3 O 3 showed: calculated %C 51.18%, %H 6.2, and %N 19.9; found %C 50.76, %H 6.3, and %N 19.48.
EXAMPLE 7 ##STR21##
Ethyl Methoxyacetylthioate
To stirred 2-methoxyacetyl chloride, 100 g (0.92 mole), 58 g (0.92 mole) ethanethiol were added dropwise. The reaction mixture was refluxed 8 hours and then stirred over the weekend. Ether (about 300 ml) was poured in, and the resulting mixture stripped under high vacuum to give 77.5 g of product. The product was used in Example 8 without further isolation.
EXAMPLE 8 ##STR22##
2-Methoxymethyl-1,3,4-Δ 2 -Oxadiazolidin-5-one
A stirred mixture of 18.50 g (0.58 mole) hydrazine and 10 ml water was cooled to 0° C.; a mixture of 77.5 g (0.58 mole) of ethyl methoxyacetylthioate (the product of Example 7) in 75 ml methanol was added dropwise. The reaction mixture was stirred overnight. The mixture was stripped and the residue dissolved in methylene chloride. The methylene chloride solution was dried with magnesium sulfate and stripped. The residue was placed in a flask with about 150 ml methylene chloride and cooled to 0° C.; 329.5 g of 12.5% phosgene (0.42 mole) were then slowly dropped in. The reaction mixture was refluxed 31/2 hours and then stirred overnight. The reaction mixture was washed with water, dried over magnesium sulfate and stripped to give the above-identified product.
Elemental analysis for C 4 H 6 N 2 O 3 showed: calculated %C 36.93%, %H 4.65, and %N 21.53; found %C 40.93, %H 5.28, and %N 21.17.
EXAMPLE 9 ##STR23##
2-Methoxymethyl-4-Dimethylcarbamoyl-1,3,4-Δ 2 -Oxadiazolidin-5-one
To a stirred mixture of 10 g (0.077 mole) of 2-methoxymethyl-1,3,4-Δ 2 -oxadiazolidin-5-one (the product of Example 8) in 150 ml dimethoxyethane, 2.6 g of 60% sodium hydride were added slowly. The resulting mixture was stirred overnight. Then 8.3 g (0.077 mole) N,N-dimethylcarbamoyl chloride were added to the mixture. The resulting mixture was refluxed 5 hours. The mixture was cooled, washed with water and extracted with methylene chloride. The methylene chloride phase was dried and stripped to give the product as a yellow oil.
Elemental analysis for C 7 H 11 N 3 O 4 showed: calculated %C 41.79%, %H 5.51, and %N 20.89; found %C 46.62, %H 6.35, and %N 19.51.
EXAMPLE 10 ##STR24##
Ethyl 2-Methylthio-Isobutyrate
(a) Into a solution of 52 g (0.8 mole) potassium hydroxide dissolved in 900 ml ethanol, 36.8 g methanethiol were bubbled to give a potassium mercaptide mixture which was used in Step (b).
(b) To 600 ml ethanol in a 2-liter, three-neck flask equipped with mechanical stirrer and dropping funnel with ice bath for cooling, 157.2 g (0.8 mole) ethyl 2-bromoisobutyrate were added. The mixture from Step (a) was then dropped in. The reaction mixture was stirred overnight. The reaction mixture was filtered and the filtrate stripped to give 84 g of the above-identified product.
EXAMPLE 11 ##STR25##
Ethyl 2-Methylthio-Isobutyrylthioate
(a) To a stirred mixture of 111 g (0.68 mole) ethyl 2-methylthio-isobutyrate (the product of Example 10) and 350 ml water, 55 g of 50% sodium hydroxide (0.68 mole) were added; the resulting mixture was stirred overnight. Concentrated hydrochloric acid was added to the reaction mixture to give a pH of about 3. The reaction mixture was extracted twice with methylene chloride. The organic phase was dried and stripped to give 71 g of product which was used in Step (b) without further isolation.
(b) The product of Step (a), 71 g, was placed in a flask and stirred. After cooling to about 10° C., 63 g (0.53 mole) thionyl chloride were added slowly dropwise. The resulting mixture was refluxed 8 hours (to remove HCl gas) and then stirred overnight at ambient temperature. The reaction mixture was cooled to about 10° C.; then 33 g (0.53 mole) ethanethiol were slowly dropped in. The reaction mixture was refluxed 8 hours and then stirred overnight at ambient temperature. The product was used in Example 12 without further isolation and/or purification.
EXAMPLE 12 ##STR26##
2-Methylthio-Isobutyryl Hydrazide
To a stirred mixture of 21.6 g (0.67 mole) hydrazine in 14 ml water cooled to about 0° C., 80 g (0.45 mole) ethyl 2-methylthio-isobutyrylthioate (the product of Example 11) in 250 ml methanol were slowly dropped in, maintaining the temperature of the reaction mixture at about 0° C. during the addition. The reaction mixture was stirred overnight and then stripped. Methylene chloride was added to the residue. The methylene chloride solution was dried with magnesium sulfate, filtered and stripped to give 61.3 g of the above-identified product as a black oil.
EXAMPLE 13 ##STR27##
2-(2-Methylthio-Isopropyl)-1,3,4-Δ 2 -Oxadiazolidin-5-one
A stirred mixture of 60.5 g (0.408 mole) of 2-methylthio-isobutyryl hydrazide (the product of Example 12) was cooled to 5° C. Then 323 g of 12.5% phosgene (0.408 mole) was added dropwise. The reaction mixture was refluxed 5 hours, stirred overnight and then refluxed an additional 2 hours. The reaction mixture was cooled and then stripped. Methylene chloride (about 200 ml) was added to the residue. The resulting mixture was washed with water and the layers separated. The organic layer was dried over magnesium sulfate, filtered and stripped to give 60 g of the product as a black oil.
Elemental analysis for C 6 H 10 N 2 O 2 S showed: calculated %C 41.36%, %H 5.78, and %N 16.08; found %C 42.88, %H 6.4, and %N 15.5.
EXAMPLE 14 ##STR28##
2-(2-Methylthio-Isopropyl)-4-Dimethylcarbamoyl-1,3,4-Δ 2 -Oxadiazolidin-5-one
To a stirred solution of 10 g (0.057 mole) 2-(2-methylthio-isopropyl-1,3,4-Δ 2 -oxadiazolidin-5-one (the product of Example 13) in dimethoxyethane, 2 g of 60% sodium hydride (0.057 mole) were slowly added. The reaction mixture was heated 45 minutes at about 50° C.; then 6.2 g (0.057 mole) N,N-dimethylcarbamoyl chloride were added. The resulting mixture was refluxed 31/2 hours and then stirred overnight. The mixture was washed with water and then extracted with methylene chloride. The methylene chloride phase was dried, stripped and then chromatographed on silica gel, eluting with ether, to give the product as an amber oil.
Elemental analysis for C 9 H 15 N 3 O 3 S showed: calculated %C 44.07%, %H 6.16, and %N 17.13; found %C 44.84, %H 6.53, and %N 17.44.
EXAMPLE 15 ##STR29##
2-(1-Methylcyclopropyl)-1,3,4-Δ 2 -Oxadiazolidin-5-thione
To a stirred mixture of 88 g (0.77 mole) 1-methylcyclopropane carboxylic acid hydrazide in 50 ml dimethylformamide, 87.8 g (1.2 mole) carbon disulfide were added dropwise. The reaction mixture was stirred overnight and then refluxed 3 hours. The reaction mixture was filtered and then stripped to give the above-identified product as a solid, melting point 91°-93° C.
Elemental analysis for C 6 H 8 N 2 OS showed: calculated %C 46.13%, %H 5.16, and %N 17.93; found %C 46.3, %H 5.34, and %N 18.94.
EXAMPLE 16 ##STR30##
2-(1-Methylcyclopropyl)-4-Dimethylcarbamoyl-1,3,4-Δ 2 -Oxadiazolidin-5-thione
To a stirred mixture of 10 g (0.064 mole) 2-(1-methylcyclopropyl)-1,3,4-Δ 2 oxadiazolidin-5-thione (the product of Example 15) in 150 ml dimethoxyethane, 2.2 g of 60% sodium hydride were added slowly. The resulting mixture was refluxed 1 hour and then cooled. To that mixture, 6.9 g (0.064 mole) N,N-dimethylcarbamoyl chloride were added; the reaction mixture was then refluxed 3 hours. After being cooled, the reaction mixture was washed with water and extracted with methylene chloride. The methylene chloride fraction was dried over magnesium sulfate and then stripped. Chromatography on silica gel, eluting with ether, gave the product as a yellow oil.
Elemental analysis for C 9 H 13 N 3 O 2 S showed: calculated %C 47.56%, %H 5.76, and %N 18.49; found %C 50.64, %H 6.17, and %N 19.15.
Compounds made in accordance with Examples 1 to 14 are found in Table I.
In addition, by following the procedures described in Examples 1 to 16 and using the appropriate starting materials, the following compounds are made:
2-cyclobutyl-4-dimethylcarbamoyl-1,3,4-Δ 2 -oxadiazolidin-5-one;
2-(1-methylcyclobutyl)-4-dimethylcarbamoyl-1,3,4-Δ 2 -oxadiazolidin-5-one; and
2-(1-methylcyclobutyl)-4-dimethylcarbamoyl-1,3,4-Δ 2 -oxadiazolidin-5-thione.
EXAMPLE A
Aphid Control
The compounds of the invention were tested for their insecticidal activity against Cotton Aphids (Aphis gossypii Glover). An acetone solution of the candidate toxicant containing a small amount of nonionic emulsifier was diluted with water to 40 ppm. Cucumber leaves infested with the Cotton Aphids were dipped in the toxicant solution. Mortality readings were taken after 24 hours. The results are tabulated in Table II in terms of percent control.
EXAMPLE B
Aphid Systemic Evaluation
This procedure is used to assess the ability of a candidate insecticide to be absorbed through the plant root system and translocate to the foliage.
Two cucumber plants planted in a 4-inch fiber pot with a soil surface area of 80 cm 2 are used. Forty ml of an 80-ppm solution of the candidate insecticide is poured around the plants in each pot. (This corresponds to 40 γ/cm 2 of actual toxicant.) The plants are maintained throughout in a greenhouse at 75°-85° F. Forty-eight hours after the drenching, the treated plants are infested with aphids by placing well-colonized leaves over the treated leaves so as to allow the aphids to migrate easily from the inoculated leaf to the treated leaf. Three days after infestation, mortality readings were taken. The results are tabulated in Table II in terms of percent control.
EXAMPLE C
Mite Adult
Two-spotted Mite (Tetranychus urticae):
An acetone solution of the candidate toxicant containing a small amount of nonionic emulsifier was diluted with water to 40 ppm. Lima bean leaves which were infested with mites were dipped in the toxicant solution. Mortality readings were taken after 24 hours. The results are tabulated in Table II in terms of percent control.
EXAMPLE D
Mite Egg Control
Compounds of this invention were tested for their ovicidal activity against eggs of the two-spotted spider mite (Tetranychus urticae). An acetone solution of the test toxicant containing a small amount of nonionic emulsifier was diluted with water to give a concentration of 40 ppm. Two days before testing, 2-week-old lima bean plants were infested with spider mites. Two days after infestation, leaves from the infested plants were dipped in the toxicant solution, placed in a petri dish with filter paper and allowed to dry in the open dish at room temperature. The treated leaves were then held in covered dishes at about 31° C. to 33° C. for seven days. On the eighth day, egg mortality readings were taken. The results, expressed as percent control, are tabulated in Table II.
EXAMPLE E
Housefly
Housefly (Musca domestica L.): A 500-ppm acetone solution of the candidate toxicant was placed in a microsprayer (atomizer). A random mixture of anesthetized male and female flies were placed in a container and 55 mg of the above-described acetone solution was sprayed on them. A lid was placed on the container. A mortality reading was made after 24 hours. The results are tabulated in Table II in terms of percent control.
EXAMPLE F
American Cockroach
American Cockroach (Periplaneta americana L.): A 500-ppm acetone solution of the candidate toxicant was placed in a microsprayer (atomizer). A random mixture of anesthetized male and female roaches was placed in a container and 55 mg of the above-described acetone solution was sprayed on them. A lid was placed on the container. A mortality reading was made after 24 hours. The results are tabulated in Table II in terms of percent control.
EXAMPLE G
Alfalfa Weevil
Alfalfa Weevil (H. brunneipennis Boheman): A 500-ppm acetone solution of the candidate toxicant was placed in a microsprayer (atomizer). A random mixture of anesthetized male and female flies was placed in a container and 55 mg of the above-described acetone solution was sprayed on them. A lid was placed on the container. A mortality reading was made after 24 hours. The results are tabulated in Table II in terms of percent control.
EXAMPLE H
Cabbage Looper Control
The compounds of the invention were tested for their insecticidal activity against Cabbage Looper (Trichoplusia ni). An acetone solution of the candidate toxicant containing a small amount of nonionic emulsifier was diluted with water to 500 ppm. Excised cucumber leaves were dipped in the toxicant solution and allowed to dry. They were then infested with Cabbage Looper larvae. Mortality readings were taken after 24 hours. The results are tabulated in Table II in terms of percent control.
TABLE I__________________________________________________________________________Compounds of the Formula: ##STR31## ELEMENTAL ANALYSIS % Carbon % Hydrogen % NitrogenCompound No. X R.sup.1 R.sup.2 R.sup.3 Physical State Calc. Found Calc. Found Calc. Found__________________________________________________________________________1 33157 O CH.sub.3 CH.sub.3 CH.sub.3 Tan Solid, 42.1 42.28 5.3 5.58 24.55 24.24 m.p. 58-61° C.2 33047 O CH.sub.3 CH.sub.3 C(CH.sub.3).sub.3 White Solid, 50.69 50.89 7.09 7.24 19.71 20.11 m.p. 71-73° C. 3 33286 O CH.sub.3 CH.sub.3 ##STR32## White Solid, m.p. 62-64° C. 48.73 48.64 5.62 5.87 21.31 20.934 34332 O CH.sub.3 CH.sub.3 ##STR33## Yellow Oil 51.18 50.76 6.2 6.3 19.9 19.48 5 33904 O CH.sub.3 CH.sub.3 ##STR34## Yellow Oil 53.32 54.5 6.71 6.93 18.66 18.0 6 33557 O CH.sub.3 CH.sub.3 ##STR35## Yellow Oil 55.22 54.61 7.16 7.09 17.56 16.75 7 34333 O CH.sub.3 CH.sub.3 ##STR36## Yellow Oil 56.9 56.91 7.56 7.61 16.59 16.13 8 35139 S CH.sub.3 CH.sub.3 ##STR37## Yellow Oil 47.56 50.64 5.76 6.17 18.49 19.15 9 35682 S CH.sub.3 CH.sub.3 ##STR38## Yellow Oil 53.51 52.34 7.11 7.24 15.6 15.92 10 34019 O CH.sub.3 CH.sub.3 CH.sub.2 OCH.sub.3 Yellow Oil 41.8 46.6 5.51 6.35 20.89 19.5111 34246 O CH.sub.3 CH.sub.3 C(CH.sub.3).sub.2 SCH.sub.3 Amber Oil 44.07 44.84 6.16 6.53 17.13 17.44__________________________________________________________________________
TABLE II______________________________________CompoundNo. A AS MA ME HF AR AW CL______________________________________1 33157 90 0 0 0 15 0 30 02 33047 100 100 0 0 100 100 90 103 33286 96 0 0 0 78 39 0 04 34332 100 0 0 0 99 100 50 05 33904 -- 0 0 0 75 78 10 306 33557 96 0 0 0 0 0 0 07 34333 100 100 0 0 0 100 30 08 35139 90 0 0 0 0 0 0 09 35682 78 0 0 96 0 0 0 010 34019 100 0 0 0 94 10 0 011 34246 100 100 94 0 99 100 90 20______________________________________ A = Aphid AS = Aphid Systemic MA = Mite Adult ME = Mite Egg HF = Housefly AR = American Cockroach AW = Alfalfa Weevil CL = Cabbage Looper
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Compounds of the formula: ##STR1## wherein X is oxygen or sulfur; R 1 and R 2 are independently lower alkyl having from 1 to 4 carbon atoms; and R 3 is lower alkyl having from 1 to 6 carbon atoms, lower cycloalkyl having from 3 to 6 carbon atoms optionally substituted with methyl or ethyl, lower alkoxyalkyl having up to a total of 8 carbon atoms or lower alkylthioalkyl having up to a total of 8 carbon atoms are insecticidal.
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BACKGROUND
1. Technical Field
The disclosure relates to a transition mode (TM) power factor corrector (PFC) power converter adapted to switch from a DCM (discontinuous current mode) to a CCM (continuous current mode) under high load.
2. Description of the Related Art
Transition mode (also known as quasi resonant) boost power factor corrector devices (PFC) function in a discontinuous current mode (DCM) and have a high efficiency. However, for a same average current value, in DCM the power transfer current reaches higher peak values of than in a switching power converter functioning in a continuous current mode (CCM). This is due to the fact that the transition mode peculiarity of requiring a nullification of the current in the inductor at every switching cycle has the drawback of producing a current ripple of amplitude that is about twice the value of the waveform of the average current.
In a PFC (power factor correction) power converter there is a current loop through a boost inductor from where a loop signal is derived for implementing an effective and reliable control of the output DC voltage. In transition mode, a constant on-time control timer of the switch of the boost inductor is generally employed for regulating the power transfer to track load requirements. Commonly, the on-time interval of the switch is set in function of the output voltage. Therefore, if the load remains constant the on-time remains constant too.
Switching from the discontinuous current mode of a TM-PFC circuit to a continuous current mode of operation for reducing the ripple amplitude specially under heavy load conditions is desirable.
The ability to switch from a DCM (discontinuous current mode) to a CCM (continuous current mode) under high load conditions generally requires a complex control circuitry, given that the common technique, based on an on-time control timer of the switch of the boost inductor, relies on a null initial current for obtaining a current proportional to the instantaneous input voltage and thus is unsuitable.
The document, Publ. No. U.S. 2013/0141056-A1, addresses a specific problem of difference between current loop gains when the PFC power converter operates in a CCM (continuous current mode) and in a DCM (discontinuous current mode).
An effective, though much simplified control method for reliably and efficiently switching a from DCM to CCM a transition mode (TM) power factor corrector (PFC) power converter is highly desired.
BRIEF SUMMARY
An exemplary embodiment of a control circuit of a transition mode (TM) power factor corrector (PFC) power converter adapted to switch from a DCM (discontinuous current mode) to a CCM (continuous current mode) when the instantaneous current in the inductor reaches a threshold value, of outstandingly simple implementation is provided.
The transition mode (TM) power factor correction device typically comprises a boost inductor, a switch, a diode, an output tank capacitor, circuit means for sensing a condition of zero current in the inductor, circuit means for turning on the switch when a zero current condition through the inductor is detected and for turning off the switch after a set on-time interval (Ton) has elapsed.
According to this disclosure, dedicated circuit means limit the off-time interval of the switch to a fraction of a complementary off-time interval (Toff) of the switch during part of a cycle of a rectified sinusoidal voltage waveform input to the converter, when the current flowing in the inductor reaches a given maximum threshold.
Generally, the maximum off-time may be limited to Toff=Toff 0 sin θ/sin θ 0 , in correspondence of a central portion of the input line voltage cycle given by: θ=π−θ 0 , where Toff 0 is the off-time interval measured at the phase angle θ 0 of the input sinusoid, at which said maximum current threshold is reached, thus causing the mode of operation of the device to switch from TM to CCM for a phase angle interval region of a rectified sinusoidal input voltage waveform centered on π/2 as defined by said maximum current threshold, under high load conditions.
An exemplary embodiment of a method for controlling a power factor correction (PFC) converter is also provided. The method comprises the steps of:
(a) setting a maximum off-time timer of the switch of the boost inductor to a value beyond any expected maximum off-time value or to infinity;
(b) sensing the current flowing in the inductor and issuing an interrupt request (IRQ) signal to a microcontroller when the current reaches a set maximum threshold;
(c) measuring the off-time of the switch after said IRQ or at every switching cycle;
(d) setting said maximum off-time timer to a maximum off-time limit corresponding to the off-time measured at the instant of generation of said IRQ or measured during a switching cycle antecedent said instant of generation of the IRQ, according to the option of step c);
(e) either maintaining the maximum off-time limit setting of said timer for twice the duration of the sinusoidal input voltage waveform decreased by the time elapsed to the instant of generation of a first IRQ or updating the off-time limit setting, according to the option of step c), for a central portion of a sinusoidal input voltage waveform; and
(f) resetting the maximum off-time limit to said value beyond any expected maximum value or to infinity.
Of course, the maximum current threshold that may be set at the design stage or programmed depending on the contemplated specific conditions of relatively high current loads, will determine at which load the PFC circuit will begin undergoing a switching from DCM to CCM at or in the neighborhood of the peak (i.e., at π/2) of a rectified sinusoidal input voltage waveform, and the angular breath of such a middle region of the input waveform, during which the CCM mode of operation will be retained.
A detailed description is given in the following embodiments with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
The disclosure may be more fully understood by reading the subsequent detailed description and examples with references made to the accompanying drawings, wherein:
FIG. 1 shows the basic circuit of a PFC power converter;
FIG. 2 shows DCM waveforms of relevant signals of the basic circuit of FIG. 1 ;
FIG. 3 shows the typical discontinuous current waveform for an input line cycle of a rectified AC sinusoidal feed voltage input to the PFC power converter operating in a transition mode (TM);
FIG. 4 shows a current waveform for a cycle of a rectified AC sinusoidal feed voltage input to the PFC power converter switching from an initial discontinuous current mode of operation to a continuous current mode of operation according to a first exemplary embodiment of this disclosure;
FIG. 5 shows a current waveform for a cycle of a rectified AC sinusoidal feed voltage input to the PFC power converter switching from an initial discontinuous current mode of operation to a continuous current mode of operation according to a second exemplary embodiment of this disclosure of a further simplified implementation;
FIG. 6 shows an exemplary embodiment of a basic implementing circuit.
DETAILED DESCRIPTION
The following description has the purpose of illustrating the general principles of the disclosure being claimed and should not be taken in a limiting sense. The scope of the disclosure is best determined by reference to the appended claims.
The peculiar aspects of this disclosure are here after described for the case of one of common PFC circuit configurations though the characteristic features of the disclosure that will be described may be embodied in any other PFC circuit configuration commonly being used by adapting, in the described exemplified manner, the control circuit of the transition mode (TM) power factor corrector (PFC) power converter to make it switch from a DCM (discontinuous current mode) to a CCM (continuous current mode) under heavy load.
Basically, a common example as depicted in FIG. 1 , a transition mode (TM) power factor correction device comprises a boost inductor L, a switch M, a diode D, an output tank capacitor Cout and a zero crossing detector for sensing a condition of zero current (or zero crossing) in the boost inductor.
In the contemplated example, an auxiliary winding Laux is magnetically coupled with the inductor as one exemplary way of implementing the zero crossing detector for sensing a condition of zero current (or zero crossing) in the boost inductor. However, other ways, equally familiar to the skilled reader, may be chosen, for example a sense resistor in a recirculation current path of the boost inductor through the ground node may be used in lieu of an auxiliary winding. Control circuit means, commonly based on a microcontroller, may be used for controlling the generation and delivery of a drive signal to the GD node, commonly a square wave, for turning on the switch M when a zero current condition through the inductor is detected (in the considered example by monitoring the voltage on the ZCD sense node), and for turning off the switch after an on-time interval (Ton) timer set by the controller has elapsed. On the sense node CS may be monitored the current that charges the boost inductor L during the on-time pulse applied to the gate of the switch M.
The basic circuit of FIG. 1 , also shows a common condition of direct AC line feed of the switching PFC power converter through a full bridge rectifier and filter capacitor C 1 .
In FIG. 2 are depicted the waveforms of relevant signals of the PFC circuit of FIG. 1 according to a typical transition mode (TM) (some time referred to as “quasi resonant switching mode” in the related technical literature) of operation of the circuit.
The drive signal V GS of the diode M is a square wave. In transition mode, each time the switch is turned on and then off, the controller waits for the current on the boost inductor L to reach zero before turning on again the switch. The timing diagrams illustrate how the turn on instant is controlled in order to produce a transition mode.
As graphically emphasized in FIG. 2 , when the current reaches zero, a resonance is stimulated that has the effect of decreasing the voltage V DS on the drain of the switch M thus ensuring a so-called “soft switching” (i.e., at null current and reduced voltage).
In the considered example, the voltage Vaux on the auxiliary winding Laux is proportional to the voltage on the boost inductor L. When the current through the diode D becomes null, it initially reverses its direction and, after recovery, the diode stops conducting. At this point, the current in the inductor L that has assumed a negative sign discharges the drain/source capacitance of the switch M thus favoring a soft switching. Because of the proportionality of Vaux with the voltage on the inductor L, the auxiliary winding Laux is exploited for detecting when the drain/source capacitance is discharging itself in order to switch on again M at the correct instant.
FIG. 3 shows the typical discontinuous current waveform for a cycle of a rectified AC sinusoidal feed voltage input to the PFC power converter operating in a transition mode (TM). The output DC power and input current waveform are controlled by regulating the duration of the on-pulse of the gate drive signal of the switch. The on-time interval of the switch is commonly set by the controller in function of the output voltage. Therefore, if the load remains constant the on-time remains constant too. Because the current at the beginning of the cycle is constant, the peak current is Ton*Vin/L, that is it is proportional to the input voltage (which is in fact the target behavior of a PFC). In this respect, a constant on-time is unsuited for a continuous current mode because it relies on a zero initial current to obtain a current pulse of amplitude proportional to the input line voltage.
The transition mode peculiarity of requiring a nullification of the current I L in the inductor at every switching cycle, has the drawback of producing a current ripple of amplitude that is about twice the average value of the power transfer current (i.e., the average current).
At heavy load, the current peaks may reach large amplitudes and this has several undesirable effects:
1. the boost inductor M must be dimensioned such to exclude the possibility of saturating and the relatively large amplitude of the current peaks in transition mode of operation of the PFC circuit dictates a significant “oversizing” if related to the average current amplitude;
2. a large ripple as typical of a transition mode of operation of the PFC circuit imposes the use of large (electromagnetic interference (EMI) filters.
Switching to a CCM mode when the amplitude of the current peaks surpasses a design threshold value reduces both the above noted effects, allowing significant reduction of size and cost of inductors and EMI filters.
According to an embodiment of the method herein disclosed, the following steps are implemented:
(a) setting a maximum off-time timer of the switch of the boost inductor to a value beyond any expected maximum off-time value or to infinity;
(b) sensing the current flowing in the inductor and issuing an IRQ signal to a microcontroller when the current reaches a set maximum threshold;
(c) measuring the off-time of the switch after said IRQ or at every switching cycle;
(d) setting said maximum off-time timer to a maximum off-time limit corresponding to the off-time measured at the instant of generation of said IRQ or measured during a switching cycle antecedent said instant of generation of the IRQ, according to the option of step c);
(e) either maintaining the maximum off-time limit setting of said timer for twice the duration of the sinusoidal input voltage waveform decreased by the time elapsed to the instant of generation of a first IRQ or updating the off-time limit setting, according to the option of step c), for a central portion of a sinusoidal input voltage waveform; and
(f) resetting the maximum off-time limit to said value beyond any expected maximum value or to infinity.
By this method of simple implementation, the off-time of the switch may, according to a first exemplary embodiment, be limited to Toff=Toff 0 sin θ/sin θ 0 , during a central portion of the input line voltage cycle given by θ=π−θ 0 , where Toff 0 is the off-time interval measured at the phase angle θ 0 , of the input sinusoid at which said maximum current threshold is reached. Of course, the controller has means for determining the phase angle θ 0 at the instant of at least said first IRQ.
The resultant current waveform for a cycle of a rectified AC sinusoidal voltage input to the PFC power converter is depicted in FIG. 4 . The effects of switching from an initial discontinuous current mode of operation to a continuous current mode of operation for a central portion of the input line cycle defined by the set value of maximum current threshold are evident. In particular the “compression” of the amplitude of the current peaks and the accompanying increment-decrement of the switching frequency.
According to an alternative embodiment that entails a reduced calculation complexity by the controller, the off-time of the switch may be limited to Toff=Toff 0 ((π/2−θ 0 /π/2), during the same central portion of the input line cycle given by θ=π−θ 0 . The resultant current waveform for a cycle of a rectified AC sinusoidal voltage input to the PFC power converter is depicted in FIG. 5 . The effects of switching from an initial discontinuous current mode of operation to a continuous current mode of operation for the central portion of the input line cycle, defined by the set value of maximum current threshold are evident also for this alternative embodiment of reduced calculation burden.
An exemplary embodiment of hardware implementation is illustrated in the circuit diagram of FIG. 6 .
A classical control circuit based on the use of a “TON timer” for controlling the duration of the on time interval of the switch M that is set by a controller μC, completing a common, output voltage regulation loop (not shown in the drawing, being immediately figured out by any expert technician), may be modified as shown and described herein below for implementing the method of this disclosure.
A comparator “Comp” of a sense signal proportional to the current flowing through the switch M during a charge phase of the inductor L, issues a logic signal that is sent to an IRQ input pin of the controller μC, when the sensed current reaches a maximum current threshold value Imax. The threshold Imax may be set in a hardwired fashion when designing the PFC circuit or programmed through the controller μC.
A “TOFFmax timer” of the off-time following a turning on instant of the switch (M) is set by default by the controller μC to a limit count amply exceeding any possible situation or to infinity (e.g., by disabling the counter output).
An “Off-time measurement” counter provides a measure of the off-time interval following every turning on instant of the switch M to the controller μC that resets it and, on the basis of the angular position relative to the rectified AC sinusoidal voltage waveform at the triggering instant of the IRQ signal and of the last measured or next measured off-time interval Toff, calculates a maximum off-time limit count at which it sets the “TOFFmax timer”.
Such a calculated maximum off-time limit may be maintained for twice the duration of the sinusoidal input voltage waveform, decreased by the time elapsed to the instant of generation of a first IRQ, that is to say for a whole central portion of the rectified sinusoidal input voltage waveform before a new default setting. Alternatively, the maximum off-time limit may be calculated at every switching cycle and repeatedly updated in the “TOFFmax timer” for the whole central portion of the rectified sinusoidal input voltage waveform, at the end of which the timer is again set to the default value.
Other “intermediate” options may also be satisfactory, keeping in mind that a repeated updating will favor a more precise tracking of the input sinusoid.
While the disclosure has been described by way of example and in terms of the preferred embodiments, it is to be understood that the disclosure is not limited to the disclosed embodiments. To the contrary, it is intended to cover various modifications and similar arrangements (as would be apparent to those skilled in the art). Therefore, the scope of the appended claims should be accorded the broadest interpretation so as to encompass all such modifications and similar arrangements.
The various embodiments described above can be combined to provide further embodiments. These and other changes can be made to the embodiments in light of the above-detailed description. In general, in the following claims, the terms used should not be construed to limit the claims to the specific embodiments disclosed in the specification and the claims, but should be construed to include all possible embodiments along with the full scope of equivalents to which such claims are entitled. Accordingly, the claims are not limited by the disclosure.
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A transition mode power factor correction converter comprising a boost inductor, a switch, a diode, and output tank capacitor, has circuit means of limitation of the off-time interval of the switch to a fraction of the off-time interval, “complementary” to the on-time interval that is normally controlled for regulating the output voltage, during part of a cycle of a rectified sinusoidal voltage waveform input to the converter, when the current flowing in the inductor reaches a maximum threshold, causing the mode of operation of the device to switch from transition mode to continuous current mode for a middle phase angle region of a rectified sinusoidal input voltage waveform, under high load conditions, defined by said maximum current threshold. Current peaks amplitude and ripple are effectively reduced for same output power.
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BACKGROUND OF THE INVENTION
This invention relates to the well-known computer control device that is commonly referred to, and known as a mouse.
Those familiar with personal computers know that a “mouse” is actually a computer input device that is used for a variety of tasks. Among other things, a mouse provides a pointing device metaphor that is used to identify (and initiate) executable programs, locate or place an insertion point icon in a document, discard files by “dragging and dropping” a file icon into a metaphorical trash can. A mouse can also be used to control the scrolling action of a screen and the images displayed thereon by software executing on a computer's processor. A mouse can also be used to select files to open or close; delete or retrieve files as well as shut down the computer to which it is coupled. A mouse and the on-screen icon it uses, is sometimes referred to as a pointing device in that it's on-screen icon is usually used to identify (or point to) one or more icons representing file or program metaphors (icons).
A computer mouse on-screen icon moves about the screen in response to the physical movement of the mouse across a surface, such as a table or desk. In other words, if a computer mouse is moved left, computer software causes its on-screen icon to also move left, generally in an amount directly related to the distance that the mouse moved across the surface. Moving a mouse right across a surface usually causes the onscreen mouse icon to also move right.
On-screen mouse icon movement is typically achieved by way of electrical signals that are output from a mouse device in response to its actual physical movement. Signals from the mouse can be made to change in response to physical movement by using either a track ball mechanism that rotates small potentiometers or using more sophisticated optical position sensors that can “see” movement of a surface with respect to the mouse.
An optical mouse is known art and is disclosed in at least U.S. Pat. No. 5,994,710 for a “Scanning Mouse for a Computer System,” which is incorporated herein by reference. In particular, however, the teachings of U.S. Pat. No. 5,994,710 that relate to optically sensing (detecting) movement of the mouse and the optical scanning of images thereon is incorporated herein by reference. An optical mouse which detects movement over a surface and which is also capable of reading optically encoded information would be an improvement over the prior art. A mouse having an optical scanning and bar code reading capability might prove to be valuable in the Internet age.
SUMMARY OF THE INVENTION
There is provided an optical mouse (for use as a pointing device with a computer) that is combined with a bar code scanner. One or more optical image sensors in combination with electronic circuitry, detects physical movement of the mouse and also detects the lines and spaces that comprise a bar code.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a simplified block diagram of a combination optical mouse and bar code scanner.
FIG. 2 depicts a simplified representation of a bar code detector circuit.
FIG. 3 shows another simplified representation of a bar code detector circuit.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
U.S. Pat. No. 5,994,710 to Knee et al, for a “Scanning Mouse for a Computer System” (the '710 patent) discloses a combination optical mouse and optical scanner. A charge coupled device (CCD) or contact image sensor (CIS) is used to sense movement of the mouse over a surface as well as “read” (scan) images into a digital representation of them. Images on a surface are scanned by a linear CIS mounted within a mouse and read into a computer a line at a time (the scanned line “width” corresponding to the length of the CIS) such that by repetitively sweeping the CIS over an image, successive passes of the mouse/scanner enables an entire image to eventually be scanned into the computer. The teachings of the '710 patent are incorporated herein by reference, particularly the teachings with respect to optically detecting movement and scanning images and as enabled by the apparatus depicted in FIG. 3 (of the '710 patent) thereof.
FIG. 1 of the instant application shows a simplified block diagram of the functional elements of an example of a combined optical mouse and bar code scanner 100 . Like the '710 patent, a light source 102 , provides a source of light that illuminates images (not shown) on a surface 104 over which the mouse is moved. Light waves from the light source 102 are reflected from the surface 104 and focused by a lens 106 onto an analog image detector array 108 .
The image array 108 produces an analog output voltage that is representative of the reflected and focused image. An analog-to-digital converter (A/D) 110 produces digital scan data that is representative of an image that was scanned.
Digital output from the A/D 110 is routed to an optical navigation circuit 114 , which detects physical movement of the mouse over a surface. Digital output from the A/D 110 is also routed to a bar code line and space detector 112 (hereafter “bar code detector”).
A simplified example of a bar code detector circuit 200 is shown in FIG. 2 . Row-by-row and column-by-column pixel data 202 from the A/D converter 110 (or other source of pixel data) is latched in a data latch 204 . A latch enable signal 206 can be used to clock data into the latch 204 by the controller 124 so that a data value 208 can be read at some later time for subsequent processing.
In one embodiment, the controller 124 can latch all of the pixels from the image array 108 (after being digitized) and write both the pixel data and the pixel data row and column address information into an array such that the value of each pixel can be recovered by the stored row and column address of each pixel. As a new image is acquired by the image array 108 (as the mouse is moved across a surface) a new value for each pixel, at each address can also be stored. By comparing successive values for one or more pixels, the presence or absence of a bar code line can be determined.
In an alternate embodiment, one pixel (or a subset or a closely spaced cluster of all pixels) can read from the image array 108 for analysis to determine if the mouse is over (and therefore scanning) a bar code. As that particular pixel data (or the pixels of the chosen subset or cluster are read) is read, it can be latched in the data latch 204 . As successive data values for that one pixel (or for successive values for the pixels of the chosen subset) are read, they can be tested (for values representing dark and light area) to determine if they represent the presence or absence of a bar code line. In yet another embodiment, pixel data values might be averaged over time or distance (movement of the mouse) in the process of deciding if a bar code line or space is being detected. Averaging or using clusters of pixels can effectively degrade the detected contrast between light and dark image regions. Whether to use or calculate pixel data averages or to use clusters of pixels is a design choice as well as is methodology employed in the calculations thereof. Optimum values and methods will be subject to some experimentation.
By using a data latch 204 and reading data from it into memory, image data processing, which might be done by the computer to which the mouse is coupled or the controller 124 within the mouse, can be deferred. For purposes of claim construction, pixel data processing that is done by either a computer (to which the mouse is coupled) or the controller 124 , is considered to be equivalent.
FIG. 3 shows another simplified embodiment of a bar code detector circuit 300 for use in a combination optical mouse and bar code scanner. Like the embodiment shown in FIG. 2, pixel data values 308 stored in a data latch 302 (latch enable omitted for clarity) that are obtained 304 from the image sensor 108 are compared in a comparator 310 to determine if the latched pixel data value represents a bar code line or space. The reference values 312 against which latched pixel data is compared can be empirically determined such that if the latched pixel data is greater or less than the comparison values a determination can be made with reasonable certainty that the image array of the mouse is likely acquiring the image of a bar code line or space. Reference pixel data values can be dynamically determined to compensate for, among other things, light source 102 intensity variations, ambient light conditions, lens 106 cleanliness or clarity and scanned surface/scanned image conditions.
The comparison results 314 can be stored in a data latch or even a memory array 316 under the control of the controller 124 or even a PC to which the mouse is connected. In such an embodiment, the data stored in the latch/array 316 can represent a number of pixel data values that were greater than, less than or equal to a reference value, enhancing the calculated determination of whether the scanned image was a bar code line or space.
Regardless of how the determination of a bar code line or space is made, the width of both the lines and spaces must also be determined. Any of the foregoing embodiments can be used to determine bar code line and space width, in part, by correlating the acquired data values with the detected movement (and velocity) of the mouse.
As shown in FIGS. 1, 2 and 3 , pixel data processing can be performed within the controller 124 within the mouse. Such processing can include the determination of a bar code line or space, as well as width, but can also include the demodulation of encoded bar code data. In other words, data that is encoded into the bar code lines and spaces can be extracted within the controller 124 . In an alternate embodiment, raw data (simply the line and space data) can be sent to the personal computer to which the mouse is attached. Such an embodiment will require that more data be passed up to the PC for processing. The relative limited processing power of most microcontrollers that are presently available however, as compared to the processing power of most personal computer CPUs might yield an overall speed improvement even if large amounts of pixel data must be sent up to the PC CPU for processing instead of within the mouse.
Those skilled in the art will recognize that at least some of the functionality provided by a hardware embodiment, such as those shown in FIGS. 2 and 3, can almost always be accomplished in software. By appropriately programming an appropriately capable microprocessor, microcontroller or combinations thereof, pixel data from the image array 108 (or from the A/D converter 110 ) can be latched, compared and processed to detect a bar code line or space as well as the relative widths thereof. In at least one embodiment, pixel data processing is performed within the controller 124 , assisted by the various hardware components set forth above. With reference to FIG. 1, controller 124 sends control signals 118 , 122 to the bar code detector 112 and optical navigation detector 114 respectively and also receives data 116 , 120 (respectively) there from. Data 120 read from the navigation detector 114 under the control signals 122 to the navigation detector 114 are used to sense movement. Whenever data from the navigation detector 114 indicates movement, control signals 118 to the bar code detector 112 can be used to read whether a line or space was read by the data 116 returned from the bar code detector 112 .
The controller 124 , which might include a microcontroller or other processor, (which preferably also includes the functionality of the bar code detector 112 ) formats the detected bar code data (encoded into the bar code symbol) and writes the data to an interface 126 for a computer. Three output lines 128 , 130 and 132 , corresponding to mouse button input/output signals 128 , light source ( 102 ) control line 130 and demodulated data output 132 , either carry data from the combination mouse/bar code scanner back to a computer for subsequent processing, or carry data from the computer to the combination mouse/bar code scanner.
In embodiments that include bar code demodulation capability, the demodulated data output 132 preferably carries demodulated data or information that was recovered from a scanned bar code. In embodiments that only read or detect a bar code line and space, the demodulated data output 132 might carry only the line and space information to the PC for subsequent processing and information recovery.
In the preferred embodiment, the light source control line 102 is used to alter the brightness of the light source. In at least one embodiment, the light source is turned off when the mouse hasn't seen motion for a while thereby saving power and lengthening the lifetime of the light source. However, if the light source is turned off, the mouse can't detect motion so the mouse is occasionally “awakened” by turning the light back on long enough to take another picture. If the new image looks like the previous one, the mouse returns to “sleep” for a while with the light off. If on awakening the new image is different, the light will be kept on as the mouse responds to movement. In addition to turning the light on or off, the light source signal line 102 can also control the intensity of the light source. If the mouse were on bright white paper, the light intensity can be reduced as compared to the intensity it might be set at if it's used on paper that is less reflective.
In the preferred embodiment, the combination optical mouse and bar code scanner is employed to “read” Internet web address data that is encoded into bar codes printed onto various media. In such an embodiment, the combination optical mouse and bar code scanner is used to “read” the universal resource locator (URL) of a web site directly into a computer and an Internet browser. By way of example, an advertisement printed in a newspaper or magazine might include a bar code or other graphical symbol, the characteristics of which represent certain data. By reading the bar code or graphical symbol, encoded data can be immediately transferred into a user's computer. If the encoded data is a web site address, an advertiser in a newspaper or magazine can quickly route prospective customers (or other individuals) to a particular web site. Alternate (and equivalent) embodiments would be used to read UPC bar codes or other as-yet determined bar codes used to track inventory, track documents marked with bar codes and so forth.
The inclusion of additional functionality of an optical bar code reader into an optical mouse can enhance the value of such an optical mouse pointing device by enabling the optical mouse/bar code scanner to provide a convenient mechanism to read encoded data directly into a computer. An Internet web site address can be quickly and reliably entered into a web browser. Inventory marked with bar codes can be scanned using the same apparatus used to control a PC. Other items marked or identified by bar codes can also be tracked by the PC using an optical mouse.
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A computer mouse uses an optical sensor to detect movement and thereby generate signals to control movement of an on-screen icon. The optical mouse also includes circuitry or a processor to detect bar codes and demodulate data encoded therein.
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This application is a continuation-in-part of U.S. application Ser. No. 030,457, filed Apr. 16, 1979, issued Dec. 15, 1981 as U.S. Pat. No. 4,305,396, titled "Improved Rate Adaptive Pacemaker". All of the disclosure of that application is incorporated herein by reference.
BACKGROUND OF THE INVENTION
This invention lies in the field of physiological stimulus systems, e.g. pacemaker systems, and in particular implantable systems for physiological stimulation and detection of the response evoked by stimulation.
For the operation of conventional demand type pacemakers, it is necessary to sense the natural QRS signals which are developed in the ventricle, so as to cause resetting of the pacemaker oscillator. The state of the art permits reliable sensing of the natural QRS signal, as is seen from the widespread use of demand pacers. It is noted that, in demand pacer operation, the QRS signal occurs at least a full heartbeat period following the last stimulus pulse, if any, such that conditions in the vicinity of the electrode are relatively quiescent. By contrast, immediately after delivery of a negative going stimulus pulse, there is a large polarization signal present at the electrode, due to the condition of the adjacent heart tissue cells and the effective capacitance of the electrode itself. Since it takes some time for this polarization signal to dissipate it has the effect of masking signals which occur shortly thereafter, e.g., the evoked QRS or evoked T wave signals.
The area of threshold tracking pacemakers best illustrates the problem generated due to the polarization signal at the electrode following delivery of a stimulus pulse. A threshold tracking system is illustrated in U.S. Pat. No. 3,920,024, incorporated herein by reference. To date, there has been no significant commercial use of the implantable threshold tracking pacer, primarily due to the difficulty of detecting the resulting evoked signal in the midst of the polarization signal. Threshold tracking pacers are discussed at length in the literature, and there has been a limited use of external threshold tracking pacers, for various clinical applications. However, they have not achieved the prominence that was predicted some years back, due to the essentially unsolved problem of reliably and accurately picking the evoked QRS signal out of the overall signal which is present at the electrode shortly after delivery of the stimulus. It is clear that the inability to accurately and reliably sense the presence or absence of an evoked heartbeat is critical to the performance of a threshold tracking pacemaker.
The advantage of the threshold tracking pacemaker has been questioned recently, due to the greatly increased power capacity of the lithium battery as compared to prior mercury zinc batteries. The threshold tracking pacemaker would save a considerable amount of energy, and thereby extend pacer lifetime substantially, due to the fact that stimulus pulses would be delivered at or near threshold, instead of at a level which provided a safety factor of 2 or 3 times. Since present day lithium batteries extend the pacer lifetime to 12 to 15 years, this foreseen relative advantage of the threshold tracking pacemaker is greatly attenuated. However, other developments which are foreseeable continue to make it desirable to achieve a solution which would permit a reliable threshold tracking pacemaker. The ability to monitor threshold and to process information obtained from the evoked heartbeat may be quite useful in future pacemaker models, such as for providing a diagnostic aid in determining patient condition. As set forth in the referenced patent application, monitored patient threshold may be used to control the rate of delivery of stimulus signals. Also, changes in electrode construction and improvements in programmability are expected to enhance the value of threshold tracking and, more generally, the value of being able to continuously monitor both evoked and natural heartbeat signals.
While the utility of the subject invention is best described in the pacemaker, or pacing system embodiment, it is to be understood that the invention has utility in other systems for physiological stimulation. The invention may be practiced in any application where it is desired to quickly determine the physiological response to an applied stimulus by detection of the resulting evoked electrical characteristic at the location of applied stimulus.
SUMMARY OF THE INVENTION
It is an object of this invention to provide a pacing system for delivering stimulus signals to a patient's heart, wherein the sensed polarization immediately following delivery of a stimulus signal is minimized.
It is another object of this invention to provide a pacing system which enables quicker and more accurate sensing of an evoked response following delivery of a stimulus.
It is another object of this invention to provide an improved pacing system and method for threshold tracking.
It is another object of this invention to provide an improved pacemaker system for sensing heartbeat signals substantially immediately following delivery of stimulus signals, the system providing for delivery of recharge pulses of optimum level and timing so as to balance out the polarization effect of a delivered stimulus signal.
In accordance with the above, there is provided an improved system for delivery of physiological stimulus signals, such as a cardiac pacemaker, which system is characterized by having output means for providing a stimulus signal, each of said signals being constituted of a series of alternating polarity pulses of respective time durations and signal levels so as to minimize the resulting polarization at the point of delivery of such signals. In particular, the stimulus signal of this invention comprises a first recharge pulse of positive polarity, followed by a negative stimulus pulse and then a succeeding positive recharge pulse, the series of pulses having a time duration which is very small compared to the time period between delivered stimulus signals.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram showing the primary components of a pacing system utilizing this invention.
FIG. 2A is a block diagram showing a current control embodiment of the output stage of the system of this invention;
FIG. 2B is a curve depicting the timing of stimulus signals delivered by the system of this invention;
FIG. 2C is a curve illustrating the sampling of the polarization at the heart for use in the polarization feedback branch of the circuit of FIG. 2A.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIG. 1, there is shown a block diagram illustrating the essential components of the pacing system utilizing this invention. The invention is illustrated in terms of a demand pacer, the features of which are well known in the art. A sense amplifier 31 detects the presence of a QRS signal, and connects a signal to a logic/control circuit 32 when a QRS has been sensed. In a threshold tracking embodiment, such as illustrated in U.S. Pat. No. 3,920,024, amplifier 31 must detect the evoked response which follows the stimulus in about 10 to 50 ms. The circuitry of block 32 performs the normal logic functions of a demand pacer such as distinguishing a sensed natural QRS signal, timing out a refractory interval, etc. For programmable pacemakers, stored information relative to pacing parameters and other program control features may be considered to be found in block 32. Also, block 32 suitably contains the desired circuitry for employing the evoked response information, e.g., tracking threshold. As illustrated, control signals may be transferred from block 32 to output 34, for controlling the output in accordance with programmed signals or for threshold tracking. Block 33 is the basic timing generator, which establishes the rate at which the pacer delivers stimulus pulses in the absence of natural patient pulses. As is known in the art, if the timing generator times out on its own, meaning that a stimulus is to be delivered, the timing signal is connected to an output circuit 34. If a signal comes from circuit 32 prior to time out in circuit 33, which signal indicates that a natural QRS has been detected, the timing generator 33 is reset without triggering an output. Output 34 represents circuitry which is utilized in generating a desired output signal, commonly referred to as an output pulse, of desired value in terms of pulse width, voltage or current. As shown further in FIG. 1, the output 34 is connected to a pacing/sensing electrode which is the end of a pacing lead (not shown), which lead provides the necessary electrical connection between the pacemaker and the patient' s heart. An electrical path is illustrated between the output of circuit 34 and the input of sense amplifier 31. Further, power is provided, suitably by a lithium type battery or any other desired source, as illustrated at 35. For unipolar pacing systems, the terminal of source 35 shown as ground is generally connected to the case of the pacemaker, illustrated at 36.
Referring now to FIG. 2A, there is shown a block diagram of an embodiment of output circuit 34 which is based upon current control of the component pulses of the delivered stimulus signal. As used in this application, the term "stimulus signal" shall refer to the group or series of pulses delivered, the negative going pulse of which is the component which actually provides the stimulus. Also, the term pulse is used in a general manner, it being understood that a pulse as actually generated and used within this invention is not confined to a sharp signal in the time domain, but may be a sloped, exponential or other form of nonlinear signal.
In FIG. 2A, the primary circuit components which generate the stimulus signal are the two current generators, namely the recharge current generator 40 and the stimulus generator 43. These two current generators are shown as ideal circuits and can be contructed in any conventional manner. They are suitably switchable on-off circuits, such that they can be turned on and off sharply, such as can be accomplished by putting a control voltage on the gate of a FET transistor or the like. When recharge current generator 40 is on; and stimulus current generator 43 is off, a current flows from V+ through the generator, through the capacitor 41 which charges up, and through the heart 42 to ground, thereby applying a positive polarity signal to the heart. When stimulus current generator 43 is on, and recharge generator 40 is off, current flows up through heart 42 as seen in the drawing, through capacitor 41 (thereby discharging it) and down through current generator 43, delivering a negative pulse to the heart. The size of the negative going pulse is designed, in accordance with well known principles, to evoke stimulation of the heart.
As seen in FIG. 2B, recharge generator 40 is first triggered for a time T 1 to produce a first positive delivery of current to the heart, stimulus generator 43 is then turned on for a time T st to deliver the negative stimulating component, and then recharge generator 40 is turned on again for a time T 2 to deliver another recharge pulse. These three pulses, preferrably time contiguous as shown, constitute the total stimulus signal which is delivered periodically by the pacemaker when no natural heart signal is detected.
In practice, the respective times T 1 and T 2 and the current levels of the recharge pulses are controlled by recharge current control and timing circuit 52. As shown, this circuit receives program information, suitably from block 32, for determining the ratio T 1 /T 2 , the amplitude of the recharge pulses, and the duration of each. In a similar manner, stimulus current control and timing circuit 50 controls the stimulus component delivered by current generator 43, and receives amplitude and duration program signals. Both circuits 52 and 50 receive basic timing signals from the timing generator 33, to determine when the series of pulses, or the overall stimulus signal is to be generated. As shown by the arrows between blocks 52 and 50, the timing signal may be connected from block 52 at the end of the first recharge pulse to trigger a stimulus pulse, and another timing signal may be connected from block 50 to 52 at the end of the stimulus pulse to trigger the second recharge signal. It is understood that timing circuitry is well known in the art, and the time durations T 1 and T 2 may be provided conveniently by one-shot or monostable multi-vibrators or their equivalent, or other digital timing mechanisms well known in the art.
The embodiment of FIG. 2A provides two or three feedback loops. Block 53 is shown connected to point X, between the two current generators, which block measures the voltage at such point X at a predetermined time between stimulus signals. By determining the variation, if any, of V X , the circuit can measure whether the net charge delivered through capacitor 41 during the preceeding impulse group is zero. If, due to improper balancing between positive and negative output currents, or for any other reason of instability, V X has been changed, an amplitude feedback signal is applied to block 52 to change the value of the recharge current. As long as the total charge delivered by the two recharge pulses and the stimulus charge is substantially zero, the voltage at point X, as sampled between stimulus signals, will not vary significantly.
A second feedback branch is connected between the output at the heart and the recharge control circuit 52. The heart voltage V h is sampled at a sample time shortly after termination of T 2 , to determine the polarization level. The polarization level is compared to a reference at block 47, and an output signal connected to block 52 to change the ratio T 1 /T 2 of the recharge pulses for succeeding stimuli. For further improvement the reference value can be related also to the stimulus duration (T st ) and/or amplitude. Changing the ratio of T 1 to T 2 changes the polarization decay characteristic, and by this means the residual polarization can be optimally reduced. A second branch 48 of this feedback loop samples V h following the delivery of a backup pulse for a threshold tracking system. It is to be understood that for a threshold tracking system where a series of backup pulses is delivered until response is evoked, V h may be monitored following each of such backup pulses.
For the circuit of FIG. 2A, the duration T 1 of the first recharge pulse is determined by the stimulus duration input, as well as the T 1 /T 2 ratio information. The amplitude is determined by the program amplitude of the stimulus current, as well as the feedback through block 53. The stimulus pulse duration T st is determined by the stimulus duration information, while the stimulus amplitude is determined by the stimulus amplitude input. The second recharge pulse duration T 2 is determined by the T 1 /T 2 ratio and by the stimulus duration input, while the amplitude is determined by the stimulus current input and by the feedback through block 53. It is important that the total charge of the two recharge pulses be substantially equal to the charge of the stimulus portion, such that the net charge delivered to the heart by the stimulus signal is substantially zero. It need not be precisely zero, since further recharge can be accomplished following recharge pulse T 2 and before the next stimulus signal. However, in order to minimize the polarization at the sensing electrode following the termination of the second recharge pulse, the net charge delivered by the three pulse components should be substantially zero. In practice, T 1 plus T 2 may be approximately 4 times T st , although this ratio may go up to 10 or more. It is, however, important that the second recharge pulse not be too long, since the evoked response can hardly be sensed until the second recharge pulse is terminated. Conversely, there is a limit in the amplitude of the two recharge pulses, since it has been found that if these pulses are made too high in amplitude this causes some reduction in the stimulation efficiency.
The advantage of the circuit of FIG. 2A is that the polarization is compensated for very accurately. This is an active system which measures the polarization, and forces adjustments through the feedback loops so as to reduce the polarization to a minimum. The disadvantages are the use of two or more feedback systems, and the extra current consumption due to the complexity of the circuit.
Reference is made to co-pending application Ser. No. 231,889, filed on the same date as this application, and issued Aug. 10, 1982 as U.S. Pat. No. 4,343,312, which shows a preferred embodiment of an output circuit of this invention in FIGS. 3A, 3B and 3C thereof.
While it has been determined that the 3 pulse arrangement provides excellent improvement in reducing the detected polarization following stimulus, improvement is accomplished by utilizing a positive recharge pulse prior to the negative stimulus pulse, even without a second recharge pulse. Such a recharge pulse is suitably no more than 10 ms, since a natural QRS can hardly be sensed during the recharge pulse. If a second recharge pulse is utilized, it is preferably of short time duration, so that the evoked response can be sensed as quickly as possible.
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A physiological stimulating system includes improved means for minimizing the polarization that results at the stimulus site, thereby enabling enhanced detection of evoked responses. In the pacemaker embodiment, the stimulus signal comprises positive recharge pulses immediately before and immediately after the negative stimulus signal, the recharge pulses being adapted in a time duration and amplitude such that the total current delivered to the stimulus site, (e.g., a patient's heart) by the stimulus signal is substantially zero.
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This is a division of application Ser. No. 919,012 filed June 26, 1978, now U.S. Pat. No. 4,194,270, 25 Mar. 1980 which is a continuation of application Ser. No. 775,022 filed Mar. 7, 1977 (now abandoned).
BACKGROUND OF THE INVENTION
This invention relates to apparatus for laying fiber fleeces or the like, usually supplied from a carding machine or the like, onto a withdrawal belt moving at a predetermined speed.
In high speed apparatus for laying fiber fleeces, any sudden change in speed of the various conveyor belts in the apparatus can cause irregularities and distortions in the fleece layer. Thus, during a sudden acceleration of the conveyor belts the fleece does not follow immediately, and at high operational speeds air currents are generated which tend to raise the fleece from the belts and can lead to narrowing or stretching of the fleece at points between conveyor belts.
One of the objectives in designing apparatus for laying fiber fleeces has been to provide control means for maintaining the conveyor belts in a predetermined relationship whereby the fleece layer is maintained more uniform. In prior art apparatus each conveyor belt is frequently controlled by a separate DC motor, the DC motors enabling digital control of the speeds of the belts. This, however, requires a complex and therefore expensive control device and also requires continuous supervision by highly skilled personnel. Furthermore, the adverse affects caused by air currents are not eliminated.
Other prior art devices have been designed to decrease the high rate of acceleration. This is difficult to control, however, as the fleece is fed to the apparatus at constant speed and must be withdrawn at constant speed.
Another prior art apparatus is known in which there is a feed belt driven at a predetermined speed, a reciprocably movable main or storage car and laying car and two conveyor belts which extend partially parallel to each other between the main and layer cars. One of the conveyor belts, a main belt, passes over rollers on the main and layer cars. Three auxiliary cars are provided which are intended to effect balance of the belt speeds during laying of the fleece in a cross-over form. Also, the drive requires at these two different gears. This apparatus has the disadvantage that it is relatively expensive and complex, both in structure and with respect to the control device required to operate the apparatus.
An object of the present invention is to provide apparatus for laying fiber fleeces which has a simplified construction and reduction in the number of parts.
A further object of the invention is to provide an apparatus in which control of the synchronous running of the moving parts is simplified.
SUMMARY OF THE INVENTION
The apparatus of the present invention includes a feed belt, a main car, a layer car, a storage car, and two conveyor belts which extend in part parallel to one another between the main and layer cars. One of the conveyor belts passes as a main belt over rollers on both the main and layer cars. The storage car has rollers around which the second conveyor belt passes. A single balance car is provided for the main belt, and the storage and layer cars are connected by a common drive unit, e.g. a chain which derives its drive from the feed belt and via the driven layer car.
The main belt which runs over both the layer and balance cars passes around the end of the storage car. This construction is compact as extra space is not required for belt travel. Only one storage car is required. It is possible for the speed of the layer car to be changed by means of the balance car to a speed different from the fleece speed, control being maintained by the common drive unit, i.e. by synchronization of the control chain. It will be appreciated that all parts of the apparatus are easily accessible and easily maintained.
The storage car has a jib supporting the second conveyor belt. The control chain may be passed over the end of the jib to the layer car. In this case the control chain is advantageously passed over a gear wheel non-rotarily connected to a laying roller of the layer car. This serves as one of the two drives for the control chain. The other drive for the control chain is derived directly from the driven speed belt.
From the driven belt wheel of the feed belt a drive chain leads over the roller of the main belt on the balance car. The drive for the second conveyor belt located on the storage car is derived from the driven main belt. Both belts thus run at the fleece speed or doffer speed. The layer car can be arranged to move reciprocably by means of a car traction chain and two gear wheels. The gear wheels mesh with a stationary measuring chain, the gear wheels being alternately provided in opposed directions with freewheel clutches. Thus, each individual layer roller of the layer car is respectively driven by each gear wheel. The measuring chain which is an endless chain passing over wheels is driven by movement of the car traction chain. This drive means eliminates the hydraulic lines normally required to operate the clutch located on the layer car which must be continuously reciprocated. The driving force is applied to those drive parts which are non-rotarily supported. The measuring chain is simply driven by the car traction chain, and consequently the layer car which is subjected to continual reciprocating motion is made considerably lighter, an important feature since the layer car is continuously being braked and accelerated.
The drive for the measuring chain is derived from a turning wheel of the car traction chain, the shaft of the turning wheel of the car traction chain being connected with the shaft of the turning wheel of the measuring chain at a drive ratio of 2:1. The corresponding chainwheels which are connected by a chain can be designed with a corresponding transmission ratio so that the shaft of the measuring chain revolves twice as fast as the shaft of the car traction chain, the turning wheels on both chains being the same size.
A clutch is located on the chain wheel of the measuring chain to engage and disengage its shaft. To effect a change in the direction of the power flow without change in direction of the layer car, a freewheel device is located on the shaft for the drive of the measuring chain. The freewheel device is attached to the machine frame and prevents the shaft of the measuring chain from rotating in the wrong direction. The engagement of the endless measuring chain with the layer car is preferably effected in such a way that the endless measuring chain is passed over a turning chainwheel of the layer car.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a diagrammatic side elevation of a first embodiment of the fleece laying machine;
FIG. 1a is a view similar to FIG. 1 on an enlarged scale;
FIG. 2 is a cross-sectional view taken along the line II--II of FIG. 1 illustrating the position of the individual drive elements;
FIG. 3 illustrates the layer car, the balance car and the storage car, the conveyor belts having been omitted;
FIG. 4 is a diagrammatic front elevation of the fleece-laying machine showing the cars at their maximum end positions;
FIG. 5 is similar to FIG. 4 but shows the positions of the balance car and the storage car when the speed of the layer car does not coincide with the fleece speed;
FIG. 6 is a diagrammatic side elevation of a further embodiment of the fleece-laying machine;
FIG. 6a is a view similar to FIG. 6 on an enlarged scale;
FIG. 7 is a cross-sectional view taken along the line II--II of FIG. 6 illustrating the position of the individual drive elements;
FIG. 8 illustrates the layer car, the balance car and the storage car, the conveyor belts having been omitted;
FIG. 9 is a diagrammatic front elevation showing the positions of the balance car and the storage car when the speed of the layer car does not coincide with the fleece speed; and
FIG. 10 is a diagrammatic plan view of the drive means for the endless measuring chain.
DETAILED DESCRIPTION OF INVENTION
The fleece-laying machine 1 has a feed belt 2 with rollers 3 and driven belt roller 4. Located transversely to the feed belt 2 is a withdrawal belt 5 on roller 6. The fleece material is deposited transversely and in a zig-zag configuration relative to the direction of feed belt 2. Instead of a transversely-moving belt 5 the withdrawal belt may run longitudinally, i.e. in the same direction as the feed belt 2. The fleece-laying machine includes three cars, namely, a layer car 7, a storage car 8 and a balance car 9. The storage car 8 is provided with a jib 10 on which is located a conveyor belt 11 which passes between rollers 12 and 13. A further conveyor 14 extends from roller 15 of the storage car 8, over a roller 16 of the balance car 9 back to a roller 17 on storage car 8, and from this point to a roller 18 of the layer car 7 and back to a roller 19 of the storage car 8, and from this point again to roller 15. The conveyor belt 14 of the storage car 8 thus extends both to the balance car 9 and also to the layer car 7, the latter being movable reciprocably across the width of the withdrawal belt 5.
The belt roller 4 of the feed belt 2 is driven at a predetermined speed, preferably the doffer speed of a carding machine or the like. From the drive wheel 4a of belt roller 4 a drive chain 20 extends over a chainwheel 22 on axle 21 of the roller 16 for the conveyor belt 14, the drive chain extending over a fixed roller 23 back to the chainwheel 4a. Thus, the conveyor belt 14 is driven from a driven belt roller 4 of the feed belt 2, and the belt 11 on jib 10 of the storage car 8 is driven by roller 17 located on the storage car 8 by means of chain 24 which extends over a chainwheel on the axle of the roller 13. Thus, belt 11 is driven at the same speed as belt 14.
The layer car 7 and the balance car 9 are connected together by a tension chain 25. The tension chain 25 is attached at 26 to the balance car 9 and at 27 to the layer car 7 and extends over a roller 28 mounted on the jib 10 of storage car 8.
Layer car 7 is driven by a car traction chain 29 which passes over fixed rollers 30 and 31. The upper bight of the car traction chain 29 is rigidly connected at 29a to the layer car 7. Rotation of rollers 34 and 35 is effected by a measuring chain 36 stretched between two countersupports 37. The withdrawal rollers 34, 35 or laying rollers are connected by transmission members 38, 39 to chainwheels 40, 41 via wheels 42, 43. Chainwheels 40, 41 are provided with free wheel clutches, respectively, which operate in opposite rotary directions, insuring that the rotary direction of the laying rollers 34, 35 always remains the same when the layer car 7 changes direction. The car traction chain 29 is driven by a reversible geared motor, e.g. a DC motor.
A common drive unit is provided between the three cars, namely, the layer, storage and balance cars. The drive unit comprises a common control chain 44. The chain 44 leads from the fixed rollers 45, 46 over a fixed driven roller 47 to rollers 48 and 49 on the jib 10 of storage car 8, from this point over chainwheels 50 and 50a, one of which is driven, depending upon the direction of movement of layer 7, and back over rollers 51, 52 and 53 located on the storage car 8. The chain wheel 50 is fixed on the same axle on which wheel 43 is located. Wheel 43, however, has a smaller diameter than the chain wheel 50. The control chain 44 also extends over chain wheel 50a which is rigidly connected to wheel 42. Roller 47 is driven through belt roller 4 by means of corresponding intermeshing gear wheels 54 and 55.
The operation of the fleece-laying machine is as follows. The fleece 56 is fed over the feed belt 2 and is then passed over roller 13 of conveyor belt 11 between the two bights of the conveyor belts 11 and 14 to the layer car 7 and between the laying rollers 34, 35 onto the withdrawal belt 5 where it is deposited in a continuous reciprocating motion on the withdrawal belt 5. FIG. 1 shows the positions of the cars at the beginning of the laying process. The peripheral speed of the belt roller 4 at the intake corresponds to the fleece speed or the doffer speed. This speed is on the one hand transmitted to the control chain 44 by means of the roller 47 and on the other hand by the drive chain 20 to the belt roller 16 of the balance car 9. The layer car 7 is set in motion via the car traction chain 29. The measuring chain 36 thus automatically sets the right chain wheel 41 of the layer car 7, with power connected to the shaft, in rotation, while the other chainwheel 40 is uncoupled, or the free wheel is effective. The control chain 44 is driven by the chainwheels 50 or 50a which run synchronously with the laying rollers 34, 35. It should be noted that the control chain 44 is driven at two different points.
When the layer car 7, seen in the plane of the drawing, moves to the right, there is imparted to the storage car 8 by the control chain 44 a movement in the same direction as that of the layer car 7 but at only half the speed. When the movement of the layer car 7 is at fleece speed, no traction is exerted on the balance car 9 either via the tension chain 25 or via the main belt 14.
When the speed of the layer car 7 is lower than that of the fleece, then there is imparted by the control chain 44 to the storage car 8 an additional movement in the direction of the movement of the layer car 7 so that the storage car 8 reaches half the fleece speed, i.e. is accelerated. The fleece 56, entering at constant speed, is therefore stored without residue by the movement of the storage car 8. As in this case the layer car 7 is moved slower than twice the speed of the storage car 8 and the main belt 14 is drawn around the rollers 19, 15 of the storage car 8. The result is that the balance car 9 moves to the right because of the traction exerted by the main belt 14.
During the movement of the layer car 7, the car speed must exceed the fleece speed, if the fleece speed at the turning point or at the beginning of the laying stretch has not been achieved. This is necessary for the median speed of the layer car 7 to be equal to the doffer speed.
When the layer car 7 reaches fleece speed the movement of the balance car 9 to the right ceases and is transformed, on exceeding the fleece speed, through the layer car 7 into a movement to the left, this movement is achieved by traction from tension chain 25.
When it has passed over the full laying width, the layer car 7 is reversed and travels to the left. Control of the layer car 7 is effected via the car traction chain 29 which is correspondingly driven. During the reversal, the right chainwheel 41, which has transmitted the rotation caused by measuring chain 36, is uncoupled or the free wheel becomes defective and the left chainwheel 40 is coupled to the shaft.
When the speed of the layer car 7 is less than the fleece speed, the control chain 44 imparts to the storage car 8 a movement opposite in direction to that of the layer car 7. When the speed of the layer car after reversal to the left is zero, the storage car 8 continues at half the fleece speed towards the right. Only when the speed of the layer car 7 during the return is higher than half the fleece speed does the storage car 8 likewise move in the direction of the layer car 7 to the left.
The balance car 9 executes the same movements in the reverse phase as during the forward phase. When the speed of the layer car 7 is less than the fleece speed, the balance car 9 moves to the right; if it is above the fleece speed, the balance car moves to the left. When only one balance car is present the balance of the movements of the cars and of the speeds is effected by the common control chain 44 driven by the belt roller of the feed belt and by the movement of the layer car passing through the storage car 8 and the layer car 7. Alternatively, the control chain 44 can be passed to the belt roller 21 of the balance car 9 and drive chain 20 can then be eliminated.
In the further embodiment illustrated in FIGS. 6-10, an endless measuring chain 36a is provided for rotating rollers 34, 35, the drive for the endless measuring chain 36a being derived from the car traction chain 29. The measuring chain 36a is passed over the wheels 57, 58 and drive for the movable measuring chain 36a is effected from the wheel 57.
The shaft 59 carrying wheel 57 is driven by a shaft 65 to which the wheel 30 for the car traction chain 29 is non-rotarily connected. Drive is effected via chainwheel 63, chain 64 and chainwheel 60; chainwheel 60 only being half the diameter of chainwheel 63. The shaft 59 thus rotates at twice the speed and moves the measuring chain 36a at twice the speed, wheel 57 having the same diameter as wheel 30.
Chain wheel 60 and shaft 59 are releasably connected to each other by a clutch 61. Also, a freewheel device 62 is located on the shaft 59, the freewheel device being stationarily mounted and preferably fixed to the frame of the machine. The freewheel device 62 prevents rotation of shaft 59 clockwise as viewed in FIGS. 6 and 6a. Clutch 61 is engaged when the layer car 7 (FIGS. 6 and 6a) moves to the left; in this case the shaft 59 rotates anti-clockwise and the measuring chain 36a is moved at double speed relative to the speed of layer car 7. At the left turning point of layer car 7 the clutch 61 is disengaged and measuring chain 36a becomes stationary. The layer car 7 then moves to the right. Thus, there is exerted on measuring chain 36a a tractive force which would rotate shaft 59 clockwise were it not prevented by the freewheel device 62. At the right turning point (FIGS. 6 and 6a) of the layer car 7 the clutch 61 is again engaged.
Measuring chain 36a extends to the layer car 7 over chainwheel 66, 67 (FIG. 6a) which are mounted on shafts 33 and 32, respectively, alternately around the chainwheels on opposite sides thereof. When the layer car 7 reverses its direction the rotary direction of layer rollers 34, 35 remains the same.
When the layer car 7 travels to the right (FIGS. 6 and 6a), the clutch 61 is disengaged. The rotary movement of the car traction shaft 65 is not transmitted to the shaft 59. The measuring chain 36a remains stationary. The storage car 8 in this instance also moves to the right. Frictional forces exert through the synchronous chain, the chainwheels on the layer wheel and the measuring chain 36a a force on the chainwheel 57 which would turn shaft 59 clockwise. This is prevented, however, by the free wheel 62 which is stationarily mounted. When the layer car 7 is at the right reversing point, the shaft 65 is stationary for the period of reversal. At this moment the clutch 61 is engaged in order to transmit the incipient rotary movement of shaft 65 (anti-clockwise) to the shaft 59 and by means of its transmission to impart to measuring chain 36a double the layer car speed. This direction of rotation is permitted by free wheel 62.
Measures may be taken to guarantee precise reversal without requiring adjustment. The part 61 may consist of a clutch and a free wheel arranged in parallel therewith to provide the power connection between the chain wheel 60 and the shaft 59. This parallel-mounted free wheel is present in addition to the free wheel 62. When the rotary movement of the layer car shaft 65 is initiated counter-clockwise, free wheel 62 is released and practically at the same instant the power flow is produced by the free wheel in part 61. The clutch in part 61 is engaged at an optional moment in time later, but before the impulse initiated by the braking or reversing movement of the layer car 7. With this arrangement it is no longer important to engage the clutch at a predetermined point in time. When the braking or reversing procedure with change in direction of the power flow is effected, an exact transmission of the rotary speed at any moment is guaranteed by the clutch. Disengagement of the clutch must again be effected at a specific point in time. The declutching procedure, however, takes considerably less time than the clutching procedure so that the necessary switching accuracy in this reversal point is easier to achieve.
While various modifications of the above described device have been shown and described in detail, it is obvious that further modifications and changes may be made within the scope of the invention without departing from the spirit thereof.
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A device is disclosed for laying fiber fleeces or the like delivered from a carding machine of the like onto a withdrawal belt driven at a predetermined speed. The device comprises a feed belt driven at a predetermined speed, storage, layer and balance cars all arranged for oscillating movements, respectively, a first continuous conveyor belt extending about rollers on the storage and layer cars and a second continuous conveyor belt extending about rollers on the storage and layer cars and extending from the storage car to a roller on the balance car. One run of each of the conveyor belts extending between the storage and layer cars confront each other for receiving the fiber fleece therebetween. Common drive means connects the storage and layer cars and further drive means extends from the feed belt to the layer car.
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FIELD OF USE
This invention relates to switching circuits suitable for semiconductor integrated circuit applications.
BACKGROUND ART
Use of a differential configuration, as in emitter-coupled logic (ECL), typically enables an electronic circuit to switch very fast. Referring to the drawings, FIG. 1 illustrates a conventional ECL gate that switches between a pair of binary logic states. The gate operates in response to a differential input voltage signal V I formed by the difference V I1 -V I2 between a pair of input voltages V I1 and V I2 , one of which may be a substantially fixed reference voltage. Responsive to differential input V I , the gate produces a pair of complementary output voltage signals V O1 and V O2 whose relative values characterize the gate's condition. The gate consists of a differential input stage 10 and an output stage 12.
Input stage 10 centers around a pair of largely identical differentially configured NPN input transistors QI1 and QI2whose bases receive input voltages V I1 and V I2 . A substantially constant current source 14 connected to a source of a low supply voltage V EE provides a supply current I E to the interconnected emitters of transistors QI1 and QI2. Their collectors are coupled through equal-value resistors RC1 and RC2 to a source of a high supply voltage V cc . Complementary intermediate voltage signals V M1 and V M2 are supplied from the QI1 and QI2collectors as outputs of stage 10.
Turning to output stage 12, it contains largely identical NPN output transistors QO1 and QO2 whose bases receive intermediate voltages V M1 and V M2 . The collectors of transistors QO1 and QO2 are tied to the V cc supply. Their emitters carry currents I A1 and I A2 . The QO1 and QO2 emitters are connected to nodes N1 and N2 from which output voltages V O1 and V O2 are taken. Output currents I 01 and I 02 flow out of the V O1 and V O2 output terminals. Largely identical substantially constant current sources 16 and 18, which are connected to the V EE supply, provide supply currents I S1 and I S2 at nodes N1 and N2.
The gate in FIG. 1 drives a parasitic load capacitance represented by capacitors CL1 and CL2. Capacitor CL1 is connected between node N1 and the V EE supply. Capacitor CL2 is similarly connected between node N2 and the V EE supply. Capacitive load currents I L1 and I L2 flow into (the upper plates of) capacitors CL1 and CL2.
The gate switches from one binary state to the other as differential input V I goes from a voltage less than -60 millivolts to a voltage greater than 60 millivolts, and vice versa. A better understanding of the switching operation is facilitated with the assistance of the waveforms shown in FIG. 2. Supply currents I S1 and I S2 have largely the same value during normal operation (since current sources 16 and 18 are largely identical). This value is represented by the symbol "I s " in FIG. 2.
Assume V I is initially somewhat less than -60 millivolts as denoted by the "-" sign in FIG. 2. Transistor QI1 is non-conductive. V M1 (not shown in FIG. 2) is at a high voltage V MH very close to V cc . Transistor QI2 is fully turned on and draws current I E through resistor RC2. V M2 (also not shown in FIG. 2) is at a low voltage V ML .
Transistors QO1 and QO2 are both turned on. V O1 is at a high voltage V OH that is approximately 1V BE below V MH . V BE is the magnitude of the standard voltage (approximately 0.8 volt) across the base-emitter junction of a bipolar transistor when it is fully conductive. Similarly, V O2 is at a low voltage V OL approximately 1V BE below V ML . I L1 and I L2 are both zero. Capacitor CL1 is charged to a high level, while capacitor CL2 is charged to a low level.
When V I is raised to a value somewhat greater than 60 millivolts as denoted by the "+" sign in FIG. 2, transistor QI2 turns off. Transistor QI1 turns on and draws current I E through resistor RC1. V M1 is thus pulled down to V ML , causing transistor QO1 to become temporarily less conductive. V O1 drops down to V OL during a fall time t F , after which transistor QO1 returns to its initial conductive level.
The mechanism by which V O1 is reduced to V OL involves discharging capacitor CL1 to a suitably low level. Capacitor CL1 discharges primarily through current source 16. Very little of the CL1 discharge occurs through the V O1 output terminal, I O1 typically consisting of the small current flowing into the base of an input transistor in a gate driven by the gate shown in FIG. 1. Consequently, the value that I L1 can reach during the switching transition is largely limited by the value of I S1 . In particular, the maximum magnitude of I L1 is largely equal to I S during the transition, as indicated in the left half of FIG. 2.
As V M1 drops down to V ML , V M2 is pulled up to V MH . Transistor QO2 pulls V O2 up to V OH during a rise time t R . More specifically, transistor QO2 temporarily becomes more conductive during time t R . The resulting increase in I A2 enables I L2 to increase temporarily in the manner depicted in the left half of FIG. 2. Capacitor CL2 is thereby charged to a high level.
The amount that I A2 can increase during the switching transition is normally considerably greater than I S . I L2 thus reaches a value substantially greater than I S and, accordingly, much greater than I L1 . Higher charge/discharge current means shorter rise/fall time. As a result, t R is significantly less than t F .
The reverse events occur when V I is returned to a value less than -60 millivolts. See the right half of FIG. 2 where t R now represents the rise time for V O1 , and t F represents the fall time for V O2 . Again, t R is significantly less than t F . For the reasons given above, the minimum value of t F is limited by the value of I S . The switching speed of the gate in FIG. 1 is thus limited by supply current I S .
Making current sources 16 and 18 larger--i.e., increasing I S --is disadvantageous because the steady-state current requirements of the gate increase proportionately. A commensurate increase in power dissipation occurs. It is desirable to increase the switching speed of an ECL gate of the type shown in FIG. 1 without drawing any significant additional steady-state current.
GENERAL DISCLOSURE OF THE INVENTION
The present invention is an electronic switching circuit capable of achieving the foregoing objective. In particular, the invention employs capacitively enhanced switching to obtain high switching speed without significantly increasing steady-state current needs. The invention is especially useful in ECL.
The present circuit contains an input stage and an output stage. The input stage operates in response to at least one input signal to produce largely complementary first and second intermediate signals. The output stage centers around a pair of three-electrode amplifiers referred to as the first and second amplifiers. The first amplifier has a first flow electrode coupled to a first node from which a first output signal can be taken, a second flow electrode, and a control electrode responsive to the first intermediate signal for controlling current transmission between the first amplifier's flow electrodes. The second amplifier has a first flow electrode coupled to a second node, a second flow electrode, and a control electrode responsive to the second intermediate signal for controlling current transmission between the second amplifier's flow electrodes.
In one version of the invention, the output stage further includes a third three-electrode amplifier, a first current supply, and a first charge/discharge element. The third amplifier has a first flow electrode coupled to a third node, a second flow electrode coupled to the first node, and a control electrode coupled to the second node for controlling current transmission between the third amplifier's flow electrodes. The first current supply provides supply current at the third node. The first charge/discharge element produces a capacitive-type charge/discharge action between the third node and a source of a first reference voltage. This version of the invention also usually includes a second current supply that provides supply current at the second node.
If the first and second amplifiers and the first and second current supplies are respectively analogized to output transistors QO1 and QO2 and current sources 1 6 and 18 in the prior art ECL gate described above, this version of the invention operates basically the same as the prior art gate except that additional current flows into the first charge/discharge element when the voltage of the output signal drops. The additional current helps to discharge the output capacitance associated with the load to which the output signal is applied. In effect, the additional current increases the value of the current provided by the first current supply during the time that the voltage of the output signal is falling. This reduces the fall time, thereby increasing the switching speed of the circuit. The third amplifier causes the charge/discharge element to function in the preceding manner.
The amount of charge that flows into the charge/discharge element during the fall time is largely equal to the amount of charge that flows out of the charge/discharge element during the subsequent time in which the voltage of the output signal returns to its initial level. The third amplifier requires very little (if any) current to keep it in the desired operational condition. As a consequence, the charge/discharge element and the third amplifier do not draw any significant additional steady-state current.
In another version of the invention, the output stage includes a fourth three-electrode amplifier and a second charge/discharge element in addition to the previously mentioned components. The fourth amplifier has a first flow electrode coupled to a fourth node, a second flow electrode coupled to the second node from which a second output signal can be taken, and a control electrode coupled to the first node for controlling current transmission between the fourth amplifier's flow electrodes. The second charge/discharge element provides a capacitive-type charge/discharge action between the fourth node and a source of a second reference voltage. The second current supply provides supply current at the fourth node (rather than at the second node) in this version of the invention.
The first charge/discharge element and the third amplifier in the second version of the present circuit speed up the switching of the first output signal in basically the same way as in the first version. Importantly, the second charge/discharge element and the fourth amplifier provide a complementary action that similarly speeds u the switching of the second output signal without significantly increasing the steady-state current requirements of the circuit. In short, the circuit switches faster without dissipating more power.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. I is a circuit diagram of a prior art ECL gate.
FIG. 2 is a graph of certain voltage and current waveforms as a function of time for the gate in FIG. 1.
FIGS. 3 and 5 are block/circuit diagrams of two general electronic circuits in accordance with the invention.
FIGS. 4 and 6 are graphs of certain voltage and current waveforms as a function of time for the respective circuits in FIGS. 3 and 5.
FIGS. 7 and 8 are circuit diagrams for ECL implementations of the gate in FIG. 5.
Like reference symbols are employed in the drawings and in the description of the preferred embodiments to represent the same or very similar item or items.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The invention employs various three-electrode amplifiers identified by reference symbols beginning with the letter "A". Each such "A" amplifier has a first flow electrode (1E), a second flow electrode (2E), and a control electrode (CE) for controlling current flow between the flow electrodes (1E and 2E). Charge carriers, either electrons or holes, that move between the flow electrodes of each "A" amplifier originate at its first flow electrode and terminate at its second flow electrode. Current flow begins when the voltage between the control electrode and the first flow electrode passes a specified threshold level. The current (if any) flowing in the control electrode is much smaller than that otherwise moving between the flow electrodes.
Each "A" amplifier preferably consists of a single transistor. In the case of a bipolar transistor, its emitter, collector, and base are respectively the first, second, and control electrodes. These elements are respectively the source, drain, and gate for a field-effect transistor of either the insulated-gate or junction type.
In some cases, each "A" amplifier could consist of more than one transistor. One example is a bipolar Darlington circuit in which the emitter of an input transistor is connected to the base of a trailing transistor. In this case, the control electrode of the "A" amplifier is (connected to) the base of the input transistor, while the first and second control electrodes are respectively (connected to) the emitter and collector of the trailing transistor.
As used in describing two (or more) of the "A" amplifiers, "like configured" or "configured the same" means that the amplifiers have corresponding elements interconnected in the same way and that each set of corresponding elements is of the same semiconductor polarity. For example, two of the "A" amplifiers are like configured if both are NPN transistors but not if one is an NPN transistor while the other is a PNP transistor. Likewise, Darlington circuits are like configured as long as the input transistors are of the same polarity and the trailing transistors are of the same polarity (even if different from that of the input transistors).
FIG. 3 illustrates a general implementation of a "single-ended" version of a switching circuit arranged according to the teachings of the invention. This circuit produces (single) output voltage signal V O1 in response to input voltage signal V I consisting of the difference between input voltages V I1 and V I2 . The circuit is formed With an input stage 20 and an output stage 22, both connected between sources of a low supply voltage V LL and a high supply voltage V HH .
Input stage 20 produces complementary intermediate voltage signals V M1 and V M2 in response to differential input V I . Voltages V M1 and V M2 switch between high and low levels that are again denoted as V MH and V ML even though their actual values may differ from those indicated above for the ECL gate in FIG. 1.
Output stage 22 contains like-configured amplifiers A1 and A2 whose control electrodes receive voltages V M1 and V M2 . The first electrodes of amplifiers A1 and A2 supply currents I A1 and I A2 to nodes N1 and N2. The A1 and A2 second electrodes are both tied to the V HH supply.
The remaining components of output stage 22 consist of an amplifier A3, a discharge capacitor CD1, and current supplies 24 and 26. Amplifier A3, which is preferably configured the same as amplifiers A1 and A2, has its control and second electrodes respectively connected to nodes N2 and N1. Its first electrode provides a current I A3 to a node N3. Discharge capacitor CD1 is connected between node N3 and a source of a reference voltage V R1 . A current I D1 flows from node N3 into (the upper plate of) capacitor CD1. Current supply 24 is connected between the V LL supply and node N3. Current supply 26 is connected between the V LL supply and node N2. Supplies 24 and 26 provide supply currents I S1 and I S2 to nodes N3 and N2 at which voltages V N3 and V N2 are present.
Output voltage V O1 is taken from node N1. Output current I O1 again flows out of the V O1 terminal. The circuit in FIG. 3 drives a parasitic load capacitance represented by capacitor CL1 connected between node N1 and the V LL supply. Current I L1 again flows into capacitor CL1.
FIG. 4 shows waveforms useful in understanding how the circuit in FIG. 3 functions. The waveforms in FIG. 4 illustrate the specific example in which currents I S1 and I S2 are both constant and equal to the same value I S . FIG. 4 also represents the example in which V I is initially at a sufficiently low value, as denoted by the "-" sign, that V M1 (not shown in FIG. 4) is at high level V MH . V M2 (likewise not shown in FIG. 4) is initially at low level V ML .
Amplifiers A1-A3 are all turned on and operate in approximately a unity-gain mode. A defined offset voltage exists between the control and first electrodes of each of amplifiers A1-A3. V O1 is thereby at a high level, represented as V OH , that is a specified amount below V MH . V N2 is at a low level, represented as V OL , that is largely the same amount below V ML . A relatively large voltage drop occurs across amplifier A3--i.e., between its first and second electrodes. Consequently, V N3 is initially at a low level V DL as indicated in the left half of FIG. 4.
I A3 initially equals I S . I D1 and I L1 are both zero. Capacitor CL1 is charged to a high level. Capacitor CD1 is charged to a low level.
The circuit in FIG. 3 is switched by raising V I to a value that is sufficiently high, as represented by the "+" sign in FIG. 4, to bring V M1 down to V ML . Amplifier A1 temporarily becomes less conductive and reduces current I A1 supplied to node N1. V M2 rises up to V MH . Amplifier A2 temporarily becomes more conductive and pulls V N2 up to V OH in rise time t R . The increase in V N2 causes amplifier A3 to become temporarily more conductive. V N3 is similarly pulled up to a high level V DH in a time largely equal to t R . Again, see the left half of FIG. 4.
As V N3 increases, capacitor CD1 charges through amplifier A3 to a high level. I D1 temporarily increases in the manner generally shown in the left half of FIG. 4, causing I A3 to increase temporarily in the same way. The presence of capacitor CD1 thereby enables I A3 to increase temporarily to a value considerably higher than I S .
The increase in the conductivity of amplifier A3 causes the voltage across it to decrease. This allows V O1 to decrease. Capacitor CO1 discharges to a low level. The discharge of capacitor CO1 occurs primarily through amplifier A3 and, thus, through capacitor CD1 and current supply 24. Because usage of capacitor CD1 allows I A3 to rise considerably above I S , the magnitude of I L1 is not limited by current supply 24 and thereby temporarily reaches a value considerably greater than Is. See the left half of FIG. 4. The result is that capacitor CL1 discharges more rapidly than what would occur if capacitor CD1 were absent. Accordingly, V O1 drops to V OL in a substantially reduced fall time t F *.
The opposite events basically occur when V I is returned to the low ("-") value except that the charge/discharge paths for capacitors CD1 and CL1 are different. Capacitor CD1 discharges through current supply 24 to a low level. Capacitor CL1 charges through amplifier A1 to a high level. Amplifier A1 conducts considerably more current than supply 24. Consequently, V O1 rises up to V OH in a rise time t R * as indicated in the right half of FIG. 4. Because supply 24 is used in discharging capacitor CD1, t R * is typically slightly less than t R .
As to capacitor CD1, the maximum magnitude of I D1 is equal to I S during the second switching transition. See the right half of FIG. 4. V N3 thereby drops to V DL in a relatively long fall time t F '. V N2 similarly drops to V OL in fall time t F which, although typically somewhat less than t F ', is still relatively large. However, t F * is the parameter that limits the circuit switching speed. Since t F * is quite small, the relatively high values for t F and t F ' do not cause a problem at normal circuit switching frequencies.
Importantly, the amount of charge that flows into capacator CD1 during a switching transition in one direction largely equals the amount of charge that flows out of capacitor CD1 during a switching transition in the opposite direction. That is, the area "under" the I D1 curve in the left half of FIG. 4 is largely equal to the area "under" the I D1 curve in the right half of FIG. 4. Amplifier A3 draws little current. Accordingly, amplifier A3 and capacitor CD1 do not draw any significant steady-state current.
Moving to FIG. 5, it shows a general implementation of a "double-ended" version of a switching circuit in accordance with the invention. The circuit in FIG. 5 produces complementary output voltage signals V O1 and V O2 in response to differential input voltage signal V I . The circuit consists of input stage 20, as described above for FIG. 3, and an output stage 28 connected between the V LL and V HH supplies.
Output stage 28 is formed with like-configured amplifiers A1 and A2, like-configured cross-coupled amplifiers A3 and A4, discharge capacitors CD1 and CD2, and current supplies 24 and 26. Amplifiers A3 and A4 are preferably configured the same as amplifiers A1 and A2. Components A1-A3, CD1, and 24 are interconnected the same as in FIG. 3.
Amplifier A4 has its control and second electrodes respectively connected to nodes N1 and N2. Its first electrode provides a current IA4 to a node N4. Capacitor CD2 is connected between node N4 and a source of a reference Voltage VR2. A current I D2 flows from node N4 into (the upper plate of) capacitor C D2 . Current supply 26 is here connected between the V LL supply and node N4. Supply 26 provides supply current I S2 to node N4 at which a voltage V N4 is present.
Output voltage V O1 , output current I O1 , and capacitor current I L1 exist or are located at the same places as in FIG. 3. Output voltage V O2 is taken from node N2. Output current I O2 again flows out of the V O2 terminal. In addition to driving the load capacitance represented by capacitor CL1, the circuit in FIG. 5 drives a parasitic load capacitance represented by capacitor CL2 connected between node N2 and the V LL supply. Current I L2 again flows into capacitor CL2.
FIG. 6 shows waveforms that illustrate how the circuit in FIG. 5 typically functions. All the definitions and initial conditions given above in explaining the operation of the circuit in FIG. 3 apply to the circuit in FIG. 5. V O2 , which basically replaces V N2 in FIGS. 3 and 4, is initially at V OL . Amplifier A4 is conductive and operates in approximately a unity-gain fashion with a defined offset voltage between its control and first electrodes. A relatively small voltage drop exists across amplifier A4--i.e., between its flow electrodes. Consequently, V N4 is initially at high level V DH as shown in the left half of FIG. 6.
As with I A3 , I A4 is initially equal to I S . Capacitor CL2 is charged to a low level, just the opposite of capacitor CL1. Similarly, capacitor CD2 is charged to a high level, just the opposite of capacitor CD1. I D2 and I L2 are both equal to zero along with I D1 and I L1 .
Raising V I to the "+" level causes the circuit in FIG. 5 to switch. Elements A1-A3, CD1, and CL1 go through substantially the same changes described above for FIG. 3. Compare FIGS. 4 and 6. Capacitor CL1 thereby discharges substantially faster than it would discharge if capacitor CD1 were absent. As indicated in the left half of FIG. 6, this enables V O1 to drop down to V OL in reduced fall time t F *.
The decrease in V O1 causes amplifier A4 to become temporarily less conductive. The increased resistance across amplifier A4 forces V N4 to drop down to B DL . Capacitor CD2 discharges through current supply 26. During the switching transition, V O2 rises to V OH as capacitor CL2 charges through amplifier A2 to a high level. Amplifier A2 conducts considerably more current than supply 26. Accordingly, V O2 reaches V OH in slightly shortened rise time t R *.
V N3 follows V O2 upward and also substantially reaches V DH in time t R *. Because the maximum magnitude of I D2 is limited to I S as shown in the left half of FIG. 6, V N4 takes a relatively long time t F " to fall to V DL . However, the elevated value for t F " is not a problem at normal circuit frequencies since t F * (the parameter which limits the circuit switching speed) is quite small.
Complementary events to those described above occur when V I is returned to the "-" level. That is, elements A2, A4, 26, CL2, and CD2 go through the same respective actions as elements A1, A3, 24, CL1, and CD1, and vice versa. As indicated in the right half of FIG. 6, V O2 thereby drops down to V OL in substantially reduced fall time t F *. V O1 goes up to V OH in slightly shortened rise time t R *.
As with the circuit of FIG. 3, the amount of charge that flows into capacitor CD1 during one switching transition is largely equal to the amount of charge that flows out of capacitor CD1 during the next switching transition. Similarily, the amount of charge that flows out of capacitor CD2 during one switching transition is largely equal to the amount of charge that flows into capacitor CD2 during the following transition. Components A3, A4, CD1, and CD2 thus improve the switching speed without significantly raising the steady-state current requirements for the circuit.
In the preceding operational examples for the circuits of FIGS. 3 and 5, it was assumed that supply currents I S1 and, in the case of FIG. 5, I S2 are fixed--i.e., supplies 24 and 26 are constant current sources. Nonetheless, qualitatively the same action occurs if I S1 and I S2 vary in a conventional manner--e.g., each of supplies 24 and 26 is implemented with a resistor. The charge exchanged between capacitors CL1 and CD1 and, in the case of FIG. 5, between capacitors CL2 and CD2, enables the circuits to switch faster without drawing significant additional steady-state current.
FIG. 7 illustrates a general ECL embodiment of the circuit in FIG. 5. V HH and V LL in FIG. 5 correspond respectively to V CC and V EE in this embodiment. Reference voltages V R1 and V R2 are both V EE here.
Input stage 20 is implemented in FIG. 7 with NPN input transistors QI1 and QI2, collector resistors RC1 and RC2, and substantially constant current source 14 arranged the same as in input stage 10 of FIG. 1. Amplifiers A1 and A2 in FIG. 5 are embodied here with NPN output transistors QO1 and QO2 as in FIG. 1. Amplifiers A3 and A4 are implemented with largely identical NPN transistors QO3 and QO4 in FIG. 7. Capacitors CD1 and CD2 are substantially equal in value. Finally, supplies 24 and 26 are respectively embodied here with largely identical substantially constant current sources 30 and 32.
Input stage 20 in FIG. 7 operates in the manner described above for input stage 10 in FIG. 1. Output stage 28 in FIG. 7 operates in the particular way described above for FIG. 5 as illustrated in FIG. 6.
Turning to FIG. 8, it depicts a preferred two-input NOR gate ECL implementation (or extension) of the circuit in FIG. 5. Many of the specific elements and parameters in FIG. 8 are the same as in FIG. 7. The correspondence between these specific items and the more general items in FIG. 5 is self-evident and, accordingly, is not discussed further here. Only the areas in which FIG. 8 goes into more detail than, or differs from, FIG. 5 are discussed below.
Input stage 20 in FIG. 8 contains largely identical NPN input transistors QI1A and QIAB, each of which corresponds to input transistor Q1 in FIG. 7. The QI1A and QI1B bases receive input voltages V I1A and V I1B , each of which corresponds to V I1 . V BB in FIG. 8 is a substantially fixed reference voltage that corresponds to V I2 in FIG. 7. Current source 14 is implemented with an NPN transistor QE and a resistor RE arranged as shown. The QE base receives a substantially constant reference voltage V RE .
Input stage 20 in FIG. 8 operates in a conventional way. When V I1A and V I2A are both at least 60 millivolts below V BB , transistor QI2 is turned on and draws all of current I E through resistor RC2. V M2 is at V ML , while V M1 is at V MH . If one or both of V I1A and V I1B is raised to a value at least 60 millivolts higher than V BB , transistor QI2 turns off. V M1 and V M2 switch values.
In output stage 28 of FIG. 8, capacitors CD1 and CD2 are respectively implemented with PN diodes D1 and D2 whose anodes are connected to the V EE supply. Diodes D1 and D2 are thus reverse biased during normal circuit operation. Supplies 24 and 26 are respectively formed with equal-value current-supply resistors RS1 and RS2 in FIG. 8. Stage 28 here operates in the manner described above except that resistors RS1 and RS2 cause I S1 and I S2 to vary linearly with V N3 and V N4 .
Output stage 28 in FIG. 8 also contains Schottky diodes S1 and S2 and equal-value discharge resistors RD1 and RD2 connected as shown. Diodes S1 and S2 permit larger voltage swings to occur in V O1 and V O2 while preventing the QO3 and QO4 collector-to-emitter voltages from dropping to unacceptably low values. Resistors RD1 and RD2 help to discharge the QO3 and QO4 bases so as to speed up the switching of transistors QO3 and QO4.
In the preferred embodiment of FIG. 8, V CC and V EE are 0 and -4.5 volts, respectively. V BB and V RE are -1.3 and -3.2 volts, respectively. Resistors RE, RC1/RC2, RS1/RS2, and RD1/RD2 are 800, 1,600, 8,000 and 30,000 ohms, respectively. Capacitors CD1 and CD2 are each approximately 200 femtofarads. Capacitors CL1 and CL2 are each typically approximately 200 femtofarads. The circuit is formed as part of a monolithic semiconductor integrated circuit.
While the invention has been described with reference to particular embodiments, this description is solely for the purpose of illustration and is not to be construed as limiting the scope of the invention claimed below. For example, the circuit in FIG. 3 could be implemented using the circuit element shown in FIG. 7 or 8. Various changes and modifications may thus be made by those skilled in the art without departing from the true scope and spirit of the invention as defined in the appended claims.
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A circuit formed with an input stage (20) and an output stage (22 or 28) uses capacitively enhanced switching to improve switching speed without significantly raising steady-state current utilization. The output stage contains a pair of amplifiers (A1and A2) that respond to complementary signals (V M1 and V M2 ) produced by the input stage. The amplifiers are coupled to a pair of corresponding nodes (N1 and N2). A third amplifier (A3) in the output stage has a control electrode coupled to one of the nodes, a flow electrode coupled to the other node, and another flow electrode coupled to a further node (N3). A current supply (24) provides current at the further node. A charge/discharge element (CD1) produces a capacitive-type charge/discharge action between the further node and a source of a reference voltage (V R1 ). The output stage may also include a fourth amplifier (A4), another current supply (26), and another such charge/discharge element (CD2) arranged in a complementary manner to the three preceding components.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The present application is a U.S. National Phase Application pursuant to 35 U.S.C. §371 of International Application No. PCT/EP211/054986 filed Mar. 31, 2011, which claims priority to European Patent Application No. 10158613.9 filed on Mar. 31, 2010 and U.S. patent application Ser. No. 12/791,499 filed Jun. 1, 2010. The entire disclosure contents of these applications are herewith incorporated by reference into the present application.
FIELD OF THE INVENTION
[0002] The present invention relates to a piston rod assembly for a drug delivery device that allows a user to select single or multiple doses of an injectable medicinal product and to dispense and to deliver the set dose to a patient, preferably by way of injection. In particular, the present invention relates to such drug delivery devices that are handled by the patients themselves, such like pen-type injectors.
BACKGROUND
[0003] Drug delivery devices allowing for multiple dosing of a required dosage of a liquid medicinal product, such as a liquid medicament, and further providing administration of the liquid to a patient, are as such well-known in the art. Generally, such devices have substantially the same purpose as that of an ordinary syringe.
[0004] Drug delivery devices of this kind have to meet a number of user specific requirements. For instance in case of those with diabetes, many users will be physically infirm and may also have impaired vision. Therefore, these devices need to be robust in construction, yet easy to use, both in terms of the manipulation of the parts and understanding by a user of its operation. Further, the dose setting must be easy and unambiguous and where the device is to be disposable rather than reusable, the device should be inexpensive to manufacture and easy to dispose. In order to meet these requirements, the number of parts and steps required to assemble the device and an overall number of material types the device is made from have to be kept to a minimum.
[0005] Typically, the medicinal product to be administered is provided in a cartridge that has a moveable piston or bung mechanically interacting with a piston rod of a drive mechanism of the drug delivery device. By applying thrust to the piston in distal direction, a certain amount of the medicinal fluid is expelled from the cartridge and may be administered to the patient by some kind of needle assembly being in fluid communication with the cartridge.
[0006] Due to inevitable manufacturing tolerances of the device and the cartridge there may for instance persist axial clearance between a cartridge's piston and the piston rod when the device is finally assembled. Typically, prior to a primary use of the device, an end-user, e.g. a patient has to conduct a so-called set-up of the drive mechanism in order to ensure, that the piston of the cartridge and the piston rod are located at a pre-defined position with respect to each other, thus ensuring, that with an initial dose setting and a subsequent dose dispensing step, a predefined amount of the medicinal product can be disposed in an accurate way. By way of the set-up step, mechanical tolerances of movable components of the drug delivery device can be annihilated.
[0007] In particular with disposable drug delivery devices, wherein the entire device is discarded after consumption of the medicament, the device is initially provided with a cartridge containing the medicament. Such disposable but also reusable drug delivery devices are assembled in a mass production process in which for instance two housing components of the drug delivery device receive a cartridge and a drive mechanism including the piston rod, respectively. Then, in a final step of assembly, the two pre-configured housing components or respective sub-assemblies are to be mutually interconnected. When reaching a defined final assembly configuration, it would be beneficial when the piston rod and the piston of the cartridge either mutually abut or when piston and piston rod are separated by a pre-defined gap.
[0008] Exact and precise mutual positioning and alignment of piston and piston rod is important and crucial for accurate and reliable functionality of the drug delivery device. Moreover, the piston rod should not exert pressure to the plunger during assembly, which may otherwise result in a rather uncontrolled expelling of the medicament prior to a first use of the drug delivery device when a needle is attached.
[0009] Since at least some or even major components of the drug delivery device are designed as plastic injection molded components, the components themselves, and their assembly is inevitably subject to certain geometric tolerances. Moreover, the cartridge itself and in particular the position of the piston within the cartridge may vary.
[0010] It is therefore an object of the present invention to provide an improved piston rod assembly for a drug delivery device which may allow compensating for geometric tolerances of the drug delivery device and its components. In a further object, the piston rod assembly and the respective drug delivery device should be intuitive and easy in handling. Furthermore, a general compatibility of the piston rod assembly and of a respective drug delivery device with existing manufacturing processes is a further aim of the invention. Finally, the invention should be implementable with reasonable costs and expenditure.
SUMMARY
[0011] In a first aspect, the invention provides a piston rod assembly for a drug delivery device which is adapted to become operably engaged with a piston of a cartridge that is filled with an injectable fluid, in particular with a medicament, such like insulin. The piston rod assembly is intended to become operably engaged with a drive mechanism of a drug delivery device allowing for setting a pre-defined dose and to induce an axial displacement on the piston rod in distal direction in order to move the piston of the cartridge in a respective direction for expelling a pre-defined amount of the medicament.
[0012] The piston rod is therefore adapted to be operably engaged with a piston of a cartridge containing a medicament. Mutual engagement of piston rod and piston preferably comprises a unidirectional thrust transferring engagement of piston rod and piston, e.g. through a mutual and releasable abutment. Hence, the piston rod assembly is adapted and intended to move the piston in only one direction. It is therefore sufficient, when respective abutment surfaces of piston rod assembly and piston are of substantially planar geometry. During a typical dispensing procedure, the cartridge itself is in fluid communication with a piercing assembly, such like a needle, a cannula, an infusion tube or with similar delivery devices.
[0013] The cartridge itself can comprise a vial or carpule, sealed by means of the movable piston. In alternative embodiments, the cartridge may also comprise a syringe, preferably adapted and designed for a single use.
[0014] The piston rod assembly further comprises at least one adjusting member displaceably disposed at the piston rod. The adjusting member is thus connected to the piston rod and can be displaced with respect to the piston rod, preferably along the piston rod's long axis, hence in axial direction. Here, the adjusting member is interconnected with a distal end section of the piston rod facing towards the piston of the cartridge. Consequently, the at least one adjusting member is to be arranged between the piston rod and the cartridge's piston. The adjusting member therefore serves as a kind of interface member intended to reduce and/or to annihilate variations of the mutual distance and/or relative position of piston rod and piston that are for instance due to manufacturing and/or assembly tolerances.
[0015] The piston rod assembly further comprises at least one interlock means which is adapted to interact with the adjusting member and/or with the piston rod for mutually locking in position the adjusting member and the piston rod in an arbitrary relative position to each other. In particular, the adjusting member's axial position relative to the piston rod can be continuously modified, preferably for eliminating said manufacturing and assembly tolerances. Once the adjusting member has been positioned in a tolerance-eliminating configuration with the piston rod, its relative position to the piston rod can be either permanently or releasably locked by way of the at least one interlock means.
[0016] During a tolerance eliminating procedure, adjusting member and piston rod are mutually displaceable with respect to each other. In other words, they may be telescopically shiftable in axial direction. Once a tolerance-eliminating configuration has been attained, adjusting member and piston rod can be mutually interlocked in such a way, that the piston rod assembly is enabled to transfer a respective thrust to the piston required for displacing the piston in distal direction. By having a piston rod and an adjusting member displaceably attached or connected thereto, the overall axial dimension and extension of the piston rod assembly becomes variable, in particular for the purpose of tolerance elimination.
[0017] Furthermore, the adjusting member and the piston rod are threadedly engaged in order to axially displace the piston rod and the adjusting member relative to each other. By way of a threaded engagement of adjusting member and piston rod, the overall axial dimensions of the piston rod assembly can be modified in a continuous way. It is of further benefit when the interlock means is adapted to inhibit self-acting relative rotation of piston rod and adjusting member. Hence, the interlock means prevents, that the adjusting member autonomously rotates with respect to the piston rod and vice versa. By way of the threaded engagement, axially directed forces and thrust can be transferred, e.g. from a drive mechanism via the piston rod to the adjusting member and finally to the piston of the cartridge.
[0018] Since the interlock means is designed for inhibiting self-acting relative rotation of piston rod and adjusting member, the interlock means itself may not have to withstand those comparatively large axial forces or respective thrust, which is required to displace the piston of the cartridge in distal direction.
[0019] In a further preferred aspect, the adjusting member comprises a threaded receptacle, which is adapted to receive a correspondingly threaded distal socket portion of the piston rod.
[0020] In an alternative embodiment, the piston rod comprises a threaded receptacle at its distal end section, which is adapted to receive a correspondingly threaded proximal socket portion of the adjusting member. Hence, the threaded engagement of piston rod and adjusting member can be generally implemented either way.
[0021] In another preferred aspect, the interlock means comprises at least one resiliently biased tongue member which is adapted to engage with a corrugated surface portion of the adjusting member or of the piston rod. Preferably, the interlock means may positively engage with a side wall of the receptacle of either the adjusting member or the piston rod. Additionally, the interlock means is preferably arranged on that part or component of the piston rod assembly comprising the socket portion.
[0022] In another preferred embodiment, the tongue member is arranged laterally offset with respect to the socket portion. With respect to the transverse plane of the piston rod assembly that extends perpendicular to the piston rod's long axis, the axially protruding socket portion is typically arranged in the centre of the piston or on the centre of the adjusting member. Here, the resiliently biased tongue member is arranged and displaced with a lateral or radial offset with respect to the socket portion. Hence, mutual arrangement of socket portion and tongue member is such that a gap is formed there between adapted to receive a side wall section of the receptacle.
[0023] In a further preferred embodiment, the radially inwardly facing side wall section of the receptacle is threaded in order to provide threaded engagement with the correspondingly threaded socket portion. The side wall section of the receptacle at its outwardly facing side is preferably corrugated or comprises a ribbed structure, by way of which a kind of positive or frictional engagement of the receptacle and the tongue member can be established in order to inhibit self-acting relative rotation of the receptacle relative to the socket portion.
[0024] In alternative embodiments it is also conceivable, that an outwardly facing side wall section of the receptacle is threaded and wherein an inwardly facing side wall section of said receptacle is corrugated or comprises a ribbed surface structure. In such embodiments, the resiliently biased tongue members are preferably arranged radially inward with respect to the threaded engagement of adjusting member and piston rod.
[0025] Mutual engagement and interaction of resiliently biased tongue members and the corrugated surface provides a kind of snap-in feature. Depending on the overall number of longitudinally extending ribs or corrugations and the pitch of the thread a fine adjustment of piston rod and adjusting member in a sub-millimetres range, preferably in a range of 1/10 mm or even 1/100-mm can be attained.
[0026] In a further preferred embodiment, threaded and corrugated side wall sections of the receptacle are arranged at least partially offset with respect to each other in axial direction. Moreover, the corrugations or the ribs of said wall section comprise an axial extension substantially corresponding with an overall axial extension of the mutually corresponding threads of receptacle and socket portion.
[0027] According to a further embodiment, the piston rod comprises at least two tongue members arranged at the piston rod and being axially displaced in proximal direction with respect to the piston rod's distal end section. Here, the tongue members, that are preferably arranged opposite to each other in the transverse plane comprise radially inwardly pointing lug portions that are adapted to engage with the corrugated or ribbed outer side wall section of a proximal end of the adjusting member comprising a cupped receptacle.
[0028] In a further aspect, it is intended, that the adjusting member comprises a contact surface at its distal end section that faces towards a proximal end section of the piston if the drug delivery device is in a final assembly configuration. The contact or abutment surface is of substantially plane shape and preferably extends in the transverse plane, hence perpendicular to the axial or longitudinal extension of the piston rod. Preferably, the distally facing outer surface of the cupped receptacle of the adjusting member serves as a contact surface. By way of a substantially planar contact surface, the piston rod assembly and the piston of the cartridge are not to mechanically engaged and may be easily separated on demand, e.g. when an empty cartridge is to be replaced by a filled one. A planar shaped abutment surface also facilitates to establish a gap of predetermined size between the piston rod assembly and the piston if required.
[0029] In a final assembly configuration of the drug delivery device, the contact surface of the adjusting member may already abut with a proximal end section of the piston. Hence, during assembly of the drug delivery device, the adjusting member is configured such, that upon reaching the final assembly configuration, the contact surface of the adjusting member gets in direct contact with a proximal end of the piston. The drug delivery device is ready to use when delivered to customers. An initial set-up step for bringing piston rod assembly and piston of the cartridge in abutment with each other is no longer required and becomes superfluous.
[0030] Preferably, mutual abutment of piston and piston rod is such, that the piston does not yet apply substantial pressure or thrust to the piston in order to prevent generation of droplet at the distal tip of a needle assembly when assembled to the cartridge. Generally, in this way, the overall device handling can be simplified.
[0031] However, in another and alternative embodiment it is also conceivable, that the piston rod assembly is configured during assembly of the drug delivery device in such a way, that a pre-defined gap between adjusting member and piston of the cartridge is attained when the device is in its final assembly configuration. Here, the adjusting member is manipulated during final assembly of the drug delivery device in such a way, that the gap matches with a pre-defined gap size. Set-up of the cartridge may for instance be implemented in the drive mechanism of the drug delivery device. Also here, the end user does not have to conduct or to trigger a set-up step in which piston rod assembly and piston of the cartridge are brought into mutual abutment.
[0032] In another independent aspect, the invention further relates to a drug delivery device for dispensing of a dose of a medicament. The drug delivery device comprises a first housing component adapted to receive and to house a cartridge that comprises the medicament, wherein the cartridge comprises a piston slidably arranged therein in an axial direction. By way of the piston, the inner volume of the cartridge is sealed in proximal direction while the cartridge further comprises an outlet, facing in distal direction and which is to be coupled with a piercing element, such like and injection needle or a cannula in a fluid-transferring way.
[0033] The drug delivery device further comprises a second housing component which is adapted to house a drive mechanism that comprises a piston rod assembly as described above.
[0034] The first and second housing components are further adapted to be interlocked by way of mutually corresponding fastening means, for instance by way of a snap-in feature or otherwise e.g. by way of a threaded engagement. During assembly and in particular before first and second housing components are joined together, the piston rod assembly, which is variable in length, is adapted to modify an axial gap between the piston rod assembly and the piston of a cartridge to a predefined gap size. Depending on the type of drive mechanism, the gap size may equal zero, wherein the piston rod assembly and the cartridge's piston mutually abut upon assembly of first and second pre-configured housing components.
[0035] The axial gap size between the piston rod assembly and the piston is modifiable by way of the threaded engagement of the adjusting member and the piston rod in order to axially displace the piston rod and the adjusting member relative to each other. The interlock means is further adapted to inhibit self-acting relative rotation of piston rod and adjusting member. By way of the interlock means, the actual length or axial extension of the piston rod assembly can be fixed.
[0036] It is even conceivable, that the interlock means is of releasable type. This way, a given axial length of the piston rod can even be modified at a later stage, e.g. when the cartridge is subject to replacement.
[0037] Alternative and in another preferred embodiment, the gap size between the piston rod assembly and the piston or between the adjusting member and the piston is larger than zero. The distance between the piston and the piston rod assembly may range between 0.1 mm to 2.0 mm and is preferably less than 1 mm. In this embodiment, compensation of the gap is implemented into the drive mechanism of the drug delivery device.
[0038] In a further preferred aspect, the axial gap size between the piston rod assembly and the piston of the cartridge is modifiable by way of rotating the adjusting member and/or the piston rod relative to each other during assembly of the drug delivery device. In particular, the piston rod may be rotatably locked with respect to first and/or second housing components while the adjusting member is threadedly engaged with a distal end section of the piston rod. However, it is also conceivable, that both, adjusting member and piston rod are rotatably supported in the respective housing components.
[0039] In a further preferred embodiment, in particular in embodiments, wherein the axial gap size between piston rod assembly and piston is larger than zero, the drug delivery device further comprises a drive member which is releasably coupled to the piston rod and further comprises a resilient member which is arranged to move the drive member in the proximal direction with respect to the second housing component of the dose delivery, such that the piston rod is moved away from the piston by a pre-defined distance from a position of use, in which piston and piston rod assembly mutually abut, into an idle position, in which a pre-defined gap between the piston rod assembly and the piston of the cartridge is attained.
[0040] This has the advantage that a simple and precise usage of the drug delivery device is enabled. A user may administer a number of pre-set doses of the medicament. For example, when, after dose delivery, a force in the distal direction exerted on the drive member for dose delivery has been removed from the drive member, the drive member is moved in the proximal direction with respect to the housing due to the resilient member mechanically interacting with the drive member. The drive member may move in the axial direction with respect to the housing and/or rotate with respect to the housing. The proximal movement of the drive member may take place before the next dose is set. The piston rod may follow at least partly this movement of the drive member in the proximal direction. In particular, the drive member may be moved directly by the resilient member in the proximal direction with respect to the housing, whereas the piston rod may be moved indirectly by the resilient member via the movement of the drive member in the proximal direction with respect to the housing that is transferred to the piston rod. Thus, the piston rod may be moved relative to the piston in the proximal direction. Thereby, the distance between the piston rod and the piston may be increased. In this way, room is provided that allows a deformed piston, in particular an elastically deformed piston, to relax in the proximal direction after dose delivery.
[0041] Accordingly, after the piston rod has been moved proximally, the pressure exerted by the piston rod on the piston may be reduced or removed from the piston. Thus, the deformed piston may mainly relax in the proximal direction after dose delivery. Uncontrolled relaxation of the piston in the distal direction which may result in unintentionally dispensing fluid from the cartridge may thus be reduced. Furthermore, an increased distance between the piston rod and the piston before setting a subsequent dose may result in reducing the risk of a medicament being unintentionally dispensed from the cartridge, due to vibrations, for example, as the mechanical connection between piston and piston rod is interrupted.
[0042] Overall, the dose accuracy may be improved by moving the piston rod in the proximal direction after dose delivery. Preferably, the piston rod is moved in the proximal direction after dose delivery only as far as it is required for allowing relaxation of the piston in the proximal direction.
[0043] Preferably, the piston is moved in proximal direction in a well-defined idle position, wherein the distance between said idle position and a position of use, in which the piston rod assembly abuts with the piston of the cartridge, is entirely controlled and adjusted by the drive mechanism. Once the relative position between piston rod and adjusting member has been adjusted for the purpose of tolerance elimination, the piston rod assembly can even be axially displaced and may even be separated from the piston without introducing any supplemental tolerances.
[0044] Moreover, the drug delivery device according to the present invention is preferably designed as disposable device. Hence, during assembly, the first housing component is equipped with the cartridge filled with the medicament. In the final assembly of the drug delivery device, first and second housing components are interconnected in a permanent way, such that after consumption of the medicament the entire drug delivery device is intended to become discarded.
[0045] When the drug delivery device enters the sales market it is already provided with a medicament-filled cartridge and it is ready to use.
[0046] In another independent aspect, the invention also refers to a method of assembling a drug delivery device, wherein in a first step the cartridge being filled with the medicament is positioned in the first housing component to form a cartridge sub-assembly. Also, in a similar way, the drive mechanism that comprises the piston rod assembly is positioned in the second housing component to form a housing sub-assembly.
[0047] Thereafter, axial position of the piston is individually determined with respect to the first housing component, and in a corresponding way, also the axial position of the piston rod assembly is determined or measured. In particular the position of the distal end face of the piston rod assembly and/or the position of the proximal end face of the piston is determined with respect to the first and second housing components, respectively. Having determined or measured axial positions of the piston and the piston rod assembly with respect to their respective sub-assembly or housing component, the axial dimensions or axial elongation of the piston rod assembly is modified by moving the adjusting member relative to the piston rod, such that the axial distance between the piston and the piston rod assembly equals the pre-defined gap size when the drug delivery device is finally assembled, e.g. by interconnecting cartridge sub-assembly and housing sub-assembly. After having modified the relative axial position of adjusting member and piston rod, first and second housing components are mutually interconnected in a final step of assembly.
[0048] Typically, axial positions of piston and/or piston rod assembly are determined with respect to selected reference points of a respective cartridge or housing sub-assembly or with respect to reference points of respective first and/or second housing components. For instance, mutually corresponding connecting or fastening means of first and second housing components may serve as reference points for determining respective axial positions of the cartridge's piston and/or of the distal end face of the piston rod assembly. Measuring of the relative or absolute positions of piston and piston rod and/or of its adjusting member is conducted by way of tactile means and/or contactless, e.g. in an all-optical way.
[0049] In a further preferred embodiment, the axial position of the piston rod assembly and in particular the axial position of the adjusting member is modified when the piston rod or the piston rod assembly is in its position of use. Additionally, also determination or measuring of the axial position of the piston rod might be conducted with the piston rod, in particular the piston rod assembly being in its position of use. This way, any axial tolerances that might be due to the functionality of the drive mechanism to displace the piston rod between a position of use and an idle position are of no consequences and do not have to be considered.
[0050] The term “medicament”, as used herein, means a pharmaceutical formulation containing at least one pharmaceutically active compound,
[0051] wherein in one embodiment the pharmaceutically active compound has a molecular weight up to 1500 Da and/or is a peptide, a proteine, a polysaccharide, a vaccine, a DNA, a RNA, a antibody, an enzyme, an antibody, a hormone or an oligonucleotide, or a mixture of the above-mentioned pharmaceutically active compounds,
[0052] wherein in a further embodiment the pharmaceutically active compound is useful for the treatment and/or prophylaxis of diabetes mellitus or complications associated with diabetes mellitus such as diabetic retinopathy, thromboembolism disorders such as deep vein or pulmonary thromboembolism, acute coronary syndrome (ACS), angina, myocardial infarction, cancer, macular degeneration, inflammation, hay fever, atherosclerosis and/or rheumatoid arthritis,
[0053] wherein in a further embodiment the pharmaceutically active compound comprises at least one peptide for the treatment and/or prophylaxis of diabetes mellitus or complications associated with diabetes mellitus such as diabetic retinopathy,
[0054] wherein in a further embodiment the pharmaceutically active compound comprises at least one human insulin or a human insulin analogue or derivative, glucagon-like peptide (GLP-1) or an analogue or derivative thereof, or exedin-3 or exedin-4 or an analogue or derivative of exedin-3 or exedin-4.
[0055] Insulin analogues are for example Gly(A21), Arg(B31), Arg(B32) human insulin; Lys(B3), Glu(B29) human insulin; Lys(B28), Pro(B29) human insulin; Asp(B28) human insulin; human insulin, wherein proline in position B28 is replaced by Asp, Lys, Leu, Val or Ala and wherein in position B29 Lys may be replaced by Pro; Ala(B26) human insulin; Des(B28-B30) human insulin; Des(B27) human insulin and Des(B30) human insulin.
[0056] Insulin derivates are for example B29-N-myristoyl-des(B30) human insulin; B29-N-palmitoyl-des(B30) human insulin; B29-N-myristoyl human insulin; B29-N-palmitoyl human insulin; B28-N-myristoyl LysB28ProB29 human insulin; B28-N-palmitoyl-LysB28ProB29 human insulin; B30-N-myristoyl-ThrB29LysB30 human insulin; B30-N-palmitoyl-ThrB29LysB30 human insulin; B29-N—(N-palmitoyl-Y-glutamyl)-des(B30) human insulin; B29-N—(N-lithocholyl-Y-glutamyl)-des(B30) human insulin; B29-N-(ω-carboxyheptadecanoyl)-des(B30) human insulin and B29-N-(ω-carboxyheptadecanoyl) human insulin.
[0057] Exendin-4 for example means Exendin-4(1-39), a peptide of the sequence H-His-Gly-Glu-Gly-Thr-Phe-Thr-Ser-Asp-Leu-Ser-Lys-Gln-Met-Glu-Glu-Glu-Ala-Val-Arg-Leu-Phe-Ile-Glu-Trp-Leu-Lys-Asn-Gly-Gly-Pro-Ser-Ser-Gly-Ala-Pro-Pro-Pro-Ser-NH2.
[0058] Exendin-4 derivatives are for example selected from the following list of compounds:
H-(Lys)-4-des Pro36, des Pro37 Exendin-4(1-39)-NH2,
H-(Lys)-5-des Pro36, des Pro37 Exendin-4(1-39)-NH2,
des Pro36 [Asp28] Exendin-4(1-39),
des Pro36 [IsoAsp28] Exendin-4(1-39),
des Pro36 [Met(O)14, Asp28] Exendin-4(1-39),
des Pro36 [Met(O)14, IsoAsp28] Exendin-4(1-39),
des Pro36 [Trp(O2)25, Asp28] Exendin-4(1-39),
des Pro36 [Trp(O2)25, IsoAsp28] Exendin-4(1-39),
des Pro36 [Met(O)14 Trp(O2)25, Asp28] Exendin-4(1-39),
des Pro36 [Met(O)14 Trp(O2)25, IsoAsp28] Exendin-4(1-39); or
des Pro36 [Asp28] Exendin-4(1-39),
des Pro36 [IsoAsp28] Exendin-4(1-39),
des Pro36 [Met(O)14, Asp28] Exendin-4(1-39),
des Pro36 [Met(O)14, IsoAsp28] Exendin-4(1-39),
des Pro36 [Trp(O2)25, Asp28] Exendin-4(1-39),
des Pro36 [Trp(O2)25, IsoAsp28] Exendin-4(1-39),
des Pro36 [Met(O)14 Trp(O2)25, Asp28] Exendin-4(1-39),
des Pro36 [Met(O)14 Trp(O2)25, IsoAsp28] Exendin-4(1-39),
[0059] wherein the group -Lys6-NH2 may be bound to the C-terminus of the Exendin-4 derivative;
or an Exendin-4 derivative of the sequence
H-(Lys)-6-des Pro36 [Asp28] Exendin-4(1-39)-Lys6NH2,
des Asp28 Pro36, Pro37, Pro38Exendin-4(1-39)-NH2,
H-(Lys)-6-des Pro36, Pro38 [Asp28] Exendin-4(1-39)-NH2,
H-Asn-(Glu)5des Pro36, Pro37, Pro38 [Asp28] Exendin-4(1-39)-NH2,
des Pro36, Pro37, Pro38 [Asp28] Exendin-4(1-39)-(Lys)6-NH2,
H-(Lys)-6-des Pro36, Pro37, Pro38 [Asp28] Exendin-4(1-39)-(Lys)6-NH2,
H-Asn-(Glu)-5-des Pro36, Pro37, Pro38 [Asp28] Exendin-4(1-39)-(Lys)6-NH2,
H-(Lys)-6-des Pro36 [Trp(O2)25, Asp28] Exendin-4(1-39)-Lys6-NH2,
H-des Asp28 Pro36, Pro37, Pro38 [Trp(O2)25] Exendin-4(1-39)-NH2,
H-(Lys)-6-des Pro36, Pro37, Pro38 [Trp(O2)25, Asp28] Exendin-4(1-39)-NH2,
H-Asn-(Glu)-5-des Pro36, Pro37, Pro38 [Trp(O2)25, Asp28] Exendin-4(1-39)-NH2,
des Pro36, Pro37, Pro38 [Trp(O2)25, Asp28] Exendin-4(1-39)-(Lys)6-NH2,
H-(Lys)-6-des Pro36, Pro37, Pro38 [Trp(O2)25, Asp28] Exendin-4(1-39)-(Lys)6-NH2,
H-Asn-(Glu)-5-des Pro36, Pro37, Pro38 [Trp(O2)25, Asp28] Exendin-4(1-39)-(Lys)6-NH2,
H-(Lys)-6-des Pro36 [Met(O)14, Asp28] Exendin-4(1-39)-Lys6-NH2,
des Met(O)14 Asp28 Pro36, Pro37, Pro38 Exendin-4(1-39)-NH2,
[0060] H-(Lys)-6-desPro36, Pro37, Pro38 [Met(O)14, Asp28] Exendin-4(1-39)-NH2,
H-Asn-(Glu)-5-des Pro36, Pro37, Pro38 [Met(O)14, Asp28] Exendin-4(1-39)-NH2,
des Pro36, Pro37, Pro38 [Met(O)14, Asp28] Exendin-4(1-39)-(Lys)6-NH2,
H-(Lys)-6-des Pro36, Pro37, Pro38 [Met(O)14, Asp28] Exendin-4(1-39)-(Lys)6-NH2,
H-Asn-(Glu)5 des Pro36, Pro37, Pro38 [Met(O)14, Asp28] Exendin-4(1-39)-(Lys)6-NH2,
H-Lys6-des Pro36 [Met(O)14, Trp(O2)25, Asp28] Exendin-4(1-39)-Lys6-NH2,
H-des Asp28 Pro36, Pro37, Pro38 [Met(O)14, Trp(O2)25] Exendin-4(1-39)-NH2,
H-(Lys)-6-des Pro36, Pro37, Pro38 [Met(O)14, Asp28] Exendin-4(1-39)-NH2,
H-Asn-(Glu)-5-des Pro36, Pro37, Pro38 [Met(O)14, Trp(O2)25, Asp28] Exendin-4(1-39)-NH2,
des Pro36, Pro37, Pro38 [Met(O)14, Trp(O2)25, Asp28] Exendin-4(1-39)-(Lys)6-NH2,
H-(Lys)-6-des Pro36, Pro37, Pro38 [Met(O)14, Trp(O2)25, Asp28] Exendin-4(S1-39)-(Lys)6-NH2,
H-Asn-(Glu)-5-des Pro36, Pro37, Pro38 [Met(O)14, Trp(O2)25, Asp28] Exendin-4(1-39)-(Lys)6-NH2;
[0061] or a pharmaceutically acceptable salt or solvate of any one of the afore-mentioned Exedin-4 derivative.
[0062] Hormones are for example hypophysis hormones or hypothalamus hormones or regulatory active peptides and their antagonists as listed in Rote Liste, ed. 2008, Chapter 50, such as Gonadotropine (Follitropin, Lutropin, Choriongonadotropin, Menotropin), Somatropine (Somatropin), Desmopressin, Terlipressin, Gonadorelin, Triptorelin, Leuprorelin, Buserelin, Nafarelin, Goserelin.
[0063] A polysaccharide is for example a glucosaminoglycane, a hyaluronic acid, a heparin, a low molecular weight heparin or an ultra low molecular weight heparin or a derivative thereof, or a sulphated, e.g. a poly-sulphated form of the above-mentioned polysaccharides, and/or a pharmaceutically acceptable salt thereof. An example of a pharmaceutically acceptable salt of a poly-sulphated low molecular weight heparin is enoxaparin sodium.
[0064] Pharmaceutically acceptable salts are for example acid addition salts and basic salts. Acid addition salts are e.g. HCl or HBr salts. Basic salts are e.g. salts having a cation selected from alkali or alkaline, e.g. Na+, or K+, or Ca2+, or an ammonium ion N+(R1)(R2)(R3)(R4), wherein R1 to R4 independently of each other mean: hydrogen, an optionally substituted C1-C6-alkyl group, an optionally substituted C2-C6-alkenyl group, an optionally substituted C6-C10-aryl group, or an optionally substituted C6-C10-heteroaryl group. Further examples of pharmaceutically acceptable salts are described in “Remington's Pharmaceutical Sciences” 17. ed. Alfonso R. Gennaro (Ed.), Mark Publishing Company, Easton, Pa., U.S.A., 1985 and in Encyclopedia of Pharmaceutical Technology.
[0065] Pharmaceutically acceptable solvates are for example hydrates.
[0066] It will be further apparent to those skilled in the art that various modifications and variations can be made to the present invention without departing from its spirit and scope. Further, it is to be noted, that any reference signs used in the appended claims are not to be construed as limiting the scope of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0067] Without limitation, the present invention will be explained in greater detail below in connection with preferred embodiments and with reference to the drawings in which:
[0068] FIG. 1 shows a sectional view of an exemplary embodiment of a drug delivery device in a first, cartridge full, position,
[0069] FIG. 2 shows a perspective and isolated illustration of the piston rod assembly with an adjusting member disassembled from the piston rod,
[0070] FIG. 3 shows the piston rod assembly according to FIG. 2 , wherein adjusting member and piston rod are mutually assembled,
[0071] FIG. 4 shows a longitudinal cross section of the piston rod according to FIG. 3 , and
[0072] FIG. 5 shows a cross section along A-A according to FIG. 4 .
DETAILED DESCRIPTION
[0073] The drug delivery device 151 comprises a cartridge housing 152 and a cartridge 153 . The cartridge 153 is retained within the cartridge housing 152 . The cartridge has an outlet 153 ′. The device 151 comprises a main (exterior) housing 154 having a proximal end P and a distal end, which is closest to the dispensing end D of the medication delivery device 1 . The proximal end of the cartridge housing 152 and the distal end of the main housing 154 are secured together by any suitable means known to the person skilled in the art. In the illustrated embodiment, the cartridge housing 152 is secured within the distal end of the main housing 154 .
[0074] The cartridge 153 from which a number of doses of a medicament M may be dispensed is provided in the cartridge housing 152 . A piston 155 is retained in the proximal end of the cartridge 153 . A removable cap 156 is releasably retained over the distal end of the cartridge housing 152 . The removable cap 156 may be optionally provided with one or more windows to the cartridge 156 ′ through which the position of the piston 155 within the cartridge 153 can be viewed.
[0075] In the illustrated embodiment, the distal end of the cartridge housing 152 is provided with a distal threaded region 157 designed for the attachment of a suitable needle assembly to enable medication to be dispensed from the cartridge 153 . In the illustrated embodiment, the main housing part 153 is provided with an insert, i.e. internal housing 158 . The internal housing 158 is secured against rotational and axial movement with respect to the main housing 154 . Alternatively, the internal housing 158 may be formed integrally with the main housing 154 . Additionally, the internal housing 158 is provided with a plurality of guide lugs (not illustrated) and pawl means 184 (cf. FIG. 1 ). The pawl means 184 may be an integrated part of the internal housing 158 or may be a separate component.
[0076] A piston rod 160 extending through the main housing 154 has a first set of indentations 161 ′ extending longitudinally along external surfaces of the piston rod 160 . In particular, the piston rod 160 is designed and arranged to be secured against rotational movement with respect to the main housing 154 . A second set of indentations 161 extends longitudinally along internal surfaces of the piston rod 160 . The first set of indentations 161 ′ of the piston rod 160 extends through and is engaged with the pawl means 184 provided on the internal housing 158 to prevent movement of the piston rod 160 in the proximal direction with respect to the housing during setting of the dose. A bearing surface 162 located at the distal end of the piston rod 160 is disposed to abut a proximal face of the piston 155 . In the illustrated embodiment the longitudinal spacing of the first set of indentations and the second set of indentations 161 is essentially equal.
[0077] A pinion gear 163 , consisting of a carrier 164 and a pinion 165 , free to rotate within the carrier 164 , is located within a channel within the piston rod 160 . Pawl arms 166 located on the carrier 164 are releasably engaged with the second set of indentations 161 of the piston rod 160 . The pawl arms 166 of the carrier 164 are designed to transmit force to the piston rod 160 in the distal direction during dispense and to allow relative movement between the pinion gear 163 and the piston rod 160 in the proximal direction during setting the dose. The teeth of the pinion 165 may be permanently engaged with teeth of a second rack (not illustrated) of the internal housing 158 .
[0078] A drive member 167 extends about the piston rod 160 and is releasably coupled to the piston rod 160 . The drive member 17 comprises a rack part and an activation part 169 . The rack part and the activation part 169 are secured to each other to prevent rotational and axial movement there between. Alternatively, the drive member 167 may be a unitary component consisting of an integrated rack part and activation part 169 .
[0079] The rack part is provided with a first rack extending along the main axis of the rack part. The teeth of the first rack of the rack part are permanently engaged with the teeth of the pinion 165 .
[0080] The drive member 167 has a plurality of guide slots (not shown) in which the guide lugs of the internal housing 158 are located. These guide slots define the extent of permissible axial movement of the drive member 167 with respect to the housing 154 . In the illustrated embodiment the guide slots also prevent rotational movement of the drive member 167 relative to the main housing 154 .
[0081] The drug delivery device 151 further comprises a resilient member 171 . The resilient member 171 is arranged to move the drive member 167 , preferably to move the drive member 167 and the piston rod 160 together, in the proximal direction with respect to the main housing 154 after dose delivery, thereby reducing or even removing pressure of the piston rod 160 on the piston 155 . The resilient member 171 is arranged to mechanically interact with the drive member 167 at a distal end side of the drive member 167 . In this exemplary embodiment, the resilient member 171 is formed integrally with the internal housing 158 . Alternatively, the resilient member 171 may be formed integrally with the main housing 154 . In another embodiment, the resilient member may be an element separate from the housing and from the internal housing. For example, the resilient member 171 is a spring, for instance a circular spring, a leaf spring or a coil spring.
[0082] The activation part 169 of the drive member 167 has a plurality of grip surfaces 172 and a dispensing face 174 . To increase intuitiveness of the operation of the medication delivery device 151 and to indicate visual feedback regarding dose setting, the main housing 154 may optionally be provided with a window to the drive member through which graphical status indicators provided on the drive member 167 can be viewed.
[0083] In the following, the operation of the drug delivery device 151 will be described.
[0084] To set a dose a user grips the grip surfaces 172 of the drive member 167 . The user then pulls the drive member 167 in a proximal direction away from the main housing 154 thereby moving the rack part in a proximal direction. The proximal movement of the rack part causes the pinion 165 to rotate and move proximally by virtue of the engagement of the teeth of the pinion 165 of the pinion gear 163 with the teeth of the first rack of the rack part and the teeth of the second rack of the internal housing 158 thus moving the pinion gear 163 in the proximal direction.
[0085] The piston rod 160 is prevented from moving proximally by interaction of pawl means 184 of the internal housing 158 with the first set of indentations 161 ′ on the piston rod 160 during dose setting. As the drive member 167 travels in the proximal direction relative to the piston rod 160 , the pawl arms 166 of the carrier 164 are elastically displaced inwardly by interaction with the second set of indentations 161 of the piston rod 160 .
[0086] The proximal travel of the drive member 167 is limited by the guide slots of the rack part. At the end of the travel of the drive member 167 , the pawl arms 166 of the carrier 164 engage with the next sequential indentation of the second set of indentations 161 of the piston rod 160 as indicated in FIG. 2 . The action of the pawl arms 166 of the carrier 164 positively engaging the second set of indentations 161 of the piston rod 160 creates an audible and tactile feedback to the user to indicate that the dose has been set.
[0087] When the dose has been set, the user may then dispense this dose by depressing the dispensing face 174 of the activation part 169 of the drive member 167 . By this action the drive member 167 and the rack part are moved axially in the distal direction relative to the main housing 154 . As the teeth of the pinion 165 of the pinion gear 163 are engaged with the teeth of the first rack of the rack part and the teeth of the second rack of the internal housing 158 , the pinion 165 of the pinion gear 163 is caused to rotate and move in the distal direction thus moving the pinion gear 163 longitudinally in the distal direction. As the pawl arms 166 of the carrier 164 of the pinion gear 163 are engaged with the second set of indentations 161 of the piston rod 160 , the piston rod 160 is caused to move longitudinally in the distal direction with respect to the internal housing 158 .
[0088] The distal axial movement of the piston rod 160 causes the bearing surface 162 of the piston rod 160 to bear against the piston 155 in the cartridge 153 causing the piston 155 to be deformed and moved distally, thereby causing a dose of medicament to be dispensed through the attached needle (not explicitly shown).
[0089] The distal travel of the drive member 167 is limited by the guide slots (not explicitly shown) of the rack part. Audible and tactile feedback to indicate that the dose has been dispensed is provided by the interaction of the pawl means 184 of the internal housing 158 with the first set of indentations 161 ′ of the piston rod 160 . Additionally, visual feedback regarding dose dispense may optionally be indicated by a graphical status indicator, provided on the drive member 167 , which can be viewed through the optional window to the drive member in the main housing 154 .
[0090] When the drug delivery device 151 is in a condition where the maximum number of doses has been delivered, a proximal face 176 of the carrier 164 abuts an internal distal face 178 of the piston rod 160 to prevent further axial movement of the pinion gear 163 and thus the drive member 167 in proximal direction.
[0091] Further doses may be delivered as required up to a pre-determined maximum number of doses. After distal movement of the drive member 167 for dose delivery is finished, the resilient member 171 has been biased. For example, a distal end face of the drive member may have moved into abutment with the resilient member 171 and the drive member 167 may have been moved further into the distal direction together with the resilient member 171 , thereby biasing the resilient member 171 . After the user removes the force acting on the drive member 167 in the distal direction, the biased resilient member 171 moves the drive member 167 and the piston rod 160 in the proximal direction with respect to the main housing 154 . Thereby, pressure of the piston rod 160 on the piston 155 is reduced as the piston rod is retracted from the piston. In this way, room for relaxation of the piston in the proximal direction may be provided. Relaxation of the piston 155 in the distal direction may be reduced or avoided in this way. Correspondingly, unintentional weeping of the device may be reduced.
[0092] Preferably, the piston rod 160 is moved away from the piston 155 by a distance and/or the drive member 167 is moved by a distance in the range of (about) 0.1 to 2.0 mm, in particular in the range of (about) 0.1 to 0.5 mm, in the proximal direction with respect to the main housing 154 by means of the resilient member 171 moving the drive member 167 in the proximal direction after dose delivery. The distance the drive member 167 is moved does not have to be the same as the distance the piston rod 160 is moved, i.e. the piston rod 160 and the drive member 167 may be coupled with mechanical advantage.
[0093] The drive mechanism illustrated and described in FIG. 1 is only exemplary and only provides one of a variety of drive mechanisms that can be used with the piston rod assembly according to the present invention.
[0094] The piston rod 200 as illustrated in FIG. 2 slightly differs from the piston rod 160 as illustrated in FIG. 1 . In FIGS. 2 through 5 , the length adjusting feature of the piston rod assembly is exemplary illustrated. The piston rod 200 comprises a socket portion 210 at its distal end section. The socket portion 210 is designed as a centrally located and distally extending stud having a threaded head 212 at its free end pointing towards the distal direction.
[0095] Here, the distally located head 212 comprises an outer thread 214 . With its opposite, proximal end section 204 , the piston rod 200 is operably engaged with the drive mechanism as exemplary illustrated in connection with FIG. 1 .
[0096] The adjusting member 202 is designed as a cupped receptacle. It is of substantially hollow cylindrical shape and comprises a receptacle having an opening facing towards the proximal direction. Hence, the adjusting member 202 is adapted to threadedly receive the head 212 of the piston rod's socket portion 210 .
[0097] As further illustrated in FIG. 4 , the receptacle 203 of the adjusting member 202 comprises an inner thread 205 corresponding and matching with the outer thread 214 of the head 212 of the socket portion 210 of the piston rod 200 . At its distal end face directed towards a piston of the cartridge, the adjusting member 202 comprises a contact surface 207 , which is substantially planar. By way of the contact surface 207 , the adjusting member may but against a proximal end face of the piston 155 , preferably across its entire cross section or surface 207 .
[0098] By way of the threaded engagement of adjusting member 202 and piston rod 200 , the overall axial length of the piston rod assembly can be continuously modified in order to reduce or even to annihilate inevitable production and/or assembly tolerances of the drug delivery device 151 .
[0099] In order to inhibit self-acting relative rotation of adjusting member 202 relative to the piston rod 200 , the piston rod 200 further comprises axially extending tongue members 216 comprising radially inwardly protruding lug portions 224 at least at their distal end section. Since the tongue members 216 are arranged laterally offset from the centrally located socket portion 210 , a circumferential gap is formed between said tongue members 216 and the socket portion 210 . The size of this circumferential gap is sufficient to receive the cylindrical side wall of the adjusting member 202 .
[0100] In order to provide a kind of snap-in functionality, the adjusting member 202 comprises a corrugated outer surface 208 at its proximal end section. Preferably, the corrugations or elongated ribs extend in longitudinal or axial direction. As illustrated in FIG. 5 , the corrugations may comprise ridge sections 218 and bottom sections 220 regularly and periodically arranged along the outer circumference of the side wall of the adjusting member 202 . Between elevated ridge sections 218 and recessed bottom sections 220 , here, a substantially straight flank or side section 222 extends.
[0101] The lug portion 224 extending radially inwardly at the tongue members 216 typically matches with the profile of the corrugated surface 208 of the adjusting member 202 . Since the tongue members 216 are resiliently biased with respect to the piston rod 200 , they can be elastically bended radially outwardly and thus allow to rotate the adjusting member 202 with respect to the piston rod 200 .
[0102] However, once a pre-defined axial position of the adjusting member has been reached, the positive and/or frictional engagement of the tongue members 216 and the corrugated surface 208 of the adjusting member 202 prevents and inhibits any further self-acting rotation of the adjusting member 202 relative to the piston rod 200 . This way, mutual engagement of tongue members 216 and adjusting member 200 provides a self-locking or self-inhibiting threaded engagement of piston rod 200 and adjusting member 202 .
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The present invention relates to a piston rod assembly for a drug delivery device, comprising: a piston rod adapted to be operably engaged with a piston of a cartridge containing a medicament, at least one adjusting member displaceably disposed at the piston rod with respect to the piston rod's long axis, and being interconnected with a distal end section of the piston rod, and at least one interlock means adapted to interact with the adjusting member and/or with the piston rod for mutually locking in position the adjusting member and the piston rod in an arbitrary relative position in order to compensate for tolerances of manufacture and/or of assembly.
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CROSS-REFERENCE TO RELATED APPLICATION
This application is a continuation of U.S. patent application Ser. No. 10/801,123, filed Mar. 15, 2004, now U.S. Pat. No. 7,018,141 which is a continuation of U.S. patent application Ser. No. 09/918,693, filed Jul. 30, 2001, now U.S. Pat. No. 6,715,964, which claims the benefit of U.S. Provisional Patent Application No. 60/221,594, filed Jul. 28, 2000. These applications are incorporated herein by reference in their entirety.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to an earth retaining system, and more particularly to a sheet pile retaining system having integral soil anchors.
2. Description of the Related Art
Marine related bulkheads constructed along the coast of Alaska experience some of the most severe environmental conditions known, including high waves and wave scour, earthquakes, ice, high tide variations, high phreatic water levels, weak soils, heavy live loads and difficult construction conditions. The need for low-cost, high load capacity docks and structures has resulted in a development of various sheet pile retaining structures.
Flat steel sheet piles have been used in perhaps the most simple form of structures featuring tension or membrane action primarily. Foundation designs of cellular cofferdams are discussed in detail in the text by Joseph E. Bowles, Foundation Analysis and Design (1977) herein incorporated in its entirety by reference. One configuration, a closed cell flat sheet pile structure, had been successfully used for many years for a wide variety of structures including cofferdams and docks. As shown in FIG. 1A , the most common use for flat sheet piles has been in closed cellular bulkhead structures of various geometrical arrangements. FIG. 1B illustrates another configuration, a diaphragm cell structure. By closing the cell structure, the entire structure acted as a deadman anchor in the retaining system to provide additional retaining support. However, positive structural aspects of this closed cell structure type were often offset by high construction costs. Several factors have contributed to higher costs, including: multiple templates required for construction alignment; close tolerances; difficulty with driving through obstacles and holding tolerance; backfilling operations using buckets or conveyors; and difficulty compacting the backfill. Modification of the closed cell to an open cell configuration provided higher accessibility and tolerance, but at a significant increase in material costs to offset the reduced load capacity of the cell configuration.
Yet another sheet pile retaining form has been the tied back wall masterpile system with flat sheet piles acting as a curved tension face. Tieback anchors with deadmen are connected to the curved tension face to provide lateral retaining strength as shown in FIG. 1C . This configuration allowed a higher load to be retained with fewer sheet piles used as the anchors and the sheets work in concert to retain the earth load. Tied back sheet pile walls often require deep toe embedment for lateral strength and if that toe embedment is removed for any number of reasons, wall failure will result. This method further required excavation for placement of the soil anchors, or an expensive and time consuming drilling operation to install the soil anchors, at the appropriate depth to integrate them with the sheet pile wall. Additionally, tied back walls are at risk in environments where waves overtop the wall and result in scour. Scour undermines the base of the bulkhead and the needed toe support resulting in failure of the bulkhead.
BRIEF SUMMARY OF THE INVENTION
The present invention overcomes the limitations of the prior art and provides additional benefits. Under one aspect of the invention, a soil retaining system combining flat sheet pile walls in an open cell configuration with soil anchors integral to the sheet pile provides an improved earth retaining system. In one embodiment of the invention, the integral soil anchors are angular interlock soil bearing surfaces which provide higher load resistance. Another aspect of the invention is a method of designing and installing a soil retaining system with an open sheet pile cell structure having integral soil anchors. The method includes, inter alia, calculating soil resistance by taking into account soil friction against the sheet pile in combination with the strength of the integral soil anchor, selecting sheet pile size and length based on these calculations; and installation of sheet pile to form a soil retaining system.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
FIGS. 1A-1C are plan views illustrating existing sheet pile wall configurations in accordance with the prior art.
FIG. 2 is a plan view of theoretical forces on a sheet pile wall in accordance with the prior art.
FIG. 3 is a plan view of an open cell sheet pile wall in accordance with principles of the present invention.
FIG. 4 is a cross sectional view along line 44 shown in FIG. 4 of forces on a sheet pile wall in accordance with principles of the present invention.
FIGS. 5A-E are cross-sectional views of additional embodiments of a first sheet pile connected to a second sheet pile illustrating integral soil anchors in accordance with principles of the present invention.
FIG. 6 is a cross-sectional view of a wye or anchor in accordance with principles of the present invention.
FIG. 7 is a cross-sectional view of yet another embodiment of the present invention illustrating a composite material sheet pile in accordance with principles of the present invention.
FIG. 8 is a cross-sectional view of an alternative embodiment illustrating a cell configuration in accordance with principles of the present invention.
FIG. 9 is a graph of soil friction and ultimate tension force in accordance with principles of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
A soil retaining system, and in particular, an apparatus and corresponding method for design and installation of an open cell sheet pile retaining wall having integral soil anchors is described in detail herein. In the following description, numerous specific details are provided, such as specific sheet pile configurations and interlock details as well as material selection, to provide a thorough understanding of embodiments of the invention. One skilled in the relevant art, however, will recognize that the invention can be practiced without one or more of the specific details. In other instances, well-known structures or operations are not shown or not described in detail to avoid obscuring aspects of the invention.
FIG. 2 illustrates a typical open cell sheet pile structure 200 . The cell 200 is typically constructed of vertical, flat sheet pile walls 210 . FIG. 2 illustrates an exemplary configuration for a sheet pile wall, namely, a “U” shaped configuration. Each “U” shaped configuration forms a cell. The closed loop of the “U” is the front face of the wall and may be exposed on one side. The legs of the “U” are typically not exposed except on an end cell. The legs of the “U” are typically referred to as tail walls 220 .
Open cell structures gain strength from the portion of the sheet pile buried in the soil fill. As illustrated in FIG. 2 , the soil contained within the open cell structure and any load placed atop that soil, namely the dead and the live load, exert a pressure P on the face of the structure. The weight of soil fill surrounding the tail walls 220 presses against sheet pile surfaces with enough force N to keep tail walls from being pulled out. Under traditional soil analysis, the theoretical soil resistance is based on an assumed soil failure plane μN that is assumed to be parallel to the sheet pile wall facing as shown in FIG. 2 .
In the present invention, a soil anchor integral with the sheet pile is designed to provide increased pull-out resistance and therefore yields a higher ultimate tension force. This higher ultimate tension force or effective overburden pressure yields a stronger retaining wall. Increased strength allowed fewer materials to be used and a more cost efficient wall to be built. These modifications of the typical closed cell to an open cellular shape with integral soil anchors serve to solve the problems associated with the closed cell configuration.
FIG. 3 , illustrates a plurality of open cell structures connected together to form an open cell sheet pile retaining system 300 . The open cell system 300 configuration is a first cellular structure 302 connected to and sharing a tail wall 220 with an adjacent second open cell structure 304 . A third adjacent open cell structure 306 shares a tail wall 220 with the second open cell 304 . The sheet pile tail walls 220 connects to a curved sheet pile cell face 210 . The tail walls 220 act as anchors for curved sheet pile cell faces 210 .
Operations and material cost savings are a significant improvement of the present invention over the prior art. By not closing the cell and by leaving the tail walls unconnected at the landward side, significant cost savings are realized from lower materials cost, increased construction tolerance and adjustment capability, and easier backfilling and compacting operations. Further, integral soil anchors in the sheet pile provide increased load resistance and allow shorter lengths of sheets to be used or lighter weight sheet pile materials to be used. The increased load resistance can result in a shorter depth of sheet penetration or a shorter overall length of tail wall to be used depending on the soil design characteristics. Open cell sheet pile structure construction can be used for various structures including oil containment, erosion control, docks in severe ice, wave or seismic environments.
FIG. 4 illustrates one embodiment of an integral soil anchor. A first sheet 440 connected to a second sheet 442 via a soil anchor 444 that includes a first interlock 446 at one end of the first sheet 440 mated to a second interlock 448 at on end of the second sheet 442 . Force lines 450 illustrate angled soil resistant anchor forces. The sheets 440 , 442 provide soil friction resistance normal to the sheets while the soil anchor 444 provides bearing and pull-out resistance at an angle greater than normal shown by force lines 450 .
The greater the size of the soil anchor the greater the resistance. A preferable soil anchor width is greater than ½″ and a more preferable soil anchor width is 3″ to an effective over burden pressure or greater and a most preferable soil anchor width is 4″ or greater as shown in FIGS. 5A-C . This configuration provides a combination that is an improved soil retaining system of greater strength than traditional sheet pile retaining walls.
FIG. 5A illustrates another embodiment of an integral soil anchor. A first sheet 540 is connected to a second sheet 542 via connection means 546 , 548 . The connection includes a first connection means 546 coupled to a second connection means 548 . The connection means 546 , 548 are shown integral to the sheets 540 , 542 , but may be affixed to the sheets such as in the rolling process by any mechanical means such as welding, bolting or other generally known attachment devices. The novel soil anchor of the present embodiment may be integral to the connection means wherein the sheet, connection means and soil anchor are formed simultaneously, or may be individually assembled components. A soil anchor 550 , 552 is integral to the coupling means 546 , 548 . The soil anchor 550 , 552 is shown as a squared off, corner of the coupling means 546 , 548 . The shape of the soil anchor is relevant to the increased resistance to force. A square shape has been shown in testing to resist higher forces than a round or angled shape. The square shape provides a greater bearing resistance against the soil.
FIG. 5B illustrates yet another embodiment of the present invention wherein the integral soil anchor, 554 , 556 is an “L” bracket affixed to an exterior side of the first and/or second connection means 546 , 548 at one end of the L and to the web of the sheet 540 , 542 at the other end of the L.
This soil anchor may be affixed subsequent to the rolling or manufacturing of the sheet pile.
FIG. 5C illustrates yet another embodiment of the present invention wherein the integral soil anchor is positioned other than at the intersection of two sheets.
An intermediate integral anchor 570 is positioned between connection means 548 , 549 on the second sheet 542 . The intermediate anchor 550 is shown as a solid block incorporated into the sheet 542 itself. Alternatively, the integral anchor 550 may be any geometric configuration and may be adhered to either an inside or an outside face of the sheet or both, or may be an integral composite component of the sheet.
FIG. 5D illustrates another embodiment of the intermediate integral soil anchor. The intermediate soil anchor 580 is a “C” shaped angle welded or otherwise affixed to the exterior of the sheet 542 . FIG. 5E illustrates an intermediate integral soil anchor 590 that is an “L” bracket affixed to a face of the sheet 542 .
The greater the size of the soil anchor the greater the resistance. A preferable soil anchor width is greater than ½″ and a more preferable soil anchor width is 3″ to an effective over burden pressure or greater and a most preferable soil anchor width is 4″ or greater as shown in FIGS. 5A-C . This configuration provides a combination that is an improved soil retaining system of greater strength than traditional sheet pile retaining walls.
Any variety of geometric shapes could be used to form the integral soil anchor. Further, the soil anchors may be positioned at any point along the sheet pile wall including at a connection point between adjacent sheet pile walls. Intermediate integral soil anchors may be combined with integral soil anchors at the connection point. Alternatively intermediate integral soil anchors may be used independently. Furthermore, multiple intermediate integral soil anchors may be positioned on a single sheet pile.
The integral soil anchors may extend the full height of the wall or may extend down the sheet pile wall some distance less than full height. Further, the integral soil anchors may be placed vertically on the sheet pile wall or may be placed at an angle. Length and positioning of soil anchors integral to the sheet pile wall is dependent on various design load parameters.
The soil anchors 544 , 550 , 552 , 554 shown in FIG. 5A-D have angular configurations to provide a greater soil resistant anchor force. Increase in the size of the soil anchor shape has been shown to increase the soil resistant anchor force linearly. The soil anchor resists forces by acting as microanchors or deadman. The soil anchor shape effects anchor resistance by a factor of up to cos 45°. A variety of soil anchor shapes, for example, round, angular, blocks, triangular or hexagonal may be used. Testing has shown that square shapes yield a greater resistance than alternative shapes.
The main structural components of open-cell construction are accomplished without the use of field welding, bolted connections, or an independent tieback system because the soil anchor is integral to the sheet piles of the retaining wall. Additionally, open-cell construction does not require sheet pile cell closure and allows for easy backfilling, since the cell is open in the back. This combination structure has the ability to resist large loads from ice and vehicles, and are highly insensitive to erosion conditions when compared with conventional sheet pile walls. The dock face can further be modified to include face ladders, mooring systems, fender systems, and varying access elevations. These features reduce costs and time required for construction. Construction costs for open-cell structures are therefore less than for other dock or bulkhead types.
Many problems are encountered in sheet pile construction and during the life of the retaining wall. An open cell sheet pile wall with integral soil anchors is a versatile retaining system that overcomes many of these problems.
One example of a design consideration to overcome is waves. Waves will produce forces on walls, but the most critical factor is wave overtopping. Open cells can withstand wave overtopping, with damage being limited to minimal loss of backfill. Further, just as river scour occurs around bridge piers, the forces from waves and associated currents cause scour at the base of impacted bulkheads. Tied back or cantilever sheet pile structures have a significant problem with any type scour because of loss of needed toe ground support. Conversely, the open cell structure with integral soil anchors is designed independent from exterior soil support, thus, scour can progress nearly to the cell bottom without any serious consequence.
Another design consideration is phreatic water. Phreatic water refers to water levels within bulkhead fill such as from tidal action which lags or leads tide levels. Very large forces from hydraulic head can be developed on bulkhead structures. Attempts to reduce this action by use of weep holes have not been totally successful because of possible drainage channel plugging and oxygenated corrosive water introduction into backfill. Open cell structures with integral soil anchors are readily designed to handle phreatic water and the associated forces without elaborate drainage or internal cell corrosion control measures.
Along with phreatic water levels, bulkhead stability is usually controlled by seismic forces. Analysis often follows classic wedge or slip circle theory that tests the overall mass stability. Open cell anchor wall resistance outside of failure planes is used to provide bulkhead stability safety factors, an important feature of this type structure. If design conditions warrant, an end anchor such as a large “H” pile may be added as an additional safety factor.
Open cell structures with integral soil anchors may be built in ice environments where ice thickness can reach one to two meters without damage to the structure. One explanation for this and a factor in design is strength of frozen bulkhead fill. As ice growth develops on water bodies, depth of frost in granular open cell backfill will often surpass the level of ice. Since frozen ground is usually stronger than ice, a naturally reinforced structure is created. Rubble ice formation early in the season, although usually impressive, is usually not a severe loading for open cells. As with seismic design, mass stability of bulkheads subject to large lateral ice loads is important.
Open cell tail wall extension having integral soil anchors can often effectively spread out dead and live loads if weak soils are encountered. Concern with such conditions is structure settlement. Flexibility of open cell wall structures with integral soil anchors readily handle unusual deformation.
The nature of large live loads, such as from cranes, cargo, stored containers, forklifts and heavy equipment is ideally suited to open cells with integral soil anchors because compacted earth fill provides sound support and the resistance nature of tail walls with integral soil anchors actually increases from such loads.
Wall heights of about 3 meters-20 meters are easily retainable for open cell construction with integral soil anchors, although longer or shorter sheets may be used. However, practical limitations are present, for example, longer sheets are difficult to handle and drive and are therefore less preferred. Cell width is preferably about 10 meters, but can be varied to account for end conditions and low wall height transitions. Tail wall lengths vary significantly subject a wide number of design parameters.
Sheet pile construction involves driving sheets a distance below the ground surface, which by its very nature, can be difficult. If very deep driving is required, difficulty can almost always be expected. Open cell structures with integral soil anchors of the present invention do not require deep embedment for stability due to the increased soil resistance provided by the integral soil anchors, and as a result are easier to construct and have redundancy for unusual conditions such as toe scour, toe liquification or overloads. Additionally, sheets of the present invention may be driven with fast vibratory hammers. Alternatively, open-cell structures with integral soil anchors may include deep embedment for additional stability.
Usually a one level template is adequate for open cell construction and wall tolerance is maintained by close attention to position and plumbness of “wye” shapes at intersections. Attention to wye position are carried through backfill operations which consists of controlled compacted layer construction. Cells are usually filled from the land using trucks, the result being the least costly method.
FIG. 6 illustrates one embodiment of a wye configuration that may be used in the present invention. The wye 600 may be used to couple a face sheet of a first cell to a face sheet of a second cell to the shared tail wall of the two cells.
Tail wall driving tolerance can be large and tail walls may be curved around obstructions. By dead ending tail walls, no close tolerance connections are required such as with closed cells. Flexibility in the position and driving tolerance of tail walls yields a significant cost savings. The cost effectiveness of this feature cannot be overemphasized.
There are numerous advantages and uses for open cell bulkheads with integral soil anchors. Higher soil resistance to pull-out forces from the integral soil anchors allow shorter tail walls to be used. This results in lower transportation and material procurement costs. Further, time and cost savings are realized because the cell is faster to construct. Furthermore, the open cell dock presents a pleasing scalloped appearance from the water side, and a neat uniform flat appearance from topside.
Open cells further include health and cleanliness advantages. An open cell dock consists of solid earth fill, providing no access under the dock for nesting disease-carrying rats and vermin common to platform-type docks. The elimination of this health risk is particularly important around food processing plants. In areas previously subjected to use, construction of the new dock encapsulates debris and hazardous materials existing on the sea floor behind the sheet pile wall and within the fill. Additionally, the open cell dock offers no space below the dock for the collection of future debris junk, and drift. Furthermore, open cell dock surfaces can be sloped away from the water so that oil and wastes, if spilled, drain away from the water-side of the dock. If not cleaned up directly, a spill could seep into the fill where it would be contained against seeping into nearby waters by the surrounding sheet pile wall.
Yet another advantage of the present invention is with respect to the protection of utilities. Utilities and fuel lines can be buried by conventional methods in the fill, where they are protected from freezing and from vehicle and vessel impact. If utility leakage should occur, any spillage is contained in the fill. Damaged utilities are readily accessible for repair. These are great advantages over conventional docks, where utilities are normally suspended under the deck or run along surfaces.
Runoff water can be kept from draining directly into marine waters. Instead, runoff may be either collected in a drain system, or seeped into the fill where it must travel long distances through filtering fill before it enters marine waters.
The present invention is adapted well to marine habitats. The protected area between fender piles and the scalloped faces of sheet pile cells can serve as a refuge for marine life. In addition, sheet pile faces and fender pile surfaces provide clean hard surfaces where anemones, urchins, and mollusks can attach themselves. Special hanging chain fish habitats have also been devised along structure faces.
Very little maintenance is required once the present system is in place. Open cell docks of the present invention consist of essentially two materials, earth fill and sheet piles with integral soil anchors. Earth fill, properly contained behind a bulkhead, and sheet piles, if properly protected against corrosion, are virtually maintenance free. There is no need for riprap under the dock, as with pile-supported docks. Riprap under pile-supported docks often subsides or can be wave-displaced over time, and may become a difficult and expensive maintenance item.
Properly constructed, the open cell dock with integral soil anchors is capable of supporting huge loads such as large cranes, heavy forklifts and heavy storage loads, without danger of collapse. Furthermore, the steel cells which are filled with earth and rock have tremendous resistance to damage by ice pans, vessel impact, and other drift forces. There are no weak elements such as vertical bearing piles, pile caps, or walers to be damaged by drift forces. Additionally, mooring devices on open cell docks have exceptionally high capacity because they are tied to the large deadweight of the dock. The components of open cell docks, earth and sheet piles, are extremely fire resistant. In addition, the dock can be used to provide a safe platform from which fire fighters could combat fires occurring on nearby boats or in waterfront buildings.
The present system is very cost effective as compared to conventional building systems. Open cell docks having integral soil anchors typically may be built for about half the cost of a heavy-duty pile-supported dock based on an “area created” basis. Furthermore, one of the two primary dock materials, earthfill can usually be obtained locally at minimal cost.
Ease of construction of the present invention allows cost savings in both time and materials. Open cell docks having integral soil anchors can be constructed entirely from the land. This eliminates the need for cumbersome barge-based construction and related oil spill hazards. Construction is so repetitive that local labor forces, inexperienced with pile driving or dock construction, have built them. Fill can be end-dumped into place since the rear side of each cell is open. Little siltation results from this construction method. No detail work such as installation of traditional walers and tiebacks is required in the tidal zone.
Yet another advantage of the present invention is that minimal embedment of sheets is required along the front face of the dock below the existing ocean bottom. This makes the open cell dock having integral soil anchors particularly attractive where bedrock is at or near the surface. Drilling and/or blasting for rock anchors or embedment would be required for other types of docks in this situation, with resulting environmental disruption. Furthermore, the open cell concept creates flat land both at the new dock and at the borrow source. If the borrow source is a hill immediately behind the dock, then valuable staging area is created. The economics of an open cell dock project look even better if the value of this additional staging area is factored in the cost.
FIG. 7 illustrates yet another embodiment of the present invention. The sheet 700 of FIG. 7 is of a shorter horizontal length L than a typical sheet and may be constructed of a composite material. Furthermore, the connection means 710 may be of a width W greater than conventional connection means. A preferable W of the connection means or soil anchor is 4″ or more. The coupling means 710 of this embodiment is shown as a block for illustrative purposes. The size of the coupling means may be increased as needed for the given design considerations to increase to soil resistance of the integral anchor.
Composite material used to construct the sheet may, for example, include formed plastics, extruded plastics, composite metal and plastic, fiberglass, carbon fibers, aluminum and the like. Composite materials have the additional advantage of flexibility of design of the coupling means.
FIG. 8 illustrates a specialized use of the composite sheets and yet another embodiment of the present invention illustrating a sleeved pile repair 800 of an existing pipe pile 820 . Special sheet piles 810 can be formed or bent to accomplish a number of tasks, including sleeved pile repair, column forming, conduits and covers. The connection means 830 can easily be slipped together to instantly form a variety of shapes for many uses. Concrete, grout or other materials 840 can be used to fill any annulus created thus creating a structural section.
An improved soil retaining system including an open cell design including integral soil anchors has lead to a versatile structure capable of wide adaptation. Resolution of not only design, but also construction problems has further reduced cost of these structures and created another tool for developing an economical solution.
The following failure testing example is provided as an illustration.
EXAMPLE 1
Testing by: D. Nottingham
C. Canfield
Apparatus: A test box 2′×2′×4″ high to hold sand was constructed of plywood and pressed board.
Materials: Silica sand in the sand of #30 to #70 sieve was obtained.
Two end sections of PS32 sheet piles were cut to about 3″ height.
Test Procedure: The silica sand was dampened and packed around the sheet pile sections. A wire was run through a hole in the box to one end of the sheets, and connected.
The assembly was pulled into the sand until stress cracks formed in the sand. The test was photographed and observed as to nature and direction cracks. Test was repeated numerous times.
Results: Cracks in sand did not form parallel to sheet pile sides, but did so at about 30 degree±angles emanating from sheet pile interlocks. This was a result of the interlocks acting as an integral microanchor. Soil friction against sheet pile sides did not appear to be present at time of soil cracking. This testing verifies the theory that the interlock provides soil resistance in addition to the normal forces resisted by the sheets themselves.
FIG. 9 illustrates a comparison of sheet pile tension resistance theories in granular soils in accordance with the above testing and in accordance with the principles of the present invention. As is shown from the graph the integral soil anchors provide greater resistance to soil forces, thus allowing lighter materials or shorter pile to resist the same forces as conventional retaining systems.
From the foregoing it will be appreciated that, although specific embodiments of the invention have been described herein for purposes of illustration, various modifications may be made without deviating from the spirit and scope of the invention. Accordingly, the invention is not limited except as by the appended claims.
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A soil retaining system combining flat sheet pile walls in an open cell configuration includes integral soil anchors providing an improved earth retaining system. Another aspect of the invention is a method of designing and installing a soil retaining system with an open sheet pile cell structure having integral soil anchors. The method includes, inter alia, calculating soil forces by taking into account material strength of sheet pile, soil friction against the sheet pile in combination with the strength of the integral soil anchor, selecting sheet pile size and length based on soil forces calculation; and installation of sheet pile to form a soil retaining system. The integral soil anchors serve to provide higher load resistance to the improved earth retaining system.
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BACKGROUND OF THE INVENTION
The present invention relates generally to the field of internal combustion engines and, more particularly, to the control of an internal combustion engine of a locomotive to reduce the adverse effects of ambient air temperature changes on the performance of the engine.
Locomotives operated in the far north and south regions of the globe are subject to severe winter weather conditions, including cold temperatures, and blowing and drifting snow. It is known that snow may be drawn into the air inlet ducts of a locomotive and may accumulate in sufficient quantities to obstruct the passage of air through the ducts. It is not uncommon for snow to accumulate on air filters disposed in the air inlet pathway of a locomotive. Such accumulations of snow may reduce the power output of the engine or cause it to cease from operating completely.
It is known to provide summer/winter doors in a locomotive which function to connect the air inlet duct with a source of warm air so that the cold ambient air is mixed with relatively warmer air prior to passing through the final air filters. If the temperature of the inlet air mixture can be maintained above the freezing point, any snow that may be deposited on the filters or ductwork will melt rather than accumulating to the point of restricting intake air. The name “summer/winter” has been applied to these doors because in the prior art they were manually operated using a simple rule of thumb, such as open in the winter and close in the summer. Warm air is available in the engine compartment of a locomotive because radiant and convected heat from the engine tends to raise the air temperature around the engine. Because of the need to protect components such as wires, hoses and fuel lines from high temperatures, locomotive engine compartments are normally ventilated. It is known to pass the exhaust air from an equipment cabinet of the locomotive into the engine compartment to provide such ventilation. The exhaust from an equipment cabinet contains filtered and slightly pressurized air from an equipment blower, and it passes out of the equipment cabinet at a relatively low temperature. This air is exhausted through the engine compartment and into the combustion air intake ductwork through the summer/winter doors.
It is known to increase the flow of warm air from the engine compartment to the inlet air supply ductwork by at least partially restricting the ambient air inlet openings when the summer/winter doors are opened. By simultaneously restricting the inlet of cold ambient air when the winter/summer doors are opened, the percentage of warm air drawn into the engine is increased. The use of such doors also helps to maintain the original air velocity through any upstream inertial filters. By maintaining the air velocity through the inertial filters, the efficiency of the inertial filters in removing snow from the intake air is maintained.
There is a continued demand for improved performance of locomotive engines, in terms of fuel economy, component loading, power output and reduced emissions. To achieve such optimized performance, the conditions of combustion within the internal combustion engine needs to be controlled. However, engine designs are limited because of the extremes of environmental conditions under which a locomotive must operate. For example, cylinder peak firing pressure may become too high as the engine is operating during cold days when the inlet air temperature is very low, thus generating excessive stress on engine components. Alternatively, cylinder exhaust temperatures may become too high as the engine is operating during hot days when the inlet air temperature is very high, thus causing turbocharger damage due to overheating and overspeed. Very high inlet air temperature may also increase engine exhaust emissions such as smoke, carbon monoxide (CO), and particulate matter (PM).
BRIEF SUMMARY OF THE INVENTION
Thus, there is a need to provide a locomotive having a reduced sensitivity to the wide range of environmental conditions under which it must operate. There is further a need for a method of operating a locomotive that makes it less sensitive to changes in ambient environmental conditions.
Disclosed herein is an apparatus and a method for reducing the sensitivity of a locomotive engine to changes in the ambient air temperature and pressure. A method for controlling a locomotive engine is described having the steps of: providing a warm air flow path between the engine compartment and the air inlet path; providing a valve for controlling the flow of warm air through the warm air flow path; measuring the ambient air temperature; and controlling the position of the valve in response to the ambient air temperature. The method may include the further steps of: measuring the ambient atmospheric pressure; and controlling the position of the valve in response to the ambient air temperature and the ambient atmospheric pressure.
A locomotive is described herein including: an engine disposed in an engine compartment and operable to burn fuel with air to produce power for the locomotive; an air inlet path for directing air to the engine; a warm air flow path connected between the engine compartment and the air inlet path; a valve disposed in the warm air flow path; sensors operable to produce an ambient air temperature signal responsive to the ambient air temperature and an ambient air pressure signal responsive to the ambient air atmospheric pressure; and a controller having the ambient air temperature signal as an input and operable to produce a valve position signal responsive to the ambient air temperature signal and optionally the ambient air pressure signal, wherein the valve is responsive to the valve position signal to control the flow of warm air through the warm air flow path.
BRIEF DESCRIPTION OF THE DRAWING
The features and advantages of the present invention will become apparent from the following detailed description of the invention when read with the accompanying drawing, in which a locomotive is illustrated having an automatic apparatus for regulating the temperature of the inlet air supplied to the engine.
DETAILED DESCRIPTION OF THE INVENTION
The FIGURE is a schematic illustration of a locomotive 10 powered by an internal combustion engine 12 located within an engine compartment 14 of the locomotive 10 . The engine 12 may be naturally aspirated or may be a turbo-charged diesel engine provided with combustion air by compressor 16 as shown in the FIGURE. The term “combustion air” is used herein to refer to the air entering the engine cylinders, downstream of any turbocharger or supercharger. The term “air used for combustion” as used herein is meant to include the air at any point of its path, from the ambient environment outside the locomotive inlet, through the inlet air ductwork, through the turbocharger, if any, and into the engine cylinders. An engine inlet 18 for air is in fluid communication with an air inlet path 20 including ductwork 22 , a plurality of inertial filters 24 , and final air filters 26 . Ambient air is drawn through the inertial filters 24 and is directed by the ductwork 22 through the final air filters 26 to the engine inlet 18 . Air may be provided to the engine 12 from the engine compartment 14 through a warm air flow path 28 . The term “warm air flow path” is used herein, however, air provided there through could be conditioned to a temperature lower than the ambient air temperature. Such a cooled air flow path embodiment is not being implemented by the assignee of the present invention at the present time. The warm air flow path 28 may be as simple as an opening in the air inlet ductwork 22 , or it may include a separate arrangement of ductwork 29 for selectively drawing conditioned air from predetermined locations within the engine compartment 14 . Valve 38 is disposed within the warm air flow path 28 and is operable to control the flow of warm air through the warm air flow path 28 . Valve 38 may be a moveable door formed in ductwork 22 , or it may be some form of butterfly, ball or gate valve or other such device operable alternatively to permit and to restrict air flow. The geometric type, size and flow area of the valve 38 are selected to be suitable for the air flow performance and capacity required for a particular application. Valve 38 may include one or a plurality of individual valves. The open/close position of valve 38 is controlled by an actuator 40 operable to move valve 38 from a first position wherein no warm air is provided to the combustion air inlet path 20 , to a second open position wherein warm air is permitted to flow through the warm air flow path 28 to the engine inlet 18 . Valve actuator 40 may be any such device known in the art, such as for example an electrical solenoid, a motor driven actuator, a hydraulic or a pneumatic actuator.
The warm air flow path 28 may include inlets located at more than one location within the engine compartment 14 . For example, one inlet 30 for warm air flow path 28 may be located proximate an exhaust pipe of engine 12 in order to draw air warmed to a very high temperature. A second inlet 32 may be located away from the hottest parts of engine 12 in order to draw air warmed to a lesser degree. The distribution of air flowing from inlets 30 , 32 may be controlled by the positioning of valves 34 , 36 , respectively.
The positioning of valve 38 by actuator 40 is controlled by controller 42 . Controller 42 may be any such device known in the art, such as a computer or microprocessor, a programmed logic controller, or a simple electromechanical device. Controller 42 may include a set of programmed logic instructions for the control of the temperature and/or density of the combustion air. Controller 42 may receive as input one or more of the following input signals: an ambient air temperature signal T A , an ambient atmospheric pressure signal P A , an inlet air temperature signal T I , and an inlet air pressure signal P I . An ambient temperature sensor 44 is operable to sense the temperature of the ambient air being drawn into locomotive 10 and to generate signal T A in response to that air temperature. Ambient temperature sensor 44 may be any such device known in the art, such as for example a resistance temperature detector (RTD). Similarly, ambient atmospheric pressure sensor 46 is operable to generate signal P A responsive to the ambient barometric pressure surrounding the locomotive 10 . Ambient atmospheric pressure sensor 46 may be any such devise known in the art. Inlet air temperature sensor 48 is located proximate the inlet 18 of engine 12 , in order to sense the temperature of the air being drawn into engine 12 . Inlet air temperature sensor 48 may be an RTD or other known device. The inlet air temperature is directly related to the ambient air temperature and to the position of valve 38 , therefore, inlet air temperature signal T I is an indirect measure of the ambient temperature, Inlet air pressure sensor 58 senses the pressure of the inlet air at a location downstream of final air filters 26 .
Controller 42 is operable to generate a valve position signal V operable to control valve actuator 40 to position valve 38 to a desired position. The performance of internal combustion engine 12 may depend upon the density of the air supplied to the engine 12 . Once an inlet air density range for preferred operation of engine 12 is established by the engine designer, a corresponding inlet air temperature range may be determined based upon the relationship of air temperature and air pressure to air density. In one embodiment, controller 42 is programmed to provide an appropriate valve position signal V in response to the single variable of the measured ambient air temperature T A . In this manner, the inlet air temperature being supplied to the engine 12 may be maintained within the calculated inlet air temperature range corresponding to the preferred inlet air density range. For example, when the ambient air temperature T A drops below a predetermined value, valve position signal V may be provided to the valve actuator 40 to open valve 38 , thereby providing warm air to mix with the ambient air within the combustion air inlet path 20 .
Because the density of the inlet air may vary depending upon the altitude and weather conditions encountered by the locomotive 10 , it may be desired to adjust the determined inlet air temperature range to take into account the actual ambient atmospheric pressure. Controller 42 may include logic for utilizing signal P A when generating valve control signal V. Such logic may function to somewhat increase the temperature of the inlet air when the locomotive encounters a relatively high ambient atmospheric pressure.
In a further embodiment, controller 42 may utilize signal T I as a direct indication of the temperature of the inlet air, and may generate valve control signal V in response to the inlet air temperature signal T I . A simple logic that may be implemented in controller 42 is to provide a valve position signal V to open valve 38 when the temperature of the inlet air T I is below a predetermined value, and to close valve 38 when T I is above a predetermined value. The predetermined value may be a fixed parameter, or it may be a calculated number corresponding to a measured ambient atmospheric pressure signal P A . The predetermined values for opening valve 38 and for closing valve 38 may be different numbers in order to avoid unnecessary cycling of the valve.
The specific logic utilized in controller 42 for the control of the inlet air temperature may vary depending upon the specific requirements of a particular application. For a typical locomotive engine 12 , it may be sufficient to control valve 38 to only two alternative positions, fully open and fully closed. Alternatively, valve 38 may have a plurality of discrete intermediate positions between a fully open position and a fully closed position, or an infinitely variable range of motion there between. If more than one valve 38 is provided, controller 42 may generate a corresponding plurality of valve control signals to open the individual valves in sequence, thereby providing a finer degree of control. Furthermore, controller 42 may also be programmed to generate control signals V 34 and/or V 36 to control the position of valves 34 , 36 to further affect the temperature of the warm air passing through the warm air flow path 28 . By individually or jointly controlling the positions of valves 34 , 36 , 38 , a wide ranger of ambient air temperatures may be moderated to achieve a preferred range of temperatures for the air provided at inlet 18 .
With valve 38 in the closed position, the air pressure and density in ductwork 22 is slightly lower than in the ambient air due to the restriction imposed by the inertial filters 24 . As valve 38 is opened to admit hotter and less dense air from the engine compartment at a pressure slightly above ambient air pressure, the pressure in ductwork 22 will rise slightly, thereby offsetting to some extent the desired reduction in inlet density afforded by the warm engine compartment air mixing with the cold ambient air. Because the pressure differential across the inertial filters 24 is now reduced, it is known that their filtering performance may be degraded also. And as long as the pressure in ductwork 22 is below ambient air pressure, there will continue to be some cold, dense air coming through the inertial filters 24 , thus limiting how high the inlet air temperature can be raised (and the inlet air density lowered) by opening valve 38 . To improve the performance of this system, there may also be provided a means for restricting the flow of ambient air through one or more of the plurality of inertial filters 24 during periods when valve 38 is positioned to permit the flow of air through warm air flow path 28 . One such means may be a door 56 operable in conjunction with valve 38 to block the flow of air through one or more of the inertial filters 24 when valve 38 moves away from a fully closed position. Door 56 may have a separate actuator or may be moved in conjunction with valve 38 by actuator 40 . Other means for restricting the flow of air through filters 24 may include flow control valves associated with one or more of the individual inertial filters 24 . By decreasing the total flow area through the inertial filters 24 when air is being supplied through the warm air flow path 28 , the pressure in ductwork 22 may be maintained at a level sufficiently below ambient pressure such that the air velocity in, and the filtering performance of, the remaining inertial filter(s) 24 may be maintained. Decreasing the flow area through the inertial filters 24 will also induce a higher percentage of the inlet air to be drawn through the warm air flow path 28 , and by this means will increase the extent to which the temperature of the inlet air may be raised (and the inlet air density lowered). Finally, because the pressure in the inlet ductwork 22 is lowered by decreasing the flow area through the inertial filters 24 , the closing of door 56 may be used to prevent, at least to an extent, the inlet ductwork 22 pressure from rising when valve 38 is partially or fully opened.
A pressure sensor 58 measures the pressure of the air within inlet air path 22 downstream of final air filters 26 . Pressure sensor 58 provides a signal P I corresponding to that pressure to controller 42 . In the prior art it is known to monitor the pressure differential across air filters and to restrict the power output of engine 12 if that difference exceeds a predetermined value. The pressure differential across the final air filters may be measured indirectly by comparing the ambient air pressure and the pressure of the air within duct 22 downstream of final air filters 26 . This protection scheme prevents adverse effects on the engine 12 due to clogged filters, and it provided an indication to the operator that maintenance was needed on the filters 26 . A build-up of snow and/or ice on the final air filters 26 could also result in the pressure differential set point being exceeded. To alleviate this situation, in one embodiment of the present invention, controller 42 may provide a signal to open, or to more fully open, valve 38 when the pressure differential across the filters exceeds a predetermined value at times when the ambient temperature is below a predetermined value, such as the freezing temperature of water. Similarly, that signal may be used to control door 56 to fully restrict the flow of air through its associated inertial filters 24 . This control scheme is designed to avoid any reduction in engine power resulting from accumulated snow or ice. Controller 42 would included programmed logic operative to compare the signals from ambient pressure sensor 46 and inlet air pressure sensor 58 , and when the indicated pressure differential exceeds a predetermined value and the ambient temperature as measured by sensor 44 is below a predetermined value, to issue a valve position control signal V to more fully open valve 38 and/or to close door 56 . The set point for this valve opening action is preferably a differential pressure value less than the pressure differential resulting in a reduction in the power output of the engine 12 ,
While the preferred embodiments of the present invention have been shown and described herein, it will be obvious that such embodiments are provided by way of example only. Numerous variations, changes and substitutions will occur to those of skill in the art without departing from the invention herein. Accordingly, it is intended that the invention be limited only by the spirit and scope of the appended claims.
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Automatic control of the temperature of the inlet air being supplied to the engine ( 12 ) of a locomotive ( 10 ) in order to optimize the performance of the engine ( 12 ) under a variety of ambient air temperatures and pressures. One or more valves ( 38 ) is utilized to control the flow of warm air from the engine compartment ( 14 ) into the air inlet path ( 20 ). The position of valve ( 38 ) is controlled by controller ( 42 ) in response to at least one of an ambient air temperature signal T A , an ambient atmospheric pressure signal P A , and an inlet air temperature signal T I . The temperature of the air flowing through the warm air flow path 28 may be controlled by selecting from among a plurality of possible inlets ( 30, 32, 50 ). By varying the volume and temperature of the air flowing through the warm air flow path ( 28 ), the temperature and density of the air supplied at the engine inlet ( 18 ) may be moderated across a broad range of ambient air temperatures and pressures.
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TECHNICAL FIELD
[0001] The present disclosure relates generally to power saws, and particularly to power saws having a debris collection system.
BACKGROUND
[0002] One type of cutting tool is a power saw that includes an electrical motor mounted below a work surface. Users frequently refer to this type of power saw as a table saw, because the work surface resembles a tabletop. The table has an opening that allows a portion of the cutting tool, such as a saw blade, to extend above the surface of the table. The blade, which is rotatably connected to the electrical motor, is movable relative to the surface of the table to enable a user of the table to make cuts of a particular depth or angle. For example, to adjust the height of the blade, a user may position a workpiece adjacent to the blade and then adjust the height of the blade such that the apex of the blade extends just above the thickest portion of the workpiece. To cut the workpiece, a user positions the workpiece on the table, such that a line representing the cutting path of the blade is aligned with a region of the workpiece to be cut, energizes the motor to rotate the blade, and moves the workpiece toward the rotating blade. As the blade cuts through the workpiece, it generates dust, chips, and other workpiece debris, which may be collected by a debris collection system.
[0003] Table saw debris collection systems, commonly referred to as dust collectors, direct the workpiece debris into a collection receptacle such as a porous bag or other suitable container. Additionally or alternatively, an external negative pressure source, such as a vacuum may be configured to draw the debris from a debris exit port of the table saw into a container. Some users, however, may desire a table saw having a dust collector, which functions effectively without a separate negative pressure source.
[0004] In some cases the user may not apply vacuum to the debris exit port, for example when a vacuum source is unavailable. In this instance, the debris may not be adequately discharged through the exit port while the blade is operating, which can lead to clogging of the debris collection system and even to binding of the blade. The user is then required to turn off the power tool and manually attempt to dislodge the debris through the exit port or disassemble the dust collection system to clean out the debris and dust. Accordingly, further developments in the area of table saw dust collection systems are desirable.
SUMMARY
[0005] A power tool includes a table structure defining a blade slot, a frame supporting the table structure, a blade assembly mounted within the frame, and a carriage assembly. The blade assembly includes a blade positioned within the blade slot and a motor assembly to rotate the blade, in which the carriage assembly supports the motor assembly relative to the table structure. The carriage assembly defines a chamber within which said blade operates and a discharge chute for discharge of dust and debris from the chamber during operation of the blade. The bottom wall of the carriage assembly below said blade defines one or more openings that are sized to permit passage of the dust and debris and to comply with finger probe test safety standards. In certain embodiments, the openings may be provided with a cover that is movable to expose or close the openings. The cover may be pivotably, slidably or rotatably mounted to the carriage assembly to move between a position closing the openings and a position in which the openings are exposed for removal of debris therethrough.
[0006] In certain embodiments, the one or more openings include a plurality of elongated slots that extend along a substantial portion of the length of the bottom wall. In embodiments with a cover, the cover may be slidably mounted within certain of the elongated slots. In other embodiments, the openings include a plurality of arc segment openings. In these embodiments, the cover may be rotatably mounted over the openings with arc segment openings that coincide with the openings in the bottom wall when rotated to a certain position.
BRIEF DESCRIPTION OF THE FIGURES
[0007] Features of the present disclosure should become apparent to those of ordinary skill in the art to which this device pertains from the following description with reference to the figures, in which:
[0008] FIG. 1 is a perspective view of a table saw.
[0009] FIG. 2 is an exploded view of certain components of the table saw of FIG. 1 .
[0010] FIG. 3 is a side perspective view of the carriage assembly of the saw shown in FIG. 2 , depicted with the cover removed.
[0011] FIG. 4 is an enlarged view of one embodiment of a dust discharge feature for use with the carriage assembly shown in FIG. 3 .
[0012] FIG. 5 is an enlarged cross-sectional view of a further embodiment of a dust discharge feature for use with the carriage assembly shown in FIG. 3 .
[0013] FIG. 6 is an enlarged view of another embodiment of a dust discharge feature for use with the carriage assembly shown in FIG. 3 .
DETAILED DESCRIPTION
[0014] For the purpose of promoting an understanding of the principles of the device described herein, reference is made to the embodiment(s) illustrated in the figures and described in the following written specification. It is understood that no limitation to the scope of the device is thereby intended. It is further understood that the device includes any alterations and modifications to the illustrated embodiment(s) and includes further applications of the principles of the device as would normally occur to one of ordinary skill in the art to which this device pertains.
[0015] As shown in FIGS. 1 and 2 , a power tool in the form of a table saw 100 includes a blade assembly 101 , a table structure 102 and a frame 104 . The table 102 includes an opening or slot 106 through which a top portion of the blade assembly 101 extends. The table 102 has a generally planar upper surface, which may be referred to as a work surface. The frame 104 is connected to a bottom portion of the table 102 and is configured to define an internal space 105 in which the bottom portion of the blade assembly 101 is positioned. In the embodiment of FIG. 1 , the table structure 102 and frame 104 may be formed from sheet metal, plastic, aluminum, composite materials, or the like. The table 102 and/or frame 104 may include handles, such as handle 108 , which enable a user to carry the table saw 100 conveniently.
[0016] In certain embodiments, the blade assembly 101 has a fixed position along the longitudinal axis L of the table 102 or along the length of the slot 106 . In other embodiments, the blade assembly 101 may be mounted to a slide assembly (not shown) that enables the blade assembly longitudinally relative to the table 102 , commonly referred to as a “push-pull” saw.
[0017] The blade assembly 101 of the table saw 100 includes an adjustment mechanism 110 for adjusting the angular and vertical position of the blade. The mechanism 110 is adapted to permit rotation of the blade assembly 101 about the longitudinal axis L so that the blade can make an oblique cut in the workpiece. The mechanism may be further adapted to raise and lower the cutting blade relative to the table 102 to adjust the depth of the cut into the workpiece.
[0018] As shown in FIG. 2 , the blade assembly 101 generally includes a blade 120 , an electrical motor assembly 122 , and a carriage assembly 124 including a cover 126 . The carriage assembly 124 includes a pivot mount 125 that is pivotably mounted to the carriage 104 or to the underside of the table 102 to permit pivoting of the blade assembly, and thus the blade 120 , about the longitudinal axis L ( FIG. 1 ). The motor assembly 122 is supported within a channel 128 in the carriage assembly configured to allow the motor assembly, and therefore the blade 120 , to move up and down relative to the table 102 and slot 106 . The blade 120 may be configured for rotary or reciprocating motion, depending upon the nature of the table saw 100 , and the motor assembly 122 is configured to drive the blade in the rotary or reciprocating motion.
[0019] The adjustment mechanism 110 incorporates a mechanism for controlled pivoting of the carriage assembly 124 relative to the table 102 , and for controlled up and down movement of the motor assembly 122 relative to the table, which ultimately provides for controlled positioning of the cutting blade 120 . It can be appreciated that a variety of adjustment mechanisms may be utilized to provide the angular and up-down adjustments for the blade 120 . For instance, a lead screw mechanism may be provided to move the motor assembly 122 , and thus the blade 120 , up and down relative to the carriage assembly 124 and thus relative to the table 102 and work surface. The angular adjustment mechanism may incorporate a locking pin, such as pin 112 , engaged within a curved slot 113 in a side wall 114 of the frame 104 . Other mechanisms are contemplated provided they are at least capable of adjusting the angle of the blade 120 relative to the table 102 and slot 106 .
[0020] The carriage assembly 124 and cover 126 define a chamber 129 within which the blade 120 rotates when it is mounted to the motor assembly 122 . The chamber 129 includes a discharge chute 130 defined at a lower portion of the chamber to direct dust and debris to an outlet 132 , as shown in FIGS. 2 and 3 . The chamber and discharge chute are configured to redirect dust and debris propelled by the rotation of the blade 120 in the direction R. Rotation of the blade can generate airflow that helps to further propel the debris along the discharge chute 130 to the outlet 132 . It is also contemplated that suction may be provided at the outlet 132 to assist in clearing the dust and debris from within the chamber 129 .
[0021] The carriage assembly 124 and more particularly the chamber 129 and chute 130 , are configured to contain and convey the majority of the dust and debris when the blade 120 is operated. However, these features have their greatest utility when coupled to a vacuum or suction source at the outlet 132 . In some cases, the user may not apply vacuum, such as when working outdoors or where a vacuum source is not available. While some of the dust and debris may be discharged from the open outlet 132 , dust will typically tend to accumulate within the discharge chute 130 . If the outlet 132 is clogged, the dust will continue to build up within the chamber 129 until the saw blade is impeded. The user must then find some way to remove the built up dust and debris, which involves shutting the power tool down and opening the carriage assembly 124 or poking an instrument through the outlet 132 to scrape out the dust and debris from the discharge chute 130 . It can be appreciated that this method for clearing the carriage assembly can be time consuming and frustrating for the user.
[0022] In accordance with one aspect of the present disclosure, the carriage assembly 124 is provided with openings that allow passage of dust and debris from the carriage assembly while still protecting the user from the blade. Thus, in one embodiment shown in FIG. 3 , the bottom wall 140 of the carriage assembly 124 includes a number of openings 142 that are sized to at least allow passage of dust generated by operation of the saw blade. The openings 142 are small enough to pass the standard finger probe test (EN 61029 ) to ensure that the user's fingertips cannot contact the saw blade through the openings. Thus, in one embodiment the openings 142 may be in the form of elongated slots each having a width of less than 0.2 in. The slots may extend along substantially the entire length of the bottom wall 140 .
[0023] The openings 142 may assume various configurations, provided that they have sufficient area to allow passage of at least saw dust and are sufficiently small to pass the finger probe test. In the embodiment shown in FIG. 3 the openings are elongated linear slots, but the openings could be curved or angled slots, or a series of circular or square perforations. The configuration of the openings may be further affected by the material and method of manufacturing the carriage assembly. For instance, elongated linear slots may be preferable for a molded plastic carriage, while drilled perforations may be preferable for a machined metal carriage.
[0024] In the illustrated embodiment the openings 142 are shown without any closure. Thus, the openings 142 remain open even when vacuum or suction is applied at the outlet 132 . However, it may be desirable to close the openings when suction is used so that all of the dust and debris is ejected through the outlet 132 . The present disclosure thus contemplates the addition of a movable closure for the openings.
[0025] In one embodiment, a movable door 150 is provided that is configured to cover the openings 142 , as shown in FIG. 4 . In one specific embodiment the cover 150 is mounted to the carriage assembly, such as at the bottom wall 140 , by a hinge 151 . The hinge 151 is configured so that the cover 150 can be pivoted between the position shown in FIG. 4 to a position covering the opening. The cover may be provided with a lip 152 that is configured to engage the carriage assembly 124 or cover 126 to hold the cover tightly against the openings 142 . Suction applied at the outlet 132 may further help pull the cover against the openings. The cover 150 may be configured with a lip 152 on opposite sides that are configured for press-fit engagement to the carriage assembly, without the need for the hinge 151 .
[0026] In another embodiment, a sliding cover 160 may be provided, as shown in FIG. 5 . In this embodiment, the cover 160 may be provided with features that engage the carriage assembly that allow the cover to slide from a position blocking the openings 142 to a position substantially clear of the openings. Thus, in one specific embodiment, the cover 160 may be provided with prongs 161 that project into one or more of the slots 142 . The prongs may be provided with lips 162 that engage the inside of the carriage assembly so that the cover is supported with the prongs extending through one or more slots. The prongs 161 may be arranged at one end of the cover 160 so that when the prongs are moved in the direction of the arrow in FIG. 5 toward one end of the slots 142 the cover 160 is substantially clear of the openings. Sliding the cover in the opposite direction closes the slots. The prongs can be configured for a close running fit between the cover and the openings to maintain as tight a seal as possible when the cover is closed. Again, suction applied through the outlet 132 may help pull the cover against the bottom wall 140 of the carriage assembly.
[0027] As an alternative to engaging within the slots themselves, the prongs 161 of the cover 160 may be arranged to engage grooves in the carriage assembly. For example, grooves may be provided in the side walls of the carriage assembly with the prongs on the cover configured to wrap around the bottom wall 140 to engage the grooves. With this construction, the prongs do not interfere with the openings 142 . The grooves and prongs may be configured to ensure a close running fit between the cover 160 and the openings.
[0028] In a further embodiment, a rotating cover 170 may be provided as shown in FIG. 6 . In this embodiment, the openings 178 are in the form of circular arc segments. The cover 170 is provided with complementary circular arc segment openings 178 that are sized to generally coincide with the openings 178 in the bottom wall 140 of the carriage assembly. The spaces 179 between the arc segments 178 of the cover 170 are sized to completely cover a respective opening 170 . The cover is rotatably mounted to the bottom wall 140 at a pivot mount 176 so that the cover 175 can be rotated in the direction of the arrows to open or close the openings 170 . A handle 179 may be provided on the cover 175 to facilitate rotation of the cover. The cover 175 and pivot mount 176 may be configured to provide a close running fit between the cover and the bottom wall 140 to ensure as tight a seal over the openings 170 as possible.
[0029] The devices and apparatuses described herein has been illustrated and described in detail in the figures and foregoing description, the same should be considered as illustrative and not restrictive in character. It is understood that only the preferred embodiments have been presented and that all changes, modifications, and further applications that come within the spirit of the device described herein are desired to be protected.
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A power tool includes a table structure defining a blade slot, a frame supporting the table structure, a blade assembly mounted within the frame, and a carriage assembly. The blade assembly includes a blade positioned within the blade slot and a motor assembly to rotate the blade, in which the carriage assembly supports the motor assembly relative to the table structure. The carriage assembly defines a chamber within which said blade operates and a discharge chute for discharge of dust and debris from the chamber during operation of the blade. The bottom wall of the carriage assembly below said blade defines a plurality of openings that are sized to permit passage of the dust and debris. The openings may be sized to comply with finger probe test safety standards. In certain embodiments, the openings may be provided with a cover that is movable to expose or close the openings.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of copending application Ser. No. 146,450, filed May 5, 1980, now U.S. Pat. No. 4,340,563.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The manufacture of nonwoven webs has matured into a substantial industry. A wide variety of processes for making such webs has been developed ranging from papermaking to spinning of polymers with air guns or mechanical drawing. A wide variety of uses also has been developed for such webs including (1) single use items such as surgical drapes, (2) multiple use products such as wiping cloths, (3) durable fabrics for the manufacture of carpeting and the like and (4) components in disposable products such as diapers and sanitary napkins. The present invention is directed to methods and apparatus for forming nonwoven webs, particularly those having a basis weight generally in the range of from 0.1 to 10 oz/yd 2 , by spinning thermoplastic polymers. Such webs find uses in the manufacture of disposable products such as diaper liners and sanitary napkin wraps. In the heavier basis weights, the webs may even be used for more demanding applications such as carpet backing, tent fabric, and the like.
In general, the present invention is directed to nonwoven webs formed by spinning filaments of thermoplastic polymers, drawing them aerodynamically to a desired denier and collecting the filaments on a porous surface in an overlapping fashion to form a web which, when bonded, provides a material having sufficient strength for many applications and which can be further treated for additional applications. More particularly, the present invention is directed to such a method and apparatus which makes nonwoven webs by forming a row or rows of filaments extending for the full machine width and drawing the filaments in a full machine wide nozzle.
2. Description of the Prior Art
It is well-known to produce nonwoven webs from thermoplastic materials by extruding the thermosplastic material through a spinnerette and drawing the extruded material into filaments by eduction to form a random web on a collecting surface.
Eductive drawing occurs where discrete jets are formed which entrain a surrounding fluid in turbulent flow. In general, eductive devices require separate sources of fluid, usually air, and produce drawing by kinetic energy. For example, U.S. Pat. No. 3,692,618 to Dorschner et al. describes such a process and apparatus for carrying it out employing a series of eductive guns through which bundles of filaments are drawn by very high speed air requiring a high pressure source. An attempt is then made to spread or oscillate the bundles to generate overlapping loops in a web which then can be bonded and employed in applications for nonwovens. Drawbacks to this process and apparatus include:
(1) the necessity for a high pressure air supply;
(2) the educting of low pressure air causing highly turbulent flows, and, therefore, filament intertwining;
(3) the difficulty of getting all the eductors to produce filaments having the same characteristics;
(4) plunging of the eductors by broken filaments; and
(5) non-uniform basis weight profiles resulting from poor bundle spreading or variations in degree of filament entanglement.
British Pat. No. 1,285,381 to Fukada et al. describes a similar eductor process and apparatus which, while employing a full machine width drawing chamber, uses exit nozzles that are subject to the same problems of plugging, rethreading, and turbulent mixing encountered with the guns of the previously described patent. This patent also discloses a noneductive arrangement having a segmented configuration. U.S. Pat. No. 3,802,817 to Matsuki et al. also describes a full width eductor device and method which, while avoiding the exit nozzle plate of Fukada et al., still requires high pressures and is limited to lower speeds for practical operation. U.S. Pat. No. 4,064,605 to Akiyama et al. similarly describes apparatus employing high speed air jet drafting.
SUMMARY
The present invention is directed to a noneductive drawing method and system for spinning thermoplastic polymer filaments. The systems of the prior art discussed above involve eductor-type devices for drawing filaments. These devices inherently create high levels of turbulence and vorticity which tend to entangle the filaments limiting the uniformity of the products made. Furthermore, such prior art systems involve small eductor throat opening which suffer drawbacks such as frequent plugging. These systems also require two sources of air and the two sets of associated equipment; one low pressure cooled air source is used to quench the molten filaments to the solidified state, and the other a high pressure air source needed to produce high velocity air to draw the filaments--the high velocity air generating high noise levels as it draws the filaments.
In contrast, the system and method of the present invention involve an initial quench chamber and the use of a continuous narrow nozzle across the entire machine width which produces a linear plane of filaments in the nozzle section having substantially constant filament distribution across the machine width, and provides good control of cross-machine uniformity. As used throughout this description, "machine width" refers to a dimension corresponding to the width generally of the spinning plate. As will be recognized by those skilled in this art, these "machines" may be combined to provide a base web of increased width. In such cases, the system of the present invention may have a width corresponding to the individual "machines" although it is preferred that the width correspond to the combination, depending on the ability to machine and maintain the nozzle dimensions. No air is educted into this system as the quench air undergoes uniform acceleration into the nozzle where the drawing force is developed so turbulence and its effects are minimal. The same air is used for two purposes: first to quench the filaments and then to draw them as the air exits through the drawing nozzle at high velocity. This double use of the air reduces utility cost and the required capital investment in air handling equipment and ducting. By selecting a suitable length of nozzle, the necessary drawing tension can be obtained with an air speed in the nozzle of only about 1.5 to four times the filament velocity. In such cases, for example, an air speed of 275 feet per second may be used to produce a filament speed of 157 feet per second requiring a plenum pressure of only 0.65 psig. for a nozzle opening of 3/8 inch (Example #6, in the accompanying Table). In that case, for example, the air requirement would be only about 43 scfm per inch of machine width for filament drawing. Filament cooling is controlled by regulating the temperature of the quench air and controlling the rate of flow of air past the filaments to an exhaust port near the top of the quench chamber. The amount of quench air exiting the duct is important to the operation of the process, so this flow rate is preferably closely monitored and controlled. If there is too high an exhaust flow, the velocity of the air through the filament bundle will cause the filaments to waver and stick to each other causing filament breakage. The filaments will also be cooled too rapidly and large denier, brittle filaments will be produced. With too little exhaust, the filaments will not be totally quenched when they enter the drawing nozzle, increasing the incidence of sticking to the nozzle surfaces.
To achieve the benefits of the present invention, it is essential that the apparatus be constructed and the method carried out within certain ranges of parameters. For example, the quench air should be maintained at a temperature in the range of from about 40° F. to 130° F. The air flow rate should be maintained within the range of from 20 to about 80 scfm per inch of machine width and the nozzle opening from about 1/8 to 1 inch. As indicated above, the exhaust flow rate is important in achieving the desired filament properties, and generally, will be within the range of from nearly 0 to about 14 scfm per inch of machine width.
The length of the quench chamber and the length of the drawing nozzle will each depend, of course, upon the material being spun and the particular web properties desired. Accordingly, these parameters may vary widely, but, in general, will be at least 2 feet and, preferably within the range of from about 50 inches to 80 inches, for the length of the quench zone and about 10 inches to 40 inches for the length of the drawing nozzle. Similarly, the spinnerette capillaries may be in many configurations but will, generally, be employed in the range of from about 3 to about 40 per square inch in a uniform capillary array. As will be apparent from the foregoing, the method and apparatus of the present invention are extremely flexible and can be varied to accommodate a wide variety of materials and operating conditions. Such is a particular advantage and feature of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a generalized flow diagram illustrating the process of the present invention;
FIG. 2 is a schematic cross-sectional perspective view of the apparatus of the present invention; and
FIGS. 3 and 4 are cross-sectional views illustrating filaments forming and laydown in further detail.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
While the invention will be described in connection with preferred embodiments, it will be understood that it is not intended to limit the invention to those embodiments. On the contrary, it is intended to cover all alternatives, modifications and equivalents as may be included within the spirit and scope of the invention as defined by the appended claims.
Turning first to FIG. 1, the method of the invention will be further described. As shown, the first step is to provide a thermoplastic polymer in fluid condition for spinning. The flexibility of the system and method of the present invention allows a wide variety of polymers to be processed. For example, any of the following may be employed: polyamides, polyesters, polyolefins, polyvinyl acetate, polyvinyl chloride, polyvinyl alcohol, and the like. It is, of course, contemplated to also utilize other spinable materials which may not be ordinarily considered polymers such as, for example, molten glass. It is important that the material be capable of being made sufficiently fluid for spinning and otherwise have the properties necessary to undergo drawing in the filament drawing zone. Other examples will become apparent to those skilled in the polymer art.
The polymer is fed from supply 10 to hopper 12, then through extruder 14, filter 16, and metering pump 17 to spin box 18. Filaments 20 are spun through spinnerette 22 with openings arranged in one or more rows forming a curtain of filaments 20 directed into the quench chamber 24. In the quench chamber 24 filaments 20 are contacted with air or other cooling fluid through air inlet 26 which fluid is maintained cooler than said filaments preferably near ambient temperatures, for example, in the range of from about 40° to 130° F. The quenching fluid is supplied under low pressure of less than 12 psi, preferably less than 2 psi, and a portion is preferably directed through the filament curtain 20 and removed as exhaust through port 28. As described above, the proportion of the air supplied that is discharged as exhaust will depend on the polymer being used and the rapidity of quenching needed to give desired filament characteristics such as denier, tenacity and the like. In general, the greater the amount of air exhausted, the larger the resulting filament denier and, conversely, the lower the exhaust air ratio, the lower the denier.
As quenching is completed, the filament curtain is directed through a smoothly narrowing lower end 30 of the quenching chamber into nozzle 32 where the air attains a velocity of about 150 to 800 feet per second. The drawing nozzle is full machine width and preferably formed by a stationary wall 34 and a movable wall 36 spanning the width of the machine. As will be described more particularly with respect to FIG. 3, the movable wall can be retracted under the quench air screens or moved toward the stationary wall. During start-up, the wall is fully retracted so the filaments fall by gravity through the wide open nozzle. The low velocity of the incoming quench air is maintained through the wide open nozzle so little aerodynamic drawing actually occurs. When polymer flow is fully established, the movable wall is moved forward to decrease the nozzle opening, increase the air velocity, and draw the filaments. If a major process upset occurs and the drawing nozzle becomes partially plugged with polymer during operation, the movable wall is momentarily drawn back until the plug falls through the enlarged nozzle. The wall is then moved forward to its normal operating position.
The position of this movable wall determines the drawing nozzle opening and thus the velocity of the air going through the nozzle for a given quench air flow rate and exhaust setting. The filament drawing force increases as the air velocity increases so the filament denier can be easily changed by simply increasing or decreasing the size of the nozzle opening. In general, the filament denier can be increased by:
(1) enlarging the nozzle opening,
(2) reducing the air flow rate through the nozzle,
(3) increasing the exhaust air flow rate,
(4) lowering the quench air temperature,
(5) decreasing the polymer temperature,
(6) increasing the polymer molecular weight, e.g., decreasing the melt flow rate, or
(7) increasing the polymer throughput per capillary.
Steps (1) and (2) reduce the air drawing force; (3) and (4) increase the polymer quench rate; (5) and (6) increase the polymer extensional viscosity and (7) increases the mass of polymer to be accelerated.
For polypropylene, the melt temperature will generally be in the range of from about 208° C. to about 320° C. with a melt index (190° C., 2160 g) of the polymer at the spinnerette in the range of about 17 to about 110. With such materials, the polymer throughput may be in the range of from about 0.25 to 4 pounds per hour per square inch of spinnerette capillary area. Under these conditions, satisfactory operations have been obtained using a nozzle gap in the range of from about 1/16 inch to about 1.0 inch.
Thus, the filament deniers can be changed relatively easily and rapidly in several different ways which do not affect the distribution of filaments out of the nozzle. In all cases, the nozzle desirably spans the entire width of the machine. Therefore, a distribution of filaments corresponding substantially identically to the distribution of orifices in the spin plate across the machine width is maintained all the way to the outlet of the nozzle.
After exiting from the nozzle, the filaments may be collected on a moving foraminous surface 38 such as an endless screen or belt to form a nonwoven web 40. By selecting the nozzle opening and forming distance, the dimensional characteristic of looping of individual filaments can be controlled to provide overlap of individual filaments. This results in a certain amount of intertwining and sufficient integrity in the resulting web to facilitate further processing such as web compacting at roll nip 40, bonding at roll nip 42, and winding at 44 of the cohesive fabric.
Turning to FIGS. 2 and 3, the quench chamber 24 and nozzle area 34 will now be described in greater detail. The spinnerette 10 may be of conventional design and arranged to provide extrusion of filaments 20 having a spacing of about 0.15 to 0.56 inch and, preferably 0.25 to 0.30 inch in one or more rows of evenly spaced orifices 46 across the full width of the machine into the quench chamber. In a preferred embodiment, the centerline of the quench chamber is offset from the spinnerette centerline to accommodate "bowing" of the filaments as quench fluid passes through. The size of the quench chamber will normally be only large enough to avoid contact between the filaments and the sides and to obtain sufficient filament cooling. Immediately after extrusion through the orifices, acceleration of the strand movement occurs due to tension in each filament generated by the aerodynamic drawing means. They simultaneously begin to cool from contact with the quench fluid which is supplied through one or more screens 25 in a direction preferably at an angle having the major velocity component in the direction toward the nozzle entrance. The quench fluid may be any of a wide variety of gases as will be apparent to those skilled in the art, but air is preferred for economy. The quench fluid is introduced at a temperature in the range of from about 40° to 130° F. to provide for controlled cooling of the filaments. As shown and discussed above, the filament curtain will be displaced somewhat from a vertical path by the transverse force of the quench flow. The quench zone may be designed to provide for such movement by positioning the spin plate several inches off the centerline of the drawing nozzle toward the quench air supply.
It is desirable to provide an offset that allows the filaments to pass into the nozzle with little or no contact with the curved entry surface. The exhaust air fraction exiting at 28 from ports 29 is very important as it affects how fast quenching of the filaments takes place. A higher flow rate of exhaust fluid results in more being pulled through the filaments which cools the filaments faster and increases the filament denier. It will be recognized that if the filaments are still molten when entering the drawing nozzle, the system will not operate reliably as sticking to the nozzle will occur. The length of the quench chamber should be sufficient for cooling the filaments to a tack-free temperature ahead of the entry to the nozzle. A length of 2 feet or more is preferred because this allows adequate time for quenching a large number of filaments at high production rates without requiring low temperature air or high exhaust flow. It is also preferred that entrance to the nozzle formed by side 36 be smooth at corner 56 and at an angle A of at least about 135° to reduce filament breakage. Some arrangement for adjusting the relative locations of sides 34 and 36 is preferably provided such as piston 35 fixed to side 36 at 37. In a particularly preferred embodiment, some means such as fins 54 are provided to prevent to turbulent eddy zone from forming. The configuration, spacing, and number of such fins will depend on factors such as chamber width and bow of the filaments, but, in general, will be thin, for example, less than 1/8 inch and spaced no more than 3/4 inch apart filling the entire corner formed by the bowed filaments.
Turning to FIG. 4, the drawing nozzle will now be described in greater detail. The filaments are directed from the quench chamber to the narrow nozzle where the drawing force is developed. The fluid pressure in the quench zone is above the fluid pressure at the exit from the nozzle to provide the desired fluid velocity and resulting filament drawing. The fluid velocity through the nozzle is selected in combination with the length of the nozzle to achieve the desired degree of drawing and resulting filament properties. The nozzle is full machine width and sufficiently narrow to produce the needed fluid velocity for a given air inflow rate. The particular nozzle opening between surfaces 32 and 34 selected will vary depending upon the desired filament properties and other process set points, but will ordinarily be in the range of from about 1/8 inch to 1 inch and preferably between 1/4 inch to 3/4 inch. In designing the noneductive drawing system of the invention, selection of the length of drawing nozzle and the preferred nozzle opening can be made to complement the fan or compressor used to provide the air. A short nozzle and large nozzle opening both mandate use of a relatively high volume flow of air, in the first instance because high drawing velocity is required, and in the second instance, because the cross-section area is large but, the required air pressure is relatively low. On the other hand, a long nozzle provides more length of filament exposed to motive shear stress from the drawing air and, hence, develops the required force with lower air velocity and thus requires less volume flow of air, but a higher pressure due to high friction loss in the nozzle.
Likewise, a smaller nozzle opening reduces the necessary volume of air flow, but also increases the required supply pressure due to increased friction loss. In general, the air pressure required is less than about 12 psi and preferably less than about 2 psi which is a small friction of that required for eductive systems. The interrelationship between these factors is well-known in the science of fluid flow and to those skilled in the technology.
At the exit of the nozzle, the flow becomes a free jet subject to turbulent diffusion of momentum. Mean velocity decreases and within a distance of about 20 times the small dimension of the nozzle opening the drawing force reaches zero and tension in the filaments is released allowing them to be displaced by local turbulent eddies. This results in the formation of irregular loops in the formed web and thereby provides a degree of physical overlapping necessary for producing an integrated web. This looping has a characteristic size or scale that is determined by the nozzle opening and the distance to the forming surface opening. In a preferred embodiment of the present invention, sides 36 and 34 forming nozzle opening 32 are of a different length, one being as much as about 3 inches and, preferably, 3/4 to 11/4 inches longer than the other. This arrangement increases regular and predictable filament wavy motion in the cross machine direction which increases web entanglement and masks momentary disruptions of filaments exiting the drawing nozzle. In all cases, however, the looping is completely free of large-scale components which are prominent in systems requiring lateral spreading of filaments between the device for producing the drawing force and the forming wire, particularly when operated at high production rates, for example, 5 pounds per inch of machine width per hour or more. Filaments coming from a small nozzle opening such as 1/8 inch have a loop primarily in the range of from about 1/8 inch to 1/4 inch in size and the largest loops or migrations of filaments of only about 1 inch when the web is collected at a distance of 15 inches from the nozzle. On the other hand, a nozzle of 1/2 inch opening generates larger loops primarily 1/4 to 1/2 inch in size. When forming takes place close to the nozzle outlet such as at a distance of 6 inches, the largest migrations of filaments are only about 1/2 inch in size. There are two ways in which the small looping of filaments in this system is important. First, the structure of the resulting web is inherently different from one in which large-scale loops dominate. The difference is particularly apparent when there are strong aggregations of filaments associated with large-scale loops so that variation in spatial distribution of basis weight is not only large in scale, but also great in intensity. With only small loops and migrations of filaments there are fewer aggregations to form heavy concentrations in the web, so that intensity of variation as well as size of variations in basis weight are small. The second advantage of small loops is that the free-jet portion of the forming operation has virtually no effect on the overall distribution of basis weight across the machine, i.e., control resides in the distribution of holes in the spin plate.
It will be apparent to those skilled in the science of fluid flow that air supplied to the quench chamber must be not only cooler than the filaments, but substantially uniform in distribution, free of secondary circulations and low in turbulence. Ideally, a streamlined flow is desired from the quench chamber into the nozzle in order to maintain a uniform, constant distribution of filaments. For this purpose, one or more screens 25 are preferably provided at the quench inlet 26. The flow undergoes great acceleration through the lower part of the quench chamber and, hence, it is not particularly susceptible to instabilities, but the approach flow must be essentially free of any large scale eddies or vorticities. Normal development of turbulence within the nozzle does not have a major effect on the filaments because of its small scale.
In accordance with the foregoing, it will be apparent that the method and apparatus of the present invention are subject to widely varying operating conditions and thereby provide great flexibility. Because of the relatively large opening of the nozzle, the system and method have a dramatically reduced tendency for plugging and provide automatic restringing if a filament breaks. Since the process is relatively insensitive to filament breakage, it is possible to spin filaments that are highly loaded with pigments and the like producing colored and additive-modified webs. Finally, the system and method are by design not subject to large-scale air turbulence nor to the erratic conditions usually encountered with filament spreading with the result that more uniform webs may be obtained of attractive appearance and consistent physical properties.
The specific examples below are illustrative of the operation and results obtained in accordance with the present invention. They were carried out on apparatus generally as illustrated in the accompanying FIGS 1-4 having parameters as indicated in the Table, a quench zone length of 56 inches, a nozzle length of 40 inches, and a capillary throughput as indicated.
TABLE__________________________________________________________________________Polypro- Polypro- Through-pylene pylene Quench Exhaust Quench putIncoming Processed Melt Jet Air Air Air Grams/ DuctMelt Melt Temp. Gap, SCFM/ SCFM/ Temp Hole/ Pressure Elonga-ExampleFlow Flow °C. Inches In In °F. Min. In. Hg. Denier Tenacity tion__________________________________________________________________________ 1 14 17 234 .375 45 1.7 94 .77 1.8 3.22 2.67 221 2 14 16.3 245 .375 36 0 102 .69 1.1 2.22 3.19 222 3 14 113 293 .0625 12.5 1.6 60 .53 13.0 2.42 2.83 133 4 (1)14 18.1 253 .375 44 4.4 106 .82 1.8 2.80 2.32 359 5 (2)14 22.3 242 .375 46 3.7 70 .75 1.4 2.57 2.99 228 6 14 18.3 305 .375 46 3.5 95 .70 1.3 2.17 3.73 227 7 14 17.5 216 .250 42 6.4 69 .77 2.9 3.16 3.51 244 8 14 17.2 276 .50 52 0 95 .56 0.8 2.38 3.36 211 9 14 82 291 .0625 19 1.6 60 .90 21.7 2.75 4.57 16810 14 82 291 .0625 16 1.6 60 .71 14.1 2.54 4.29 17711 14 17 260 .375 49 0 71 .77 1.5 2.89 2.76 22712 14 19 274 .250 35 7.3 99 .48 5.6 2.94 2.92 25213 14 18 314 .375 46 3.7 115 .70 1.4 2.70 2.74 25014 14 24.7 256 .1875 37 1.6 47 .93 9.9 2.49 2.63 8315 14 43.5 218 .125 30 0 62 .52 24 1.41 2.22 11716 14 20 268 .50 39 0 86 .56 0.5 2.65 2.08 23017 14 17.9 276 .375 42 4.8 100 .60 2.1 2.39 2.84 18018 14 19.6 212 .50 48 2.7 60 2.68 0.9 19.99 1.86 29519 42 70.4 230 .125 35 0 93 .28 15.7 .83 2.38 21520 14 17.8 237 .250 38 7.5 70 .66 4.1 3.10 1.45 28821 14 82.5 291 .125 23 1.6 60 .71 8.7 2.39 3.78 10422 42 54.4 230 .375 47 3.4 60 2.94 1.2 10.8 1.69 32423 14 21.4 272 .250 38 6.4 80 .75 4.2 3.65 1.91 17824 14 18.1 310 .375 47 3.2 70 .70 1.2 2.10 3.14 20625 14 19.1 234 .375 45 3.9 99 .66 1.6 3.08 2.59 22226 42 62 230 .375 35 0 85 .57 15.5 1.77 2.99 27227 (3)-- -- 273 .375 51 2.6 65 .95 .8 4.80 3.75 147__________________________________________________________________________ NOTES: (1) For this example, TiO.sub.2 pigment was added to a level of 7.28% by weight. (2) For this example Triton X102 was added to a level of 0.8% by weight. (3) For this example the polymer used was Nylon 6.
Sound level measurements were taken under conditions where the apparatus was operated with a nozzle gap of 1/4 inch and full open, with background of 80 to 90 dB. At five foot elevations from the floor to operator ear level only one reading, taken 12 inches below the nozzle opening, exceeded 100 dB at 100.5. The rest were below 90 dB.
In summary, the foregoing specific examples illustrate the present invention and its operation. Preferred embodiments include the formation of low basis weight webs from fine polypropylene filaments of under 5 denier and production rates over 5 pounds per inch per hour; point bonding these webs to produce a nonwoven material useful for many applications including (1) liners for sanitary products, (2) limited use garments, (3) surgical drapes and (4) durable goods.
Thus it is apparent that there has been provided, in accordance with the invention, an improved method and apparatus for forming nonwoven webs that fully satisfy the objects, aims, and advantages set forth above. While the invention has been described in conjunction with specific embodiments thereof, it is evident that many alternatives, modifications, and variations will be apparent to those skilled in the art in light of the foregoing description. Accordingly, it is intended to embrace all such alternatives, modifications, and variations as fall within the spirit and broad scope of the appended claims.
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An improved method and apparatus for forming nonwoven webs by spinning filaments into a quench chamber where they are contacted with a quenching fluid, then utilizing the quench fluid to draw the filaments through a two-dimensional nozzle spanning the full machine width, and collecting the filaments as a web on a porous surface. In contrast with the prior art, low motive fluid pressures can be used, and a non-eductive drawing means utilized to minimize air turbulence and the resulting filament entanglement in the drawing means while maintaining substantially constant cross machine filament distribution. The apparatus and process reduce problems relating to filament breakage and spreading and result in increased productivity and improved web formation. Other advantages include the ability to continuously spin highly pigmented polymer filaments and reduced hazards associates with high noise levels.
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[0001] This application is based on and claims the benefit of priority from Taiwan Patent Application 103146660, filed on Dec. 31, 2014, now pending, which is hereby incorporated by reference.
BACKGROUND
[0002] The embodiments generally relates to live migration of a virtual machine, and more particularly, to the arrangement and management of appliances providing services to the virtual machine during the migration of the virtual machine.
DESCRIPTION OF THE PRIOR ART
[0003] In data centers, a virtual machine on one host is commonly required to be migrated to another host for load balancing or host maintenance. In order not to interrupt the operation of the virtual machine (or to reduce the downtime to minimum), the adopted approach is called “live migration”. The publication “Live migration of virtual machines” by Clark, Christopher, et al. on Proceedings of the 2nd conference on Symposium on Networked Systems Design may serve as reference. In addition, vMotion of VMware Company or Hyper-V live migration of Microsoft Company may also serve as references.
[0004] On the other hand, in data centers, an appliance (which may be a physical appliance or a virtual appliance) is commonly disposed for each host to provide service to the host and the virtual machine thereon. More particularly, in order to prevent network attacks, the use of security appliances (such as firewalls and intrusion detection and prevention devices) to protect hosts and virtual machines is an essential requirement.
[0005] To ensure that services provided to the virtual machine do not have interruptions or errors during the migration among different hosts, many approaches have been proposed in the prior arts such as US Pub. 2013/0275592, U.S. Pat. No. 8,775,625, and US Pub. 2014/0101656. The publication “SECURITY IN LIVE VIRTUAL MACHINE MIGRATION” by Shah Payal Hemchand may also serve as reference.
SUMMARY OF THE INVENTION
[0006] In one aspect, the present embodiments provide a method of facilitating live migration of a virtual machine in a network system. More particularly, to ensure that services (such as intrusion detection and prevention, firewalls, and load balancing) provided to the virtual machine do not have interruptions or errors during the migration of the virtual machine among different hosts, it is recognized that a new method is required for the arrangement and management of appliances providing services to the virtual machine.
[0007] In prior art, the appliance may be disposed in front of each host or directly disposed on each host as a virtual appliance. Regardless of the approach, in general, the appliance only provides service to the corresponding host and the virtual machine thereon; therefore, when the virtual machine is migrated from one host to another host, additional appliances are required for takeover to provide service. However, for certain services (especially services related to network security), the takeover of appliances to provide services is a technical challenge.
[0008] For example, to provide correct services, the appliance may have to collect the operation history and context information of the virtual machine and analyze them. Taking the intrusion prevention systems (IPS) as an example, the state information about the external network flow of the virtual machine is required to be collected. During the migration of the virtual machine, the replacing appliance does not have the historical information of the virtual machine, and thus may result in interruptions or errors in the service.
[0009] For instance, before migration, a virtual machine may have established a TCP/IP connection with another virtual machine on the same host, and the appliance for the host may acquire the connection record and state information to analyze and determine that the connection between the two virtual machines is an internal connection. However, when the virtual machine is migrated to a new host, the connection with another virtual machine on the original host is still maintained, yet the appliance of the new host will not be aware that such a connection is actually an internal connection, and may result in errors when determining or counting specific security events. It is evident that such an issue shall be more problematic during live migration.
[0010] Although prior art such as US Pub. 2014/0101656 provides a synchronization approach for session information of two appliances, the various services, especially services related to network security, provided by the appliances require more information than session information (such as a connection table for intelligent analysis) to operate properly. Unlike simple session information, a lot of information involves more network entities and different network levels, and if the synchronization or sharing of such information between two appliances is to be carried out without causing errors in intelligent analyses by the appliances, the process shall be inconceivably complicated, not to mention the situation in live migration (which involves frequent exchange and synchronization of information between two appliances); therefore, such an approach is not feasible in practice.
[0011] Accordingly, the present embodiments provide disposal of a temporary appliance between the appliance providing service to the original host and the appliance providing service to the migration destination host. The temporary appliance may be a physical appliance or a virtual appliance.
[0012] According to one embodiment, a virtual machine operates on an original host before migration, and an appliance providing service to the original host correspondingly generates or collects related history and context information according to the operation of the virtual machine. During the live migration of the virtual machine (i.e., when the virtual machine still has ongoing operations), the history and context information generated by the present operations of the virtual machine are cloned to the temporary appliance. Subsequently, the temporary appliance immediately takes over from the appliance providing service to the original host to continue to provide service to the present operations of the virtual machine until the present operations terminate. Following this termination, the temporary appliance may be removed or provided to other applications.
[0013] Operations of the virtual machine generated after migration to the destination host, i.e., new operations other than the ongoing operations of the virtual machine on the original host, are provided with service from the appliance providing service to the destination host. By such an allocation, services without interruptions may be provided to the virtual machine. More importantly, the complicated issue involving the aforementioned information synchronization between the appliance providing service to the original host and the appliance providing service to the migration destination host may be avoided.
[0014] In addition, in the situation that the appliance providing service to the original host is a virtual appliance and is disposed on the original host along with the virtual machine, the approach provided in the present embodiment(s) is more advantageous. More particularly, after the virtual machine has completed migration, the original host along with the virtual appliance thereon may be turned off together (such as for maintenance) or provided to other applications (such as load balancing), and resources are not required to be preserved for the migrated virtual machine. If the temporary appliance also exists in the resource pool of the data center as a virtual appliance, the appliance providing service to the original host may be deemed as being cloned and migrated from the original host to the resource pool to act as the temporary appliance. For resource pools, vSphere Resource Pools of VMware Company may serve as reference.
[0015] In one embodiment, a method of facilitating live migration of a virtual machine in a network system is disclosed. The network system includes a first host, a second host, a first appliance providing service to the first host, a second appliance providing service to the second host, and a third appliance. At least one virtual machine is disposed on the first host and has a first network flow that is ongoing. The first appliance generates state information about the first network flow. During the migration of the at least one virtual machine to the second host, the method controls the third appliance to obtain a copy of the state information about the first network flow, and controls the third appliance to take over from the first appliance to provide service to the first network flow during the migration of the at least one virtual machine until the first network flow terminates.
[0016] In other embodiments, a management controller executing the above method and a network system including the management controller are also disclosed. In still another embodiment, a network controller used in the network system is also disclosed.
[0017] Reference throughout this specification to features, advantages, or similar language does not imply that all of the features and advantages that may be realized with the present invention should be or are in any single embodiment of the invention. Rather, language referring to the features and advantages is understood to mean that a specific feature, advantage, or characteristic described in connection with an embodiment is included in at least one embodiment. Thus, discussion of the features and advantages, and similar language, throughout this specification may, but do not necessarily, refer to the same embodiment. Furthermore, the described features, advantages, and characteristics may be combined in any suitable manner in one or more embodiments. One skilled in the relevant art will recognize that the embodiments may be practiced without one or more of the specific features or advantages of a particular embodiment. In other instances, additional features and advantages may be recognized in certain embodiments that may not be present in all of the embodiments.
[0018] The following description, the appended claims, and the embodiments of the present invention further illustrate the features and advantages.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] In order that the advantages of the embodiments will be readily understood, a more particular description of the embodiments briefly described above will be rendered by reference to specific embodiments that are illustrated in the appended drawings. Understanding that these drawings depict only typical embodiments and are not therefore to be considered to be limiting of its scope, the embodiments will be described and explained with additional specificity and detail through the use of the accompanying drawings.
[0020] FIG. 1 shows a network system of an embodiment of the invention.
[0021] FIG. 2 shows a flowchart of a method of an embodiment of the invention.
[0022] FIG. 3 shows a server of an embodiment of the invention.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0023] Reference throughout this specification to “one embodiment,” “an embodiment,” or similar language means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment. Thus, appearances of the phrases “in one embodiment,” “in an embodiment,” and similar language throughout this specification may, but do not necessarily, all refer to the same embodiment.
[0024] As will be appreciated by one skilled in the art, the present embodiments may be embodied as a computer system/device, a method or a computer program product. Accordingly, the present embodiments may take the form of an entirely hardware embodiment, an entirely software embodiment (including firmware, resident software, micro-code, etc.) or an embodiment combining software and hardware aspects that may all generally be referred to herein as a “circuit,” “module” or “system.” Furthermore, the present embodiments may take the form of a computer program product embodied in any tangible medium of expression having computer-usable program code embodied in the medium.
[0025] Any combination of one or more computer usable or computer readable medium(s) may be utilized. The computer-usable or computer-readable medium may be, for example but not limited to, an electronic, magnetic, optical, electromagnetic, infrared, or semiconductor system, apparatus, device, or propagation medium. More specific examples (a non-exhaustive list) of the computer-readable medium would include the following: an electrical connection having one or more wires, a portable computer diskette, a hard disk, a random access memory (RAM), a read-only memory (ROM), an erasable programmable read-only memory (EPROM or Flash memory), an optical fiber, a portable compact disc read-only memory (CD-ROM), an optical storage device, a transmission media such as those supporting the Internet or an intranet, or a magnetic storage device.
[0026] Note that the computer-usable or computer-readable medium could even be paper or another suitable medium upon which the program is printed, as the program can be electronically captured, via, for instance, optical scanning of the paper or other medium, then compiled, interpreted, or otherwise processed in a suitable manner, if necessary, and then stored in a computer memory. In the context of this document, a computer-usable or computer-readable medium may be any medium that can contain, store, communicate, propagate, or transport the program for use by or in connection with the instruction execution system, apparatus, or device. The computer-usable medium may include a propagated data signal with the computer-usable program code embodied therewith, either in baseband or as part of a carrier wave. The computer usable program code may be transmitted using any appropriate medium, including but not limited to wireless, wireline, optical fiber cable, RF, etc.
[0027] Computer program code for carrying out operations of the present embodiments may be written in any combination of one or more programming languages, including an object oriented programming language such as Java, Smalltalk, C++ or the like and conventional procedural programming languages, such as the “C” programming language or similar programming languages. The program code may execute entirely on the user's computer, partly on the user's computer, as a stand-alone software package, partly on the user's computer and partly on a remote computer or entirely on the remote computer or server. In the latter scenario, the remote computer or server may be connected to the user's computer through any type of network, including a local area network (LAN) or a wide area network (WAN), or the connection may be made to an external computer (for example, through the Internet using an Internet Service Provider).
[0028] The present embodiments are described below with reference to flowchart illustrations and/or block diagrams of methods, apparatus (systems) and computer program products. It will be understood that each block of the flowchart illustrations and/or block diagrams, and combinations of blocks in the flowchart illustrations and/or block diagrams, can be implemented by computer program instructions. These computer program instructions may be provided to a processor of a general purpose computer, special purpose computer, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, create means for implementing the functions/acts specified in the flowchart and/or block diagram block or blocks.
[0029] These computer program instructions may also be stored in a computer-readable medium that can direct a computer or other programmable data processing apparatus to function in a particular manner, such that the instructions stored in the computer-readable medium produce an article of manufacture including instruction means which implement the function/act specified in the flowchart and/or block diagram block or blocks.
[0030] The computer program instructions may also be loaded onto a computer or other programmable data processing apparatus to cause a series of operational steps to be performed on the computer or other programmable apparatus to produce a computer implemented process such that the instructions which execute on the computer or other programmable apparatus provide processes for implementing the functions/acts specified in the flowchart and/or block diagram block or blocks.
[0031] Referring now to FIG. 1 through FIG. 3 , computer systems/devices, methods, and computer program products are illustrated as structural or functional block diagrams or process flowcharts according to various embodiments. The flowchart and block diagrams in the Figures illustrate the architecture, functionality, and operation of possible implementations of systems, methods and computer program products according to various embodiments. In this regard, each block in the flowchart or block diagrams may represent a module, segment, or portion of code, which comprises one or more executable instructions for implementing the specified logical function(s). It should also be noted that, in some alternative implementations, the functions noted in the block may occur out of the order noted in the figures. For example, two blocks shown in succession may, in fact, be executed substantially concurrently, or the blocks may sometimes be executed in the reverse order, depending upon the functionality involved. It will also be noted that each block of the block diagrams and/or flowchart illustration, and combinations of blocks in the block diagrams and/or flowchart illustration, can be implemented by special purpose hardware-based systems that perform the specified functions or acts, or combinations of special purpose hardware and computer instructions.
[0032] <System Architecture>
[0033] FIG. 1 shows a network system ( 10 ) of an embodiment. For simplification, FIG. 1 only shows a management controller ( 100 ), hosts ( 110 ) and ( 120 ), and a resource pool ( 130 ). In one embodiment, the network system ( 10 ) is located in substantially the same physical area, such as a server room, and the hosts or other devices of the network system ( 10 ) may connect to each other via local area network. However, in other embodiments, the hosts or other devices of the network system ( 100 may be distributed in different areas and are connected to each other via wide area Internet; under such a situation, communication between the hosts ( 110 ) and ( 120 ) may have to pass through a gateway or other network devices (both not shown), and the gateway may provide network address translation (NAT) function.
[0034] The hosts ( 110 ) and ( 120 ) each has other physical computing resources (not shown) such as processors, memories, etc., and the resource pool ( 130 ) may have one or multiple hosts or computing resources (also not shown) that are comparable with the hosts ( 110 ) and ( 120 ) and are preserved in advance. The hosts ( 110 ) and ( 120 ) and the resource pool ( 130 ) are connected with the management controller ( 100 ) for communication, and establish or handle one or multiple virtual machines or virtual appliances according to instructions of the management controller ( 100 ). VMware vCenter of VMware Company may serve as reference for details of the management controller ( 100 ) not directly involved with the present embodiments.
[0035] More particularly, in this embodiment, the network system ( 10 ) further includes appliances ( 115 ) and ( 125 ), and as shown in the figure. The appliances ( 115 ) and ( 125 ) are disposed on the hosts ( 110 ) and ( 120 ) as virtual appliances to provide service to the virtual machines on the hosts ( 110 ) and ( 120 ), respectively. For virtual appliances, the technical document “Virtual Appliances: A New Paradigm for Software Delivery” by VMware may serve as reference. It should be noted that the present invention is not limited to virtual appliances.
[0036] In this embodiment, the appliances ( 115 ) and ( 125 ) are virtual intrusion prevention systems (IPS) for protecting the security of the virtual machines on the hosts ( 110 ) and ( 120 ). In other words, external network communications of each the virtual machines on the hosts ( 110 ) and ( 120 ) are all monitored by the appliances ( 115 ) and ( 125 ).
[0037] To provide external network communication of the virtual machine, as shown in FIG. 1 , the hosts ( 110 ) and ( 120 ) further include virtual network switches ( 118 ) and ( 128 ), respectively, for providing network switching to the virtual machines or virtual appliances on the hosts. For virtual network switches on hosts, U.S. Pat. No. 7,643,482 or software-defined networking (SDN) switches in prior art may serve as reference.
[0038] In this embodiment, the management controller ( 100 ) also serves as a network controller to set the network switches ( 118 ) and ( 128 ) (such as flow tables; “OpenFlow Switch Specification” published by Open Networking Foundation may serve as reference). However, in other embodiments, an additional exclusive network controller (not shown) may be disposed to set the network switches ( 118 ) and ( 128 ), and does not necessarily have to be integrated with the management controller ( 100 ); SDN switches in prior art may serve as reference.
[0039] It should also be mentioned that, in this embodiment, in addition to each of the virtual machines or virtual appliances on each host of the network system ( 10 ) being able to communicate with each other via SDN, they may also communicate with other hosts via SDN. In other words, every unit in FIG. 1 may communicate with each other via SDN. In this aspect, the network system ( 10 ) may further require additional SDN switches and SDN controllers (not shown), yet this part is well known to those skilled in the related art and is not described in detail here.
[0040] <Method Flow>
[0041] The embodiments of the present invention shall be described with reference to the flow in FIG. 2 in accordance with the devices shown in FIG. 1 . For illustrative purposes, it is assumed that the host ( 110 ) has a virtual machine VM having ongoing operations. The virtual machine VM is provided as a cloud web server and has a network flow F 1 that is ongoing; Amazon Web Services (AWS) may be referred to for this aspect. The appliance ( 115 ) for the host ( 110 ) monitors the network flow F 1 to determine whether there are malicious attacks against the virtual machine VM. The network flow F 1 may include communications between the virtual machine VM and one or multiple IP addresses (such as different visitor devices). For further descriptions about network flows of the virtual machine VM, the aforementioned U.S. Pub. US2013/0275592 may serve as reference. In this embodiment, the appliance ( 115 ) establishes a corresponding connection table about the network flow F 1 to record the state and other details of the network flow F 1 , and analyzes the information in the connection table to determine whether specific network events have occurred, and a count of the specific network events may be calculated. For the connection table and specific network events in the above, Security Network Protection of IBM Company, general IPS, or U.S. Pat. No. 7,827,272 may serve as reference.
[0042] Step ( 200 ): in this embodiment, the host ( 110 ) is required to be turned off for the purpose of maintenance, and thus the management controller ( 100 ) requires the live migration of the virtual machine VM to the host ( 120 ). The details of the live migration of the virtual machine VM from the host ( 110 ) to the host ( 120 ) are provided in prior art and are not described here.
[0043] Step ( 202 ): in this embodiment, the management controller ( 100 ) migrates the virtual appliance ( 115 ) on the host ( 110 ) to the resource pool ( 130 ) by cloning to become a virtual appliance ( 135 ). By directly cloning, the virtual appliance ( 135 ) is essentially the same as the virtual appliance ( 115 ), and thus the virtual appliance ( 135 ) shall have state information about the network flow F 1 and the count of the specific network events from the virtual appliance ( 115 ). Due to the adoption of direct cloning, the aforementioned complicated issue involving information synchronization may be avoided.
[0044] In addition to migrating the entire virtual appliance to the resource pool ( 130 ) by direct cloning, in other embodiments, the management controller ( 100 ) may first require the resource pool ( 130 ) to establish the virtual appliance ( 135 ), and then the virtual appliance ( 115 ) provides a copy of the connection table of the network flow F 1 , the count of the specific network events, or other required records to the virtual appliance ( 135 ). Such an approach that only copies the information renders the virtual appliance ( 135 ) capable of receiving record copies from other appliances, which is particularly advantageous when virtual machines on multiple hosts are all migrating at the same time; by such an approach, the virtual appliance ( 135 ) may be utilized as a temporary appliance that takes over from multiple appliances instead of from only the appliance ( 115 ) (described in Step ( 204 )). In addition, it may be understood that, such an approach may also be suitable for situations in which the appliance ( 115 ) and the appliance ( 135 ) are physical appliances.
[0045] Step ( 204 ): the management controller ( 100 ) serves as the network controller and modifies the settings of the virtual network switch ( 128 ) on the host ( 120 ) to redirect the network flow F 1 of the virtual machine VM to the appliance ( 135 ), and requires the appliance ( 135 ) to take over from the appliance ( 115 ) to provide service to the network flow F 1 , i.e., to continue to monitor the network flow F 1 to determine whether there are malicious attacks against the virtual machine VM (which has migrated to the host ( 120 )). Since the appliance ( 135 ) has all records about the network flow F 1 and the count of the specific network events of the appliance ( 115 ), i.e., the appliance ( 135 ) has the complete historical record about the network flow F 1 , errors when determining whether there are malicious attacks may be avoided.
[0046] On the other hand, a network flow F 2 newly generated after the migration of the virtual machine VM to the host ( 120 ) is still directed to the appliance ( 125 ) for the host ( 120 ), and the appliance ( 125 ) monitors the network flow F 2 to determine whether there are malicious attacks against the virtual machine VM on the host ( 120 ).
[0047] Step ( 206 ): when the network flow F 1 terminates, the management controller ( 100 ) notifies the resource pool ( 130 ) to remove the appliance ( 135 ) to release hardware resources, or to provide the appliance ( 135 ) to other applications. In general, the network flow terminates when the communication ends; for example, when a packet includes a FIN flag, it means that the network flow represented by the packet terminates.
[0048] FIG. 3 further shows a hardware environment block diagram of a server ( 300 ) which may function as the management controller ( 100 ) in FIG. 1 .
[0049] In one embodiment, the server ( 300 ) has a processor to execute dedicated application programs; a storage device to save various information and program codes; a communication and input/output device to act as an interface for users to communicate with; and peripheral devices or other specific usage devices. In other embodiments, the present invention may also be implemented with other forms and have more or less apparatuses or devices.
[0050] As shown in FIG. 3 , the server ( 300 ) may have a processor ( 310 ), memory ( 320 ), and an input/output (I/O) unit ( 340 ). The I/O bus may be a high-speed serial bus such as a PCI-e bus, yet other bus architectures may also be used. Other connections to the I/O bus may be connected directly to the devices or through expansion cards. The I/O unit ( 340 ) may also be coupled to a hard disk ( 350 ) or a local area network (LAN) adaptor ( 360 ). By the LAN adaptor ( 360 ), the server ( 300 ) may communicate with other computer devices through a network ( 330 ). The network ( 330 ) may be implemented with any type of connection including static LAN connections or wide area network (WAN) connections or dialup networking by Internet service providers; the connection scheme is also not limited and may include wired or wireless connections such as communications with user computers by wireless networks of GSM or Wi-Fi. However, it should be understood that other hardware and software components (such as additional computer systems, routers, firewalls, etc.) may be included in the network despite not being shown in the figures. The memory ( 320 ) may be a random access memory (RAM), a read-only memory (ROM), or an erasable programmable read-only memory (EPROM or Flash memory). The memory ( 320 ) is used to save an operating system, program codes of a dedicated main program AP, and all kinds of information. The operating system is executed on the processor ( 310 ) and coordinates and provides control of various devices in the appliance ( 300 ); the processor ( 310 ) may access the memory ( 320 ) to execute the main program AP to implement the management controller ( 100 ) in FIG. 1 or carry out the steps of the method shown in FIG. 2 .
[0051] Those skilled in the art may understand that the hardware of the server ( 300 ) in FIG. 3 may have various modifications according to different embodiments. Other internal hardware or peripheral devices such as Flash ROM, equivalent non-volatile memory, optical drive, etc. may be added to or replace the hardware shown in FIG. 3 .
[0052] Moreover, the hardware of the server ( 300 ) in FIG. 3 could be adopted by the host ( 110 ), the host ( 120 ), or hosts in the resource pool ( 130 ).
[0053] The present invention can be embodied in any other specific manners without departing from the spirit or essential features of the present invention. Every aspect of the aforesaid embodiments of the present invention must be deemed illustrative rather than restrictive of the present invention. Hence, the scope of the present invention is defined by the appended claims instead of the above description. All equivalent meanings and scope which fall within the appended claims must be deemed falling within the scope of the appended claims.
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Embodiment pertain to facilitation of live migration of a virtual machine in a network system. The network system includes a first host, a second host, a first appliance for providing service to the first host, a second appliance for providing service to the second host, and a third appliance. At least one virtual machine is disposed on the first host and has an ongoing first network flow. The first appliance has generated state information about the first network flow. During the migration of the at least one virtual machine to the second host, the third appliance obtains a copy of the state information about the first network flow; and the third appliance takes over from the first appliance to serve the first network flow during the migration of the at least one virtual machine, until the first network flow is terminated.
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BACKGROUND OF THE INVENTION
[0001] The instant invention relates to retractable blade arrowheads. The instant application claims priority to U.S. Provisional Patent Application Ser. No. 62/285,679; 62/389,059; and 62/392,245 filed Nov. 5, 2015; Feb. 16, 2016; and May 24, 2016 respectively. Broadhead arrowheads are known and comprise either fixed or retractable blades. Fixed blade broadheads are mechanically simple but suffer from relatively high aerodynamic drag from the exposed fixed blades. Fixed blade broadheads also require care in handling and storage to prevent blade dulling and accidental injury. The blades of many retractable blade broadheads do not fully retract into the body of the arrowhead and thus suffer from the same aerodynamic drag and safety problems as fixed blade broadheads.
[0002] As discussed in U.S. Pat. No. 4,998,738 and U.S. Pat. No. 5,112,063, the objective for any hunting arrow with deployable cutting blades is to have the blades retracted to a more aerodynamic position during the flight of the arrow and to have the blades open to a cutting position which causes maximum hemorrhaging when the arrow strikes its quarry. As discussed above, traditional broadheads have fixed, exposed cutting blades which are subject to wind drag and other adverse wind effects during the flight of the arrow. It has been found that broadheads designed with deployable blades overcome the problems associated with wind effects and are more accurate than traditional fixed blade broadheads.
[0003] U.S. Pat. No. 2,859,970 discloses a cone which houses a pair of cutting blades therein where the cutting blades are mounted on a pivot pin. The Doonan device is frictionally fit over the tip of a target arrow. The intended design of the Doonan device is such that during the flight of the arrow, the cutting blades stay within the cone, thereby overcoming adverse wind effects on the flight of the arrow. When the cone strikes the animal, the arrow shaft rams the target tip into the back of the cutting blades such that they open up from the cone by pivoting on the pivot pin. One problem with the Doonan device is that the shaft of the arrow is likely to ram the cutting blades of the cone open just as the arrow is shot because of the inertia of the cone relative to the speed of the arrow. Another problem with the Doonan device is that the frictional engagement of the cutting blades against sidewalls of slots in the cone is not easily controllable.
[0004] U.S. Pat. No. 4,932,671 shows a phantom bladed broadhead where the cutting blades remain inside a cylindrical ferrule body during flight and are rammed open by a plunger, positioned to slide rearward from the front of the body, when the plunger impacts against the body of the animal. In Anderson, the cutting blades are not connected to the plunger but are pivotally connected to the cylindrical body by a ring which passes through a forward cut out section of each blade.
[0005] U.S. Pat. No. 4,504,063 discloses a broadhead which is designed to have a slimmer profile during flight and a wider, cutting profile upon impact. In LeBus, a plunger, which extends from the front of the broadhead while it is in flight, includes a weight at its rear section that acts against notches formed on the inside surfaces of the cutting blades when the broadhead strikes an animal. LeBus utilizes an O-ring to help hold the cutting blades in their slimmer profile during flight wherein the O-ring fits in a notched portion at the base of each cutting blade and the O-ring expands when the weight at the rear of the plunger forces the cutting blades open. Since the blades of the LeBus broadhead are always slightly open, the archer must be very careful when installing the O-ring so as not to get cut on the sharp blades of the broadhead.
[0006] U.S. Pat. No. 5,102,147 and U.S. Pat. No. 8,118,694 disclose broadheads having fully retracting blades. U.S. Pat. No. 7,713,152; U.S. Pat. No. 7,905,802; U.S. Pat. No. 8,905,874; and US Patent Application Publication 2015/0184986 disclose broadheads having partially retracting blades. The instant invention is directed at providing a better retractable blade arrowhead having fully retracting blades.
SUMMARY OF THE INVENTION
[0007] The instant invention is an important advance in the art of retractable blade arrowheads. The instant invention is an arrowhead comprising: (a) a cylindrical ferrule; (b) a tip; (c) a first blade; (d) a second blade; (e) a hinge pin; and (d) a shear pin, the ferrule having a longitudinal axis, the ferrule having a passageway thereinto along the longitudinal axis of the ferrule, the tip having a shank dimensioned to pass into the passageway, the ferrule having a first elongated aperture into said passageway on one side of the ferrule into which the first blade is positioned, the ferrule having a second elongated aperture into said passageway on the other side of the ferrule into which the second blade is positioned, the first blade having a first aperture near one end and a second aperture near the other end, the second blade having a first aperture near one end and a second aperture near the other end, the hinge pin positioned through the first aperture of the first and second blades, the hinge pin positioned near the shank of the tip, the ferrule having a bore therethrough transverse to the longitudinal axis of the ferrule, the shear pin positioned through said bore and through the second apertures of the first and second blades so that when the arrowhead strikes a game animal the shank of the tip pushes the hinge pin and blades to move in a direction along the longitudinal axis of the ferrule away from the tip to shear the shear pin so that the blades swing out from the ferrule on the hinge pin.
[0008] In another embodiment, the instant invention is an arrowhead comprising: (a) a cylindrical ferrule; (b) a tip; (c) a first blade; (d) a second blade; and (e) a hinge pin, the ferrule having a longitudinal axis, the ferrule having a passageway thereinto along the longitudinal axis of the ferrule, the tip having a shank dimensioned to pass into the passageway, the ferrule having a first elongated aperture into said passageway on one side of the ferrule into which the first blade is positioned within the ferrule, the ferrule having a second elongated aperture into said passageway on the other side of the ferrule into which the second blade is positioned within the ferrule, the first blade having a first aperture near one end and a detent projection near the other end, the first blade detent projection being an interference fit in the first elongated aperture, the second blade having a first aperture near one end and a detent projection near the other end, the second blade detent projection being an interference fit in the second elongated aperture, the hinge pin positioned through the first aperture of the first and second blades, the hinge pin positioned near the shank of the tip so that when the arrowhead strikes a game animal the shank of the tip pushes the hinge pin and blades to move in a direction along the longitudinal axis of the ferrule away from the tip so that the blades swing out from the ferrule on the hinge pin.
[0009] In yet another embodiment, the instant invention is a kit of parts packaged for retail sale, comprising: the arrowhead of the instant invention employing a shear pin made of an elastomer; and (b) a plurality of shear pins colored coded to correspond to the durometer value of the shear pin.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is an exploded view of the parts of a highly preferred embodiment of the instant invention;
[0011] FIG. 2 is a side view of the assembled arrowhead of FIG. 1 ;
[0012] FIG. 3 depicts the arrowhead of FIG. 1 in flight;
[0013] FIG. 4 depicts the arrowhead of FIG. 1 upon impact with the target;
[0014] FIG. 5 depicts the blades of the arrowhead of FIG. 1 fully deployed after impact with the target; and
[0015] FIG. 6 is an exploded view of the parts of another highly preferred embodiment of the instant invention.
DETAILED DESCRIPTION OF THE INVENTION
[0016] Referring now to FIG. 1 , therein is shown an exploded view of the parts of a highly preferred arrowhead 10 of the instant invention. Arrowhead 10 includes cylindrical ferrule 13 , tip 11 and tip retraction spring 12 . The term “cylindrical” is defined herein to include a conical shape. Tip 11 has the terminal shape of a three sided pyramid and is notched with notches 11 a . Tip plunger 11 b is passed through spring 12 into ferrule 13 . Set screw 15 retains tip 11 in ferrule by engagement near tip plunger flat portion 11 c . Blade 20 is inserted into elongated aperture 17 in ferrule 13 . Blade 21 is inserted into an elongated aperture (not shown) opposite elongated aperture 17 in ferrule 13 so that pin 24 is passed through aperture 20 b in blade 20 and aperture 21 b in blade 21 . Then pin 24 is slid up elongated aperture 16 in ferrule 13 so that shear pin 18 can be passed through an aperture (not shown) opposite aperture 25 in ferrule 13 , through aperture 21 a of blade 21 , through aperture 20 a of blade 20 and then through aperture 25 of ferrule 13 so that bulbous portion 18 b of shear pin 18 is positioned in aperture 25 with shear pin tail 18 a extending from ferrule 13 . Threaded shank 19 permits arrowhead 10 to be screwed into the shaft of an arrow or into the shaft of a crossbow bolt. A preferred shear pin 18 of the instant invention has a central diameter of 0.093 inches and is molded of an elastomer having a durometer value selected to shear upon impact of the arrowhead with a target. The preferred durometer value for use with a compound bow is a value on the A scale of between 40 and 45 . Since a crossbow typically has a higher bolt acceleration upon firing, the preferred durometer value for use with a crossbow is a value on the A scale of between 50 and 60 .
[0017] Referring now to FIG. 2 , therein is shown a side view of an assembled arrowhead 10 with shear pin tail 18 a shown extending from ferrule 13 . Shear pin tail 18 a is removed before use of arrowhead 10 . Blades 20 and 21 are positioned on top of each other and folded into body 13 as seen through elongated aperture 17 in ferrule 13 .
[0018] Referring now to FIG. 3 , tip 11 is shown in its extended position retained by set screw 15 . Shear pin 18 retains the blades of the arrowhead within ferrule 13 . Hinge pin 24 is shown at one end of elongated aperture 16 . FIG. 3 shows arrowhead 10 of FIG. 1 in flight.
[0019] Referring now to FIG. 4 , when arrowhead 10 of FIG. 1 strikes a target game animal (such as a deer) tip plunger 11 b is forced into ferrule 13 to force blades 20 and 21 from ferrule 13 shearing shear pin 18 as pin 18 is slid in the direction away from tip 11 along elongated aperture 16 . Notch 20 c in blade 20 and notch 21 c in blade 21 are preferred to better enable blade 20 and blade 21 to fully deploy as shown in FIG. 5 . The spring constant of tip retraction spring 12 and shear strength of shear pin 18 are readily confirmed by experiment. For example, if the spring constant of tip retraction spring 12 and shear strength of shear pin 18 are too low, then blades 20 and 21 will deploy in the air upon firing of the arrowhead thereby increasing the aerodynamic drag of the arrowhead. And, if the spring constant of tip retraction spring 12 and the shear strength of shear pin 18 are too high, the blades will fail to deploy upon striking the target. High power crossbows typically require higher shear strength shear pins while longbows typically require lower shear strength shear pins. Notches 11 a in tip 11 shown in FIG. 1 are highly preferred because the pointed edges thereof increase the initial force of the tip shank 11 b into ferrule 13 when arrowhead 10 strikes a game animal. It should be understood that an arrow tip terminating in a pyramid point wherein the edges of the faces of the pyramid are notched with cylindrical notches transverse to the edges of the pyramid is novel and unobvious as a separate invention disclosed herein. It should also be understood that tip 11 shown in FIG. 1 is not critical in the instant invention and that any tip shape can be used in the instant invention. Preferably, the arrowhead 10 of FIG. 1 is sold in a package that includes spare color coded shear pins of different shear strength together with recommendations for use with different bows, compound bows and crossbows.
[0020] Referring now to FIG. 6 therein is shown an exploded view of the parts of another highly preferred arrowhead 30 of the instant invention similar in many respects to the arrowhead 10 of FIG. 1 . Arrowhead 30 includes ferrule 33 , tip 31 and tip retraction spring 32 . Tip plunger 31 b is passed through spring 32 into ferrule 33 . Set screw 35 retains tip 31 in ferrule by engagement near tip plunger flat portion 31 c . Blade 40 is inserted into elongated aperture 37 in ferrule 33 . Blade 41 is inserted into an elongated aperture (not shown) opposite elongated aperture 37 in ferrule 33 so that pin 44 is passed through aperture 40 b in blade 40 and aperture 41 b in blade 41 . Then pin 44 is slid up slot 36 in ferrule 33 . Detent projection 40 a on blade 40 and detent projection 41 a on blade 41 are an interference friction fit in their respective elongated apertures of ferrule 33 and serve to retain blades 40 and 41 in ferrule 33 before arrowhead 30 strikes a game animal or other target. The spring constant of tip retraction spring 12 and the friction of the interference fit of the detent projections 40 a and 41 a on blades 40 and 41 are readily confirmed by experiment. For example, if the spring constant of tip retraction spring 12 and the friction of the detent projections are too low, then blades 20 and 21 will deploy in the air upon firing of the arrowhead thereby increasing the aerodynamic drag of the arrowhead. And, if the spring constant of tip retraction spring 12 and the friction of the detent projections are too high, the blades will fail to deploy upon striking the target. High power crossbows typically require stronger springs and higher detent friction while longbows typically require weaker springs and less detent friction of the detent projections. Threaded shank 39 permits arrowhead 30 to be screwed into the shaft of an arrow or into the shaft of a crossbow bolt.
[0021] The tip and blades of the instant invention can be made of any suitable material but preferably are made of a metal such as stainless steel. The ferrule of the instant invention can be made of any suitable material but preferably is made of aluminum shaped by automatic machine tools. The shear pin of the instant invention can be made of any suitable material (such as brass, tin or a thermoplastic) but preferably is made of an elastomer such as silicone rubber.
CONCLUSION
[0022] While the instant invention has been described above and claimed below according to its preferred embodiments, it can be modified within the spirit and scope of this disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the instant invention using the general principles disclosed herein. Further, the instant application is intended to cover such departures from the present disclosure as come within the known or customary practice in the art to which this invention pertains.
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A broadhead arrowhead having fully retractable blades wherein a plunger of the tip of the arrowhead causes the blades to shear a shear pin and deploy when the arrowhead strikes a target. In an alternative embodiment, the blades are retained in the arrowhead by a friction fit that is overcome to deploy the blades when the arrowhead strikes a target.
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TECHNICAL FIELD
[0001] The present disclosure relates to a device and to a method for fabricating three-dimensional structures from pasty or plastics substances spread in thin layers, for example, in superposed plane layers.
[0002] This type of device is known more particularly by the generic term “3D printer”.
[0003] The present disclosure is intended more particularly for fabricating three-dimensional structures of very large dimensions, in particular in the field of masonry construction of buildings, i.e. construction using mortars comprising a hydraulic binder such as lightweight lime or cement, for example, mortars that are insulating and strong, and for example, fiber-reinforced.
BACKGROUND
[0004] In the field of 3D printers the term “structure” is used to designate prototypes or short runs of parts such as pump components, statuettes, bottles, or any other part that was used in the past to be molded or made entirely by hand, and that by virtue of these machines are now designed by computer in the form of digital 3D models and made in entirely automatic manner, layer by layer by said 3D printer.
[0005] In the field of construction, this involves making buildings, e.g. houses, blocks of flats or offices, warehouses, or any other type of construction requiring structures that are solid and that can be constructed quickly.
[0006] Construction techniques have changed a great deal in the last few decades, and it is always desired to simplify them and to automate them so as to increase the quality of the finished product while reducing costs and building times.
[0007] The principle of 3D printers is known, consisting in designing an object in three dimensions and then fabricating it layer by layer. To do this, the 3D digital model is cast as parallel slices of constant thickness and the machine deposits the pasty or liquid material successively layer by layer on each of the planes, and does so in a manner that is quasi-continuous. Depending on the technique involved, the material is deposited on the preceding layer either in the form of droplets, or in the form of a bead of molten plastics material and distributed by an injection head, or indeed by using a laser beam to melt a thin layer of previously deposited hot-melt powder, or by polymerizing a liquid film by using a laser beam.
[0008] It is generally desired to obtain good quality for the finished item, which leads to making layers that are thin, which in certain circumstances may be of the order of one hundredth of a millimeter thick, which may involve a considerable length of time to make parts having a volume of a few cubic decimeters.
[0009] That technique has recently been used in an attempt to make in the same layer-by-layer manner construction elements and small buildings by using robotic devices, either of the gantry type or else robots of the selective compliance articulated robot arm (SCARA) type, or indeed hexapod type robots, known to the person skilled in the art.
[0010] All of those devices are operated automatically from a digitally controlled controller, known to the person skilled in the art in the field of robotics and thus requiring little labor when making the structure.
[0011] Those techniques are well suited to prefabricating elements in a workshop or to making small works, but once dimensions become large, i.e. more than 5 meters (m), or 10 m, the devices become very large, since they need to be very accurate and thus very rigid.
[0012] Patent FR 2 739 887 in the name of the Applicant is known, which discloses a device that uses cables to position a tool in two dimensions on a wall that is immense, and more particularly on the facade of a work that is plane or slightly curved.
[0013] Devices are known that have been in use for more than ten years for moving a camera over a stadium above players or competitors in order to track sporting events closely. The device is constituted by four pylons generally situated at corners of the stadium, with fast winches installed at their top ends and controlled digitally in known manner, said winches being connected to the camera by fine cables, typically made of Kevlar, with the adjustment of the length of each of the cables serving to position the camera appropriately in a plane in order to obtain the looked-for images. By controlling the set of winches in real time, it is possible to make the camera travel over an area covering almost all of the stadium, and this can be done at speeds that can be impressive.
[0014] The positioning of the camera as performed in that way is not very accurate since the cables are under extreme tension to ensure that the camera remains above the athletes. The altitude of said camera is generally not very well controlled, and several accidents have been reported in the media, in particular collisions with athletes. In that application, accuracy is not of very great importance since the intended purpose is to position the camera approximately in order to obtain the hoped-for striking images.
[0015] Patent US 2013/0292039 is known, which describes a device for making 3D structures that is similar to the above-described cameras, the motor drives for the cables and the injection head together with the supply of material all being arranged at the moving head. In that application, the tensions in the cable are considerable, or even unacceptable if it is desired to fabricate elements of large dimensions, since all of the vertical forces are taken up by the cables connected to the stationary pylons.
[0016] Also known are patents WO 2005/097476 and EP 1 872 928, which describe a three-dimensional rectangular gantry for making three-dimensional structures of large dimensions. In that application, the horizontal beams of the three-dimensional fabrication gantry need to be very strong and thus to have a very large second moment of area in order to limit sagging under load in order to ensure that movements are accurate and repeatable. Those devices are described more particularly as being for prefabricating structural elements in a factory. Under such circumstances, the modularity and the considerable weight of the various elements are not suited for direct use on the site where the building is being constructed, since the equipment must be capable of being moved easily from one building site to another.
SUMMARY
[0017] The present disclosure seeks to obtain positioning with extreme accuracy in three dimensions XYZ, and more particularly in the vertical direction Z, which is the most difficult to control when the dimensions of the structure are large, or even immense. The present disclosure makes it possible to omit conventional installations of the scaffolding type or heavy structures of the gantry type, it being understood that such devices need to be extremely rigid in order to guarantee accurate positioning.
[0018] An object of the present disclosure is to provide an industrial device for fabricating structures of large dimensions automatically.
[0019] The present disclosure is a device for depositing pasty material for fabricating a three-dimensional structure of large dimensions layer by layer, the device comprising:
at least three first supports (P 1 , P 2 , P 3 ) at a distance from the ground and not in alignment supporting three respective first cable tensioning devices (M 1 , M 2 , M 3 ); and at least one second support ( 5 b ) kept at a distance from the ground ( 10 ), for example, above the first three supports, for example, suitable for being moved at least over the area between said three first supports; and a material feed pipe ( 2 b ), for example, filled with pasty substance, held suspended above the ground ( 10 ) and suitable for being moved at least over the area between said three first supports; and a deposition head, for example, an extrusion head ( 2 a ) at the end of said feed pipe ( 2 b ) suspended from a second tensioning device ( 4 ), for example, by a suspension cable ( 4 a ), for example, secured to a first carriage ( 3 ) suitable for being moved relative to said second support ( 5 b ); and three cables referred to as “positioning” cables ( 7 , 7 - 1 , 7 - 2 , 7 - 3 ) of respective lengths (L, L 1 , L 2 , L 3 ), each connected at one end to said deposition head, and each connected to a respective one of the three first tensioning devices (M 1 , M 2 , M 3 ) at its other end, the three said positioning cables being suitable for being tensioned with different adjustable lengths by different actuation of the three first tensioning devices (M 1 , M 2 , M 3 ) and of said second tensioning device ( 4 ), and being suitable by means of their adjustable lengths for defining an upside-down pyramid with a triangular top base, the bottom point of said upside-down pyramid defining a deposition point in three-dimensional space that is situated substantially at the deposition head at the bottom end of the feed pipe ( 2 b ), for example, kept substantially vertical, said deposition point being suitable for being moved in the three dimensions XYZ of three-dimensional space between the three pylons by different actuation of at least one of the three said first tensioning devices (M 1 , M 2 , M 3 ), and for example, by moving said first carriage.
[0025] According to the disclosure, at least one of the first supports is a pylon (P), for example, a substantially vertical pylon, for example, anchored in said ground, and supporting a first winch (M).
[0026] It can be understood that the first supports supporting the first winches are not necessarily at the same levels as one another, and that they may be situated high up, being secured to an existing building, or that they may be constituted by pylons.
[0027] In the disclosure, said beam ( 5 b ) constitutes the boom of a tower crane ( 5 ) anchored to the ground ( 10 ), said boom supporting said first carriage and being movable in turning relative to the tower.
[0028] In a variant of the disclosure, the beam ( 20 b - 5 b ) constitutes the substantially horizontal beam of a gantry ( 20 ) that is movable along a horizontal axis YY, that is for example, perpendicular to the axis XX of the beam.
[0029] In a variant of the disclosure, the three first tensioning devices are actuated, and for example, said second tensioning device is actuated, and more for example, said first carriage is moved under digital control by a control station ( 8 ) for moving said deposition point.
[0030] In the disclosure, the suspension cable ( 4 a ) is kept vertical by adjusting the movements of the first carriage ( 3 ) along said boom and/or the movement of said boom in a horizontal plane in translation and/or in rotation, for example, under digital control from a control station ( 8 ).
[0031] In a variant of the disclosure, the suspension cable ( 4 a ) is kept vertical by adjusting the position in the horizontal XY plane of the first carriage ( 3 ) on the basis of information from two inclinometers ( 11 ) secured to said suspension cable ( 4 a ) or to said pipe ( 2 b ), said inclinometers being situated in two vertical reference planes, which are for example, mutually perpendicular.
[0032] The suspension cable ( 4 a ) is thus kept vertical by adjusting the position of the carriage corresponding substantially to the same pair of Cartesian coordinate values xy or of polar coordinate values (ρ) and angle (φ) corresponding to the pair of values xy.
[0033] In another variant of the disclosure, the feed pipe ( 2 b ) is suspended from said first suspension cable ( 4 a ) via a support for guiding the swan-neck type device, and the deposition head comprises a nozzle supported by a support guide ( 6 ) connected to said positioning cables ( 7 ).
[0034] In the disclosure, the first winch ( 4 ) is of controlled tension and supports 40% to 95%, for example, 70% to 85% of the total weight of the portion of the feed pipe ( 2 b ) that is suspended substantially vertically and is filled with pasty substance, plus the weights of the support guide ( 6 ), and of the nozzle ( 2 a ), possibly together with the weights of the swan neck ( 4 b ), of the suspension cable ( 4 a ), and of a pipe portion ( 2 b ) in a festoon configuration.
[0035] It can be understood that the first winch may support only the feed pipe 2 b , the support guide 6 , and the nozzle 2 a , since the swan neck and the suspension cable do not exist in some variants.
[0036] In a variant of the disclosure, at least four pylons (P) are installed, respectively fitted with a plurality of four first winches (M) that are respectively connected to a said deposition head ( 2 a ) by a plurality of cables, three cables of said plurality of cables acting sequentially to perform the role of tensioned positioning cables, the other cables performing the role of secondary cables that are not tensioned.
[0037] In a variant of the disclosure, the feed pipe ( 2 b 1 ) passes around the support guide ( 6 - 6 a ), the support guide presenting an axial orifice of small diameter ( 6 a 1 ) onto which the set of positioning cables ( 7 ) converge.
[0038] The disclosure provides a method of fabricating three-dimensional structures from pasty substances deposited using a device of the disclosure, the method being characterized in that a said structure is fabricated by depositing a said pasty material in successive thin layers, for example, by extrusion, for example, in superposed horizontal layers by moving said deposition head, the three said positioning cables being tensioned with lengths (L 1 , L 2 , L 3 ) that are adjusted by different actuation of the three first tensioning devices (M 1 , M 2 , M 3 ) so as to define an upside-down pyramid of triangular top base, for example, substantially horizontal, the bottom point of said upside-down pyramid defining a point in three-dimensional space situated substantially at the deposition head, at the bottom end of the material feed pipe, said deposition point being moved in the three dimensions XYZ of the three-dimensional space between the three pylons by different actuation of at least one of the three first tensioning devices (M 1 , M 2 , M 3 ) and for example, by moving said first carriage.
[0039] The disclosure is intended more particularly for fabricating structures having a smallest dimension in a horizontal plane of at least 5 m, for example, at least 10 m, for making a masonry construction.
[0040] In the disclosure, said pasty material is a mixture of inert substances such as clay, sand, straw, reinforcing fibers made of plastics material or of steel, and for example, including a hydraulic binder, such as a cement, so as to form a lightweight mortar that is strong and for example, insulating. In a variant of the disclosure, said pasty material comprises a hot-melt material or a thermosetting material comprising one or more components.
BRIEF DESCRIPTION OF THE FIGURES
[0041] Other characteristics and advantages of the present disclosure appear in the light of the following detailed description of embodiments given with reference to FIGS. 1 to 5 :
[0042] FIG. 1 is a side view of a building being constructed with a device of the disclosure comprising a tower crane, three winches installed respectively at the tops of three pylons, and three respective cables connected to a mortar injection head supported by the carriage that is movable along the crane boom, a flexible hose delivering the mortar;
[0043] FIG. 2A is a side view of the device of the disclosure while it is being prepared, showing the means for stabilizing the pylons, guylines and tie rods connecting together the tops of said pylons, wherein a motor-driven winch secured to the movable carriage supports the injection head together with the flexible hose feeding mortar;
[0044] FIG. 2B is a variant of FIG. 2A in which the movable carriage supports a simple set of pulleys, the cable passing around said pulleys being connected to a counterweight;
[0045] FIG. 3 is a plan view seen from above relating to FIG. 1 and showing the walls and the internal partitions of a building under construction, three cables 7 - 1 , 7 - 2 , and 7 - 3 being active, i.e. being positioning cables, while the cables 7 - 4 , 7 - 5 , 7 - 6 are secondary cables, and thus inactive for positioning purposes at the instant in question;
[0046] FIG. 4 is a side view of a device of the disclosure in which the motors move along the pylons so that the positioning cables remain substantially in a horizontal plane;
[0047] FIG. 5 is a side view of a device of the disclosure in which the tower crane is replaced by a gantry traveling on rails;
[0048] FIG. 6 is a side view of a device of the disclosure in which the winches are installed on existing buildings, the feed pipe being suspended from a stationary point;
[0049] FIG. 7 is a side view of a support guide having lugs for attaching positioning cables; and
[0050] FIGS. 8A to 8D show a variant of the means for attaching the positioning cables to the support guide 6 .
DETAILED DESCRIPTION
[0051] FIG. 1 is a side view of a building 1 under construction using a device of the disclosure. The device of the disclosure comprises:
a tower crane 5 comprising a mast post 5 a , a boom 5 b , a first movable carriage 3 on the underside of said boom 5 b and suitable for moving in translation along the axial direction of said substantially horizontal boom; and three pylons P 1 -P 2 -P 3 positioned in a triangle close to the tower so that turning the boom 5 b enables the movable carriage 3 to be placed above at least the area defined by said pylons; and a nozzle 2 a suspended from the first carriage 3 by means of a cable 4 a connected to a winch 4 secured to said first carriage 3 ; and a mortar feed pipe 2 b fitted at its bottom end with a nozzle 2 a for depositing mortar 2 , said pipe being connected to a swan-neck type support 4 b serving to support the mortar feed pipe 2 b locally in a substantially vertical position, with the pipe thereafter being suspended in festoons to a plurality of second carriages 2 d that are movable in translation on the underside along said boom 5 b towards the pylon 5 a of the tower crane, and then descending, for example, inside said pylon and exiting at the base of the pylon where it is connected to said mortar pump 2 c.
[0056] The nozzle 2 a is secured to a guide 6 connected to three cables 7 - 1 , 7 - 2 , and 7 - 3 , which cables are connected at their other ends respectively to three winches M 1 , M 2 , and M 3 that are situated, for example, at the same height, respectively at the tops of three pylons P 1 , P 2 , and P 3 anchored in the ground 10 respectively at P 1 a , P 2 a , and P 3 a . Actuation of each of the winches M 1 -M 2 -M 3 is digitally controlled from a control station 8 shown in FIG. 2A , with electrical power supply for the winches (not shown) running along each of the pylons, the instructions for actuating the winches and for moving the nozzles 2 a being transmitted either via a shielded cable or optical fiber, or for example, by radio, as represented in FIG. 2A by antennas M 1 a , M 2 a , & M 3 a for controlling the respective winches M 1 , M 2 , and M 3 , with positioning orders being transmitted by the antenna 8 a of the control station 8 . Thus, the control station 8 serves to adjust the length L of each of the cables 7 - 1 , 7 - 2 , and 7 - 3 , i.e. the lengths L 1 -L 2 -L 3 , between the support guide 6 and respective ones of the winches M 1 -M 2 -M 3 . The point of coincidence where said three cables meet is thus situated on the longitudinal axis of the support guide 6 and defines unambiguously an accurate point in three-dimensional space of coordinates xyz, said point of coincidence of the three cables being situated below the plane of said three winches. It is thus possible to move the guide 6 , and thus the extrusion head or nozzle 2 a , in all directions, i.e. in all three directions X, Y, and Z, by adjusting the respective lengths L 1 -L 2 -L 3 of each of the three cables 7 - 1 , 7 - 2 , and 7 - 3 from the control station 8 .
[0057] FIG. 3 shows a plan view of the top of the building under construction. The extrusion head, which is not visible since it is situated under the boom 5 b of the crane 5 and under the first carriage 3 , is positioned unambiguously in three dimensions by the set of three cables 7 - 1 , 7 - 2 , and 7 - 3 . In this configuration, the extrusion head or nozzle 2 a can be moved only inside the triangle formed by the three pylons P 1 -P 2 -P 3 . That is why a plurality of pylons, winches, and additional cables are added, namely three pylons P 4 -P 5 -P 6 that are arranged in such a manner that the polygon defined by the set of pylons contains all of the building under construction. Only three of all these cables are used for accurately positioning the nozzle 2 a , depending on the zone in which the structure is being constructed.
[0058] For this purpose, it is appropriate to consider two types of function, and thus of status, for each of said cables:
firstly there are cables referred to as “positioning” cables: such as the cables 7 - 1 , 7 - 2 , & 7 - 3 in FIG. 3 , which act to determine unambiguously the three-dimensional position of the extrusion head 2 a over a limited area inside a prism of vertical axis ZZ and of triangular section formed substantially by the three pylons P 1 -P 2 -P 3 ; and secondly cables referred to as “secondary” cables since they do not participate in the three-dimensional positioning, such as the cables 7 - 4 , 7 - 5 , and 7 - 6 in FIG. 3 , said cables then not being tensioned, and thus remaining slightly slack; during the process of positioning the nozzle 2 a over the entire area of the building, each of the cables can change status, it being understood that at any point in the three-dimensional construction space the extrusion head or nozzle 2 a is positioned by three positioning cables selected sequentially from the set of cables, the other cables then temporarily having the status of secondary cables.
[0062] The term “secondary cable” is used herein to mean a cable in the non-tensioned state, i.e. a slack cable, so that the length L given to said cable by the control station 8 is slightly longer than the theoretical length L t that would be calculated for said cable to be a cable of the positioning cable type. For example, the slack of the cable may be adjusted to a value in the range 2 centimeters (cm) to 10 cm, i.e. the actual length of said secondary cable is then adjusted so that the value L=L 1 +2 cm to 10 cm. It is then not under tension and therefore does not participate in positioning during this sequence. When that same cable changes status, i.e. when it returns to being a positioning cable, its length is adjusted to the value L=L t . The cable will then be under tension and it will thus become one of the three cables participating in positioning during the new sequence.
[0063] It may be observed in FIG. 3 that the number of pylons could have been limited to four, since the polygon P 1 -P 4 -P 5 -P 6 contains the entire building under construction. It is possible to reach any point of the construction with this limited number of pylons. Nevertheless, in certain circumstances, for reasons of accuracy in positioning, it is advantageous to add additional pylons in order to facilitate construction, e.g. with buildings of great length, i.e. buildings that are two, three, or four times longer than they are wide.
[0064] In FIG. 2B , the first carriage 3 is fitted with a set of idle pulleys 4 c over which the cable 4 a passes, there being a counterweight 4 d fastened to the bottom left-hand end of that cable so as to compensate in part for the weight of the swan neck 4 b , of the mortar feed pipe 2 b , and of the guide 6 , e.g. 70% to 85% of the total weight, which total weight varies depending on the altitude Z of the working plane and on the XY position. The remaining percentage of the total weight is taken up by the tension in said three positioning cables, with this tension providing the accuracy for said positioning.
[0065] The tensioning may advantageously be monitored by a force sensor 4 e located between the bottom end of the suspension cable 4 a and the swan neck 4 b , as shown in FIG. 5 , the measured value of the force then making it possible to adjust the torque of the winch 4 , and thus the tension in said suspension cable 4 a.
[0066] The verticality of the cable is advantageously adjusted by the control station 8 . For this purpose, since the xyz position of the extrusion head 2 a is known, it is advantageous to adjust the values of the parameters of the tower crane, namely the polar coordinates ρ and φ so that they correspond very exactly to the xy coordinates of said extrusion head. For this purpose, the turning of the crane (angle φ) and the positioning ρ of the first carriage along the boom 5 b are controlled in known manner by said control station 8 .
[0067] In a variant of the disclosure, the verticality of the cable 4 a is adjusted by a double inclinometer 11 shown in FIG. 2A . It is constituted by a tube 11 a surrounding the cable 4 a with small clearance, so as to allow said cable 4 a to perform vertical movements. Said tube 11 a is suspended from the first carriage 3 and is held in the vertical plane of the crane boom 5 b without being free to turn about its vertical axis ZZ. A first inclinometer α measures the angle of the cable 4 a relative to the vertical in a vertical plane containing the crane boom 5 b , i.e. in the plane of FIG. 2A . A second inclinometer β measures the angle of the cable 4 a relative to the vertical in the plane perpendicular to the vertical plane containing the crane boom 5 b , i.e. in the vertical plane perpendicular to the plane of FIG. 2A . With these two angles being measured, action is taken on the polar coordinate ρ of the first carriage 3 in order to bring the value of the angle α to zero, i.e. said first carriage is moved forwards or backwards. In the same manner, action is taken on the polar coordinate φ of the crane boom in order to bring the value of the angle β to zero, i.e. the crane boom is turned either clockwise or counterclockwise. By continuously adjusting the polar coordinates of the first carriage 3 as a function of the values α and β, the cable 4 a is to be found continuously in the desired substantially vertical position.
[0068] FIG. 4 shows a feed pipe 2 b connecting the deposition head 2 a to a motor-driven pulley 4 e secured to the carriage 3 , and leaving said pulley 4 e in order to form suspended festoons under the beam 5 b . The feed pipe 2 b is kept under tension by said motor-driven pulley and the inclinometer 11 is then installed directly on said feed pipe and slides with small clearance thereover.
[0069] FIG. 4 is a side view showing a variant of the disclosure in which the three dimensioning cables are situated substantially in the same horizontal plane. The winches M 1 -M 2 -M 3 are then vertically movable along respective racks P b secured to each of the pylons P. Since the device works plane by plane, when there is a change of altitude Z, all of the winches are moved upwards so that all of the cables, i.e. the positioning cables and the secondary cables, remain substantially in the same plane. Under such circumstances, it is appropriate to consider that two of the three dimensioning cables are actually used for positioning purposes, while the third cable under tension serves to ensure that the positioning is in the plane AA; the other cables then have the status of secondary cables and they are kept slack, i.e. without significant tension.
[0070] Thus, in this variant described with reference to FIG. 4 , the configuration is planar and similar to using cables for positioning on a facade in two dimensions, with the entire weight of the swan neck 4 b , of the mortar feed pipe 2 b , and of the guide 6 being supported by the winch 4 secured to the first carriage 3 . Adjusting the length of the cable 4 a then makes it possible to keep the end of the extrusion head or nozzle 2 a in the mortar deposition plane BB.
[0071] This variant of the disclosure may use multiple pylon-rack-winch assemblies that are vertically movable and thus more complicated to construct and to control, and it therefore does not constitute a variant of the disclosure.
[0072] In FIG. 5 , the tower crane is replaced by a gantry 20 constituted by two substantially vertical pillars 20 a interconnected by a horizontal beam 20 b supporting the first carriage 3 together with the second carriages 2 d supporting the mortar feed pipe 2 b in the festoon configuration. The pillars 20 a of the gantry move along the axis YY perpendicular to the XZ plane of the figure on motor-driven wheels 20 d running on rails 20 c . By adjusting the y position of the gantry along the YY axis in controlled manner, and also the ρ=x position of the first carriage 3 along the beam 20 b , the cable 4 a is maintained in a position that is substantially vertical, in the same manner as described above with reference to FIGS. 1 to 4 . Nevertheless, the layer-by-layer movement of the extrusion head or nozzle 2 a over the entire area of the building under construction may involve continuous movements of the entire gantry. Such a gantry is of considerable size, both in height and in width, and it needs to present great rigidly so as to be capable of being moved without danger, and above all so as to be capable of withstanding strong winds in the event of a storm, even if not in operation. It is thus of considerable weight, which weight needs to be subjected to incessant movements using drive motors of considerable power.
[0073] Advantageously, and as shown in FIGS. 2B and 3 , the rigidity of the set of pylons is considerably improved by installing guylines 12 anchored in the ground of 12 a at one end and anchored at the other end 12 b on a respective pylon P, for example, in the top third of said pylon P. Likewise, the pylons P are secured to one another, for example, at the tops of the pylons, by tie rods 13 installed between each adjacent pair of pylons in the polygon formed by the set of pylons. Each tensioner 13 is secured to a respective pylon at each of its ends 13 a . In these figures, the means for tensioning the guylines 12 and the tie rods 13 are not shown. In FIG. 3 , only one guyline is shown for the pylon P 3 only.
[0074] To ensure the best positioning effect, i.e. the best centering effect of the positioning cables, as shown in FIG. 2B , the angle γ of each positioning cable 7 relative to the horizontal must lie in the range 10° to 80°, and for example, in the range 25° to 70°. Specifically, for angles of about 10°, the weight of the elements supported by the cable 4 a when resolved as forces in each of the three positioning cables, leads to high levels of force in each of the cables, which goes against the looked-for purpose, i.e. great accuracy and limited forces. Likewise, for angles of the order of 80°, the forces resolved in the three positioning cables give rise to forces that are small or even very small, thereby considerably reducing the centering effect, and thus the accuracy of the positioning.
[0075] In FIGS. 2A, 2B, and 4 , use is advantageously made of the mast post 5 a of the crane 5 to perform the function of the pylon P 3 .
[0076] By way of example, in order to construct a building that is 15 m high, 15 m long, and 12 m wide, a tower crane is installed, for example, a self-erecting crane of Manitowoc-Potain (France) model IGO 21 type possessing an under-hook height of 19 m and a boom length of 26 m, or a larger model such as the IGO 50 model possessing an under-hook height of 23 m and a boom with length of 40 m.
[0077] The crane has its hook-support carriage modified by being fitted with a linear coder so as to enable the distance ρ to be adjusted automatically, and also a rotary coder on the substantially vertical axis of the mast post of said crane in order to adjust the angle φ of said mast post relative to north, as shown in FIG. 3 . Six pylons P 1 -P 6 that are 18 m high are arranged as shown in FIG. 3 and fitted with digitally controlled winches, each situated at the top of a pylon. The positioning cables connecting the extrusion head guide to each of said winches have a diameter of 4 mm, and for example, of 3 mm or even 2 mm. The guide 6 and the extrusion head or nozzle 2 a weigh about 5 kilograms (kg) to 10 kg. The suspension cable 4 a is a cable having a diameter of 6 mm, and it is connected to the first carriage 3 via the swan neck 4 b supporting the mortar feed pipe 2 b , which feed pipe is constituted by a flexible hose having an inside diameter of 30 mm and weighing substantially 2.5 kilograms per linear meter (kg/m) when full of mortar.
[0078] The device then deposits a layer having a thickness in the range 1 cm to 4 cm along the selected path at a continuous speed of 0.1 meters per second (m/s) to 0.25 m/s.
[0079] The positioning cables and the secondary cables 7 are of small diameter, since the forces required for holding the extrusion head or nozzle 2 a in an extremely accurate position are very low throughout the entire duration of the construction process. Likewise, the cable 4 a supporting part or all of the vertical load of the swan neck, a portion of the pipe, the guide 6 , and the extrusion head 2 a is of small diameter, since the forces in question are very small.
[0080] The very small forces, a few kilograms, or possibly a few tens of kilograms, in the positioning cables 7 apply very limited forces to the tops of the pylons P, so they bend very little, thereby guaranteeing great accuracy in the positioning of the extrusion head 2 a in three dimensions X-Y-Z. Furthermore, since the positioning cables are of very small diameter, they are practically insensitive to wind, and since their linear weight is also very small, they take uplines that are almost straight between the winches M and the extrusion head 6 , thereby guaranteeing extreme overall rigidity and thus extreme accuracy in the positioning of the extrusion head 2 a , which can thus be moved in fully controlled manner so as to make, layer by layer, all of the walls and partitions of the building, as can be seen in FIG. 3 .
[0081] This disclosure is described in the context of constructing buildings of large dimensions, however it is very advantageous for making all types of construction out of pasty or plastics materials presenting sufficient cohesion after a few seconds or a few minutes to make it possible to proceed layer by layer, for example, in layers that are substantially horizontal, so that the layer that has been made is sufficiently firm when the following layer is applied. This avoids localized or complete collapses of the structure, and the structure can be made automatically and continuously with a minimum of labor, thus making it possible to reduce the cost of construction considerably.
[0082] In a variant of the disclosure shown in FIG. 6 , the structure to be constructed lies between two buildings 30 a and 30 b , and use is advantageously made of the highest and most distant points of said existing buildings for installing supports for the winches M. Such anchor points present a great advantage in terms of rigidity and simplicity, compared with the above-described pylons P.
[0083] In another variant of the disclosure, also shown in FIG. 6 , the suspension cable 4 a and its tensioning system 4 are suspended from a stationary point, for example, situated at a very great altitude vertically over the geometrical center in the XY plane of the structure under construction, e.g. at an altitude that is greater than two to five times the greatest dimension of said structure in the horizontal plane, plus the height of said structure. Thus, during movements of the deposition head 2 a , the cable 4 a is no longer vertical, but describes a cone of horizontal section perpendicular to its vertical axis that corresponds to the outline of the structure under construction, with the angle at the apex of said cone varying, depending on the position of the deposition head 2 a , in the range δ=0° to δ=10° to 15°, or even more. In this configuration, the point at which the pasty material is deposited is no longer very exactly vertically below the bottom end of the upside-down pyramid, but is slightly offset. This offset does not significantly disturb the construction process since the offset is only a few millimeters or possibly one or two centimeters, providing use is made of a stationary point that is situated at very great height, as mentioned above. Furthermore, said offset is the same layer after layer and can be corrected by modifying the path to be followed by said deposition head 2 a simply within the control device 8 .
[0084] For structures of medium or small dimensions, the tower crane may be replaced merely by a builders' hoist comprising a pylon 5 a with a bearing at its top secured to a beam 5 b that is substantially horizontal. A carriage 3 that is free to travel along said beam supports a hoist 4 supporting the cable 4 a . The beam 5 b is free to turn at the top of the pylon: the movements of the deposition head 2 a entrain the cable 4 a , which is no longer vertical, and makes an angle δ with said vertical. The horizontal component created by this angle δ in the hoist acts both in the carriage, which then moves naturally along said beam 5 a , and on the beam of angle φ relative to the north that varies automatically so that said angle returns substantially to zero, i.e. so that the cable is substantially vertical. The larger the angle δ, the greater the return effect. The residual angle, i.e. the angle that does not give rise to any movement of the carriage 3 , nor of the beam 5 a , is of the order of 3° to 5° and does not significantly reduce the accuracy of positioning and disturbs the construction process very little.
[0085] The winches M are described as being installed at the tops of the pylons P or on the structures of existing buildings, however they could also be installed in any other position, e.g. on the ground; under such circumstances, the cables 7 connecting the guide 6 to the winches need to be deflected by idle pulleys installed at the tops of the pylons or at the tops of existing buildings.
[0086] As shown in FIG. 1 , the suspension cable 4 a , the feed pipe 2 b 1 , the support guide 6 , and the nozzle 2 a are situated on the same substantially vertical axis ZZ under the effect of the weight of the various elements. As a result, the attachment points of the cables need to be situated on the outside wall of the support guide 6 . In FIG. 7 , there can be seen a said support guide 6 connected to the positioning cables 7 - 1 and 7 - 2 via lugs 6 b 1 and 6 b 2 . Because the diameter of said support guide is large, e.g. in the range 60 mm to 100 mm, the center lines of said tension cables intersect at a point that varies relative to the axis ZZ of said support guide during movements of the head. This variation in the horizontal plane constitutes a positioning error, but is always less than the radius of said support guide; furthermore, it is additional to variation in the height of said point of intersection relative to the actual positioning of the nozzle. To mitigate this drawback, which can lead to positioning errors of 25 mm to 60 mm, or even more, it is advantageous to use the device described with reference to FIGS. 8A to 8D . As shown in FIG. 8D , the cables 7 - 1 and 7 - 2 , and other positioning cables, if any, converge on the axis of the support guide 6 a , penetrate into a hole of small diameter 6 a 1 passing axially through said support guide, and then through a pierced plate 6 a 2 where said cables are held in position by a device that is not shown. The top face 6 a 3 is advantageously funnel-shaped with a radius of curvature such that said positioning cables never come into contact with a sharp edge. Since the diameter D is small, e.g. 8 mm to 10 mm, or even less, errors due to variations in the point of intersection are reduced drastically compared with the situation shown in FIG. 7 , where the reference diameter lies in the range 60 mm to 100 mm. These variations are specifically of the order of a few millimeters, and can therefore be considered as being negligible.
[0087] To ensure that the suspension cable 4 a , the feed pipe 2 b 1 , and the nozzle 2 a remain together on a common vertical positioning axis ZZ under the effect of the weight of the various elements, the feed pipe 2 b 1 is advantageously deflected at the support guide 6 . This deflection is shown in FIG. 6A and is for example, undertaken in a vertical plane by means of a plurality of bends 2 b 2 - 2 b 3 - 2 b 4 - 2 b 5 associated with straight portions of pipe. FIG. 8B is a section in plane BB of FIG. 8A and shows the limited interference between the positioning cables 7 and the deflection of the pipe 2 b 1 in the zone of the support guide 6 . A rotary joint 2 b 5 shown in FIG. 8A is advantageously installed so that the avoidance device constituted by the bends 2 b 2 - 2 b 5 can turn freely whenever it interferes with any one of two adjacent cables, namely 7 - 2 or 7 - 3 .
[0088] This disclosure is described for making structures using pasty substances, and more particularly mortars based on cements or on lime, however it can advantageously be used for making metal structures by localized melting of a metal wire, such as an iron or a bronze wire, using localized and powerful heater means, such as a plasma torch, titanium inert gas (TIG) welding, or a laser. For this purpose, the heater means take the place of the nozzle 2 a , and the electrical power or laser beam together with the metal being transferred by means of an umbilical taking the place of a pipe 2 b for feeding pasty substances. As they advance, the localized heater means can thus melt the previously deposited layer N and the additional metal so as to form the layer N+1, which solidifies quickly while waiting for the layer N+2 to be made during the next pass. Such a device is particularly suitable for making works of art, such as for example statues, or any other constructional or decorative element of large dimensions.
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A device for fabricating structures of large dimensions, layer by layer.
The invention relates to a device making use of positioning an extrusion head in three dimensions by means of cables in order to deposit a pasty material continuously in thin layers, e.g. a mortar comprising either a hydraulic binder or thermoplastic compounds or thermosetting compounds or curable compounds.
The invention is for making industrial elements of very large dimensions, and more particularly for making buildings.
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BACKGROUND OF THE INVENTION
The present invention relates to a portable barrier system, and more particularly, a barrier system for use with outdoor activities such as athletic events which require a predefined field layout or for use with entertainment events having an outdoor stage where a discreet distance between spectators and the stage is desired to be maintained.
In the prior art, portable athletic event barriers have generally been relatively expensive and difficult to erect and disassemble before and after the athletic events. Generally such prior art barriers are of a relatively low height which a spectator might easily step across. The basic function of the prior art devices was merely to outline the area of play and the area beyond which it was desired to maintain control of spectators. Additionally, the prior art also describes various embodiments of highway and construction barriers one of which is the New Jersey style barrier.
The New Jersey style barrier has a relatively wide base having side walls which extend upwardly from the pavement a short distance; thereafter the walls of the barrier extend upwardly and inwardly for a distance; and finally, the upper portion of the barrier extends upwardly in a vertical plane. In the past, the barriers were made of poured concrete. The disadvantages of this was occasioned by the high weight which occasioned special equipment for handling the barriers. More recently, however, the highway barriers have been made from a semi-rigid plastic material having an opening to permit liquid to be introduced into the interior to give weight or ballast and an opening near the bottom to permit the liquid to be drained in order that the barriers might be easily moved for relocation.
One disadvantage of these later barriers was the intricate means of interlocking one barrier end onto another such that problems were occasioned by production molding of the barriers. Additionally, one type of barrier required lifting and sliding the ends into interlocking relation while other barrier types required use of a metal pin or post to join them. Further, the construction type barrier is generally not of a configuration and height to be conveniently used in spectator type situations.
SUMMARY OF THE INVENTION
It is an object of this invention to provide a crowd control barrier which is relatively light in weight for ease of transportation and which provides sufficient height to control access of a crowd to the playing or entertainment area while permitting the spectators to easily view the event. It is also an object of the present invention to provide a crowd control barrier which may be easily positioned in the desired configuration and rigidly locked into place.
The above objects are provided by the crowd control barrier of the present invention which comprises an elongated hollow container having a base portion, having a first vertical side wall extending upwardly perpendicular to the base portion a predetermined distance, a second vertical side wall extending upward a lesser distance, and a third vertical side wall thereafter extending upward in an inwardly sloping direction and a top portion joining the upper extremities of the first side wall and the third or sloping side wall. Additionally, end walls are provided to enclose the unit and a means to allow it to be filled with a liquid and a means to discharge the liquid are formed into the unit. Further, two cylindrical recesses are formed in the top portion, perpendicular thereto and extending into the interior of the unit to permit a net or the like to be placed above the unit for added safety or security.
A pair of recesses are formed into the base unit to permit use of a forklift in moving and arranging the unit. Further, a pair of spaced-apart slots are formed in each end wall such that they may be placed over a section of a standard dimension wooden board such as a 2"×4" stud having a predetermined length. When placed into position over the 2×4 studs and abutted end to end with another unit, filling the unit with a liquid causes the semi-rigid plastic material to deform slightly clamping the 2×4 studs into place and providing a locking means for the system.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the crowd control barrier of the present invention.
FIG. 2A is an end view of the crowd control barrier of the present invention.
FIG. 2B is a top view of the crowd control barrier of the present invention.
FIG. 2C is a bottom view of the crowd control barrier of the present invention.
FIG. 3 is a bottom view of an alternate embodiment of the crowd control barrier of the present invention.
FIG. 4A is an end view the crowd control barrier of the present invention empty of liquid.
FIG. 4B is an end view of the crowd control barrier with liquid added showing the deformation of the semi-rigid plastic material.
FIG. 4C is a cut out portion of the end view of FIG. 4B showing the deformation of the semi-rigid plastic clamping the 2×4 utilizing and locking the units together.
FIG. 5A and FIG. 5B are top and bottom views of a curved embodiment of the crowd control barrier of the present invention.
FIGS. 6A, 6B, and 6C are indicative of various emplacements which may be used for various purposes.
FIG. 7 shows a perspective view of the portion of one of the units of the crowd control barrier of the present invention in a reversed configuration for utilization in a winter sport.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIG. 1, the barrier system 10 of the present invention includes a number of straight control barrier units 12 and a curved control barrier unit 40 joined together in a manner hereinafter set forth. Each barrier unit 12, 40 of the invention comprises an elongated hollow container having a base portion 19 with side walls 20, 22, end walls 16, 18 and a bottom 14. Side walls 20, 22 rise substantially vertical with side wall 20 extending upward a distance greater than the vertical rise of side wall 22. An intermediate wall portion 24 extends inwardly from the upper edge of side wall 22 toward the upper edge of side wall 20. A top portion 26 is joined to end walls 16, 18 and side wall 20 and intermediate wall 24 to enclose the barrier units 12, 40. One embodiment of the present invention envisions a base footprint of 33/4'×51/2'×4' in height.
Cylindrical, recessed fill plugs 25,31 are formed in top 26 to permit, when either plug is removed, a liquid to be introduced into the interior chamber of barrier units 12, 40. Additionally, the fill plugs 25,31 are dimensioned to receive a pair of cylindrical uprights (not shown) which may be used to support a net or the like therebetween for added safety or security. Likewise, a recessed drain plug 27 is formed into side wall 22 to permit draining the liquid from the interior chamber of barrier units 12, 40 when it is desired to relocate or reposition the barrier 10.
Still referring to FIGS. 2A through 2C, a plurality of notches or slots 30 are formed at the juncture of bottom 14 and end walls 16, 18. An equal number of slots 30 are formed in each side wall 16, 18 and extend a predetermined distance from side wall 16, 18 toward the opposing side wall 18, 16 respectively. The slots are further positioned so that when an end 16 is abutted to an end 18 the slots 30 in each end 16, 18 are in alignment. Each slot 30 is dimensioned to receive in relatively snug fit, a standard 2"×4" wood stud or board 32 dimensioned such that when an end wall 18 of one unit 12 or 40 is abutted against an end wall 16 of a second unit 12 or 40, the 2×4 stud 32 positioned in slot 30 will be in snug contact with the surfaces of slot 30.
Still referring to FIG. 2, a second set of slots 28 are formed at the juncture of bottom 14 and sidewall 22 and extend from sidewall 22 inwardly a predetermined distance toward side 20. The slots are dimensioned and spaced apart in order to receive the tines of a standard fork lift for ease in moving and transporting the barriers. Referring also to FIG. 3, a second adaptation of the fork lift slots 29 are shown extending between side 20 and side 22.
The actual embodiment will be dependent upon the type of activity for which the units 12, 40 are utilized. If the units 12,40 are utilized to delimit the playing field for a game such as hockey or the like which has a relatively small game piece which may inadvertently be knocked into one of the fork lift slots 28, the adaptation depicted in FIG. 2 showing the slots 28 extending from side 22 almost but not completely to side 20 is advantageous in that it presents a solid wall 20 to the playing area. Where, however, the playing piece used is large such as in the case of soccer, or system 10 is used as a barrier for crowd control at an enterprise where no game pieces would be utilized, the embodiment shown in FIG. 3 wherein fork lift slots 29 extend completely transversely through the body of the barriers of 12, 40 would simplify production of the units.
Barriers 12, 40 are made of a resiliently deformable plastic material selected from materials having strong, semi-rigid and energy absorbing properties. The materials are selected from a polymeric group which will deform under internal pressure but will not fail in a brittle manner. In addition, the material is selected to provide a smooth exterior surface on units 12, 40 so as to reduce abrasions from collisions of players or crowds pushing against the barrier 10.
When the term "semi-rigid" is used, it means that the units 12, 40 are made from a material that is capable of allowing a slight flexing when water is introduced into the interior chamber of the units 12, 40. This is in opposition to a rigid material which would hold its shape regardless of the interior loading of the water. As will be hereinafter explained, the flexure under load becomes important to the locking mechanism by which the units 12, 40 are held in place when positioned for use.
In practice, the units 12, 40 while empty of any liquid are relatively light in weight and may be easily transported to the site where they are to be used. The units 12, 40 may then be placed or otherwise positioned in the desired layout at the location where the control barrier 10 is needed. As the units 12, 40 are being positioned, 2×4 studs 32 are placed such that when an end 18 is positioned against and end 16, slots 30 in the abutting units completely cover studs 32.
Once positioned, liquid is introduced into the hollow interiors of units 12, 40. Referring now to FIGS. 4A, 4B and 4C, FIG. 4A shows a unit prior to introduction of liquid into the hollow interior. In this configuration, the control barrier units 12, 40 may be easily moved and repositioned until the desired configuration is obtained. Referring to FIG. 4B, as liquid 42 is introduced into the interior chamber of the barriers 12, 40, the weight of the liquid 42 causes a slight flexure in the vertical walls 20, 22 and 24 of barrier 12, 40. Of utmost importance, however, is the flexure occasioned on slots 30. As the pressure increases, the slot 30 tends to bow out and clamp firmly onto studs 32. Liquid 42 not only adds weight to barriers 12, 40 helping to hold them in place, but also clamps the barriers to the studs 32 so that the normal force of a crowd pushing against the barrier 10 or of a player running into the barrier 10 would not be sufficient to dislodge the units 12, 40 of barrier 10 from their positions.
Referring now to FIG. 5, unit 40 is shown having a curved configuration which permits installation of a control barrier 10 in a smoothly flowing curved or circular arrangement. Except for having predetermined curved walls 20', 22' and 24' along with bottom 14' and top 26', formed to join with side walls 20', 22' and 24'. End walls 16 and 18 are identical to end walls 16 and 18 of unit 12. Thus, the construction of unit 40 is identical to that described for unit 12 as had been above indicated.
Referring now to FIGS. 6A, B and C, various configurations of the control barrier system 10 are indicated showing the flexibility by which the system can be readily configured. FIG. 6A depicts use of the barrier 10 to provide a playing field layout while FIGS. 6B and 6C depict use of the barrier 10 for crowd control during an event might be presented on a stage.
in addition, referring now to FIG. 7, the barrier system 10 may be utilized in constructing an ice rink or, in view of modern times, a half-pipe configuration for use with snowboards and the like, whereby snow or an ice surface 60 is placed against the sloping surface of units 12, 40 to provide a relatively slick surface to the users.
Still referring to FIG. 7, an inset 60 is shown formed in side 20 of the unit 12. It is envisioned that advertising material may be placed in the inset and covered with a clear cover material (not shown) such as plastic or the like.
Although particular embodiments of the invention have been described herein, it will be understood that the invention is not limited to the embodiments disclosed and that variations can be made therein without departing from the essential features of the invention and the preferred embodiments are not intended to limit the spirit or scope of the invention as set forth in the appending claims.
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A portable crowd control barrier for use in sporting or entertainment events having lightweight body members formed of a resiliently deformable material and each defining an interior chamber and having slots formed in endwalls thereof to receive wooden studs such that the introduction of liquid into the interior chambers deforms the body members, clamping the walls of the slots against the studs and locking the system in place.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] The application is a Divisional of co-pending U.S. patent application Ser. No. 10/231,321, filed Aug. 30, 2002.
FIELD
[0002] The embodiments disclosed herein relate generally to semiconductor processing, and more particularly to fabrication of electrically conductive interconnects.
BACKGROUND
[0003] As the size of semiconductor devices continues to decrease, the stresses which such devices experience increases. For example, the electric current densities experienced by semiconductor devices can be great, particularly in areas in which current flows from one metal interconnect layer to another metal interconnect layer by a small connection referred to as a via.
[0004] This increased current density in a localized area such as a via can result in a phenomenon known as electromigration. Electromigration is generally the movement of atoms of a metal interconnect in the direction of current flow. This phenomenon is pronounced in areas with high current density (e.g., such as a via between interconnects).
[0005] Thus, in some respects the via acts as a bottleneck for current flow in the semiconductor device. Over time, the atoms which move away from the via due to electromigration will reduce the path through which current can flow near the via, and eventually, enough atoms will move away from the via to cause an open circuit, in which no current will flow from one metal interconnect layer to the next. Thus, electromigration is a serious problem which must be considered when reducing the size of semiconductor devices.
[0006] In order to address the problem of electromigration, one method used to construct semiconductor devices includes doping the entire metal interconnect layer with metallic dopants in order to prevent movement of the atoms of the metal interconnect layer in the direction of current flow. However, blanket doping of the metal interconnect layer results in an increased resistivity of the interconnect layer, which degrades performance of the semiconductor device. In some cases, blanket doping can increase the resistance of the device up to 20%, which is unacceptable. Thus, other ways to address electromigration are desired.
DESCRIPTION OF THE DRAWINGS
[0007] Various embodiments are illustrated by way of example and not by way of limitation in the figures of the accompanying drawings in which like references indicate similar elements. It should be noted that references to “an,” “one,” or “various” embodiments in this disclosure are not necessarily to the same embodiment, and such references mean at least one.
[0008] FIG. 1 is a flow chart of one method according to an embodiment.
[0009] FIG. 2 illustrates forming an opening in a dielectric layer to expose a portion of an electrically conductive layer below the dielectric layer.
[0010] FIG. 3 shows implantation of a dopant into the electrically conductive layer through the opening formed in FIG. 2 .
[0011] FIG. 4 shows a doped region which results from annealing the electrically conductive layer after the dopant from FIG. 3 has been implanted.
[0012] FIG. 5 shows filling the opening in the dielectric layer with electrically conductive material to complete the structure of FIG. 4 .
[0013] FIG. 6 shows a second embodiment in which an opening is formed in a dielectric layer to expose a portion of an electrically conductive layer.
[0014] FIG. 7 shows implanting a dopant into the electrically conductive layer through the opening formed in FIG. 6 .
[0015] FIG. 8 shows filling the opening in the dielectric layer with electrically conductive material.
[0016] FIG. 9 shows annealing the electrically conductive layer to form a doped region in the electrically conductive layer and a doped region in the electrically conductive material deposited in FIG. 8 .
DETAILED DESCRIPTION
[0017] Various embodiments disclosed herein have selectively doped regions in the metal interconnect layer around the via in order to prevent electromigration while avoiding the increased resistivity caused by blanket doping the entire metal interconnect layer. In the following description, for the purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the various embodiments. In other instances, well known structures and devices are omitted or simplified in order to avoid obscuring the details of the various embodiments.
[0018] The following description and the accompanying drawings provide examples for the purposes of illustration. However, these examples should not be construed in a limiting sense as they are not intended to provide an exhaustive list of all possible implementations.
[0019] Referring now to FIG. 1 , a flow chart is shown which describes a method of selectively doping a portion of a metal interconnect layer according to one embodiment of forming a circuit structure. First, an electrically conductive layer is formed at block 20 . At block 22 , a dielectric layer is formed on the electrically conductive layer formed in block 20 .
[0020] Next, an opening is formed in the dielectric layer to expose a portion of the electrically conductive layer at block 24 . The exposed portion of the electrically conductive layer is the area to be selectively doped. At block 26 , the dopant is implanted into the electrically conductive layer through the opening in the dielectric layer.
[0021] In various embodiments, the dopant used can be at least one of tin, aluminum, silicon, and magnesium. These, and other dopants, are known to prevent electromigration of the atoms that make up the metal interconnect layer. For example, the interconnect layers can be comprised of aluminum, copper or some combination thereof including, but not limited to, alloys of aluminum or copper.
[0022] When implanting either aluminum or magnesium as a dopant, one can use, for example, an implantation energy of approximately 50-200 KeV (with a target of 100 KeV) and a dose of approximately 5×10 14 −1×10 16 per square centimeter. When implanting tin as a dopant, one can use, for example, an implantation energy of approximately 200-400 KeV (with a target of 300 KeV) and a dose of approximately 5×10 14 −1×10 16 per square centimeter.
[0023] Although the dopant implantation characteristics may vary, various embodiments have the following implantation characteristics. Aluminum and/or magnesium can be used as the dopant with an ion implantation energy of 50-200 keV (100 keV preferred) with a dose of 5×10 14 −1×10 16 per square centimeter. Tin can be used as the dopant with an ion implantation energy of 200-400 keV (300 keV preferred) with a dose of 5×10 14 −1×10 16 per square centimeter.
[0024] Although the active mechanism for each dopant varies, the end result is that the dopants inhibit electromigration. For example, some dopants may act to inhibit electromigration of copper interconnect atoms by coarsing. Coarsing refers to the dopant enlarging the copper grain, which is generally small in an undoped state. This enlargement of the copper grain boundary eliminates the diffusion path for copper atoms when experiencing high current densities. Other dopants, such as tin, inhibit electomigration by blocking, which refers to the dopants depositing in the grain boundaries of the copper and blocking the diffusion path to inhibit electromigration.
[0025] After doping the electrically conductive layer at block 26 , the electrically conductive layer is annealed at block 28 . It is worth noting that the annealing process is not necessary but can be used to cause migration of the dopant through a portion of the electrically conductive layer. If included, the annealing process comprises heating the electrically conductive layer to a temperature between 100° Celsius and 400° Celsius for a period sufficient to cause the migration (e.g., diffusion) of the dopant. In various embodiments, the period sufficient to cause migration of the dopant is between 1 minute and 15 minutes.
[0026] The opening in the dielectric layer is filled with an electrically conductive material at block 30 in order to form a via or other conductive element. Although the method disclosed in FIG. 1 describes that the opening in the dielectric is filled after the annealing process, the opening can be filled prior to annealing in an alternative embodiment shown in FIGS. 6-9 .
[0027] FIGS. 2-5 show an embodiment in which the annealing process is conducted prior to filling the dielectric opening with electrically conductive material. Specifically, FIG. 2 shows electrically conductive layer 32 and dielectric layer 34 coupled to electrically conductive layer 32 . In addition, dielectric layer 34 has opening 36 formed therein, which exposes a portion of electrically conductive layer 32 . Opening 36 can be formed by any suitable patterning technique including etching.
[0028] FIG. 3 shows the implantation of dopant 38 into electrically conductive layer 32 through opening 36 . In the embodiment shown, dopant 38 is deposited across the entire length of dielectric layer 34 . However, it is contemplated that other techniques could be used to selectively dope only through opening 36 without doping the remainder of dielectric layer 34 . FIG. 4 shows doped region 40 which results from annealing electrically conductive layer 32 as described above in reference to FIG. 1 .
[0029] FIG. 5 shows the structure of FIG. 4 after filling opening 36 with electrically conductive material 42 . In the embodiment shown, electrically conductive material 42 is deposited according to a dual damascene process. However, the various embodiments disclosed herein contemplate other techniques for electrically coupling different layers (e.g., interconnects) and components.
[0030] The embodiment shown in FIG. 5 will generally have current flowing from the left side of electrically conductive material 42 to the right side of electrically conductive layer 32 . Thus, electromigration (e.g., of copper atoms from left to right) would be most likely to occur beneath the location at which electrically conductive material 42 contacts electrically conductive layer 32 , which is one impetus for doping in that location. Thus, doped region 40 is disposed such that at least a portion of doped region 40 is adjacent to the location where electrically conductive layer 32 contacts electrically conductive material 42 . However, as shown in FIG. 5 , the current may flow in either direction.
[0031] In addition, doped region 40 occupies less than the entire length of electrically conductive layer 32 . In various embodiments, doped region 40 occupies much less than the entire length of electrically conductive layer 32 . In fact, in various embodiments, doped region 40 is restricted to an area proximally adjacent to the location where electrically conductive material 42 contacts electrically conductive layer 32 . The area will generally be defined by the amount of dopant introduced into conductive layer 32 and annealing conditions that may cause the dopant to migrate within conductive layer 32 .
[0032] The restriction of length of doped region 40 to a location which is adjacent to the location in which electrically conductive material 42 contacts electrically conductive layer 32 tends to minimize the resistivity added by dopant 38 . However, doped region 40 still provides for reduced electromigration of the material which comprises electrically conductive layer 32 (e.g., copper, aluminum, other conductive material, or a combination thereof). The reduction of electromigration, in turn, increases the reliability of the semiconductor device which uses this method and structure.
[0033] Focusing now on FIGS. 6-9 , an alternative embodiment is shown in which FIG. 6 depicts electrically conductive layer 132 with dielectric layer 134 coupled to electrically conductive layer 132 . Dielectric layer 134 has opening 136 which exposes a portion of electrically conductive layer 132 . FIG. 7 shows dopant 138 being implanted through opening 136 into the exposed portion of electrically conductive layer 132 .
[0034] FIG. 8 shows that opening 136 is filled with electrically conductive material 142 . In FIG. 8 , electrically conductive material 142 is deposited in dielectric layer 134 according to a dual damascene process. However, other techniques and structures are contemplated.
[0035] FIG. 9 shows first doped region 140 in electrically conductive layer 132 and second doped region 144 in electrically conductive material 142 . First doped region 140 and second doped region 144 are formed by annealing electrically conductive layer 132 after dopant 138 has been implanted into electrically conductive layer 132 . Dopant 138 is able to diffuse to form first doped region 140 and second doped region 144 . One advantage of this embodiment is that current can flow in either direction through the structure of FIG. 9 without causing electromigration of the material which comprises electrically conductive layer 132 and electrically conductive material 142 .
[0036] Although not shown in the figures, it is contemplated that a barrier layer could be disposed between the electrically conductive layer and electrically conductive material. Such a barrier layer would prevent electromigration between electrically conductive layer 132 and electrically conductive material 142 . However, in various embodiments, the barrier layer would not prevent the diffusion of dopant 138 into both electrically conductive layer 132 and electrically conductive material 142 . An example of this can be seen in FIG. 9 .
[0037] Also absent from the figures is the removal of excess dopant from the top of the dielectric layer in embodiments in which the dopant is implanted across the length of the dielectric layer. Such a removal could be achieved by a chemical mechanical polish or other suitable procedure.
[0038] It is to be understood that even though numerous characteristics and advantages of the various embodiments have been set forth in the foregoing description, together with details of structure and function, this disclosure is illustrative only. Changes may be made in detail, especially matters of structure and management of parts, without departing from the scope of the various embodiments as expressed by the broad general meaning of the terms of the appended claims.
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A method and structure to reduce electromigration failure of semiconductor interconnects. In various embodiments, the area around a via is selectively doped with metallic dopants. The method and resulting structure reduce electromigration failure without adding unnecessary, performance-degrading resistance.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is based upon and claims the benefit of priority from the prior Japanese Patent Application No. 11-353171, filed Dec. 13, 1999, the entire contents of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to a method of manufacturing a disc drive such as a DVD drive, to an apparatus for manufacturing the optical disc drive, and to the optical disc drive.
[0003] [0003]FIG. 5 shows a conventional optical disc drive such as a DVD drive. A disc table 2 is fitted on a rotational shaft 1 a of a spindle motor 1 serving as a drive motor. An optical disc 3 such as a DVD disc is supported on the disc table 2 and rotated.
[0004] An important requirement for the optical disc drive is the “surface precision” of a disc mounting surface 2 a of the disc table 2 relative to an axis S of the spindle motor rotational shaft 1 a (i.e. the precision of the level of the disc mounting surface relative to the rotational shaft while the surface is being rotated). If there occurs even a slight surface run-out of the disc table 2 (i.e. “wobbling” of the table 2 ) while the rotational shaft 1 a is being rotated, the surface of the optical disc 3 will similarly wobble, resulting in defective information reproduction or recording.
[0005] In particular, in a DVD drive which requires high rotational precision, a brushless motor is used as the spindle motor 1 . In order to enhance the surface precision of the disc table 2 , the run-out of the disc mounting surface 2 a of the disc table 2 is detected after the DVD drive is assembled as shown in FIG. 5. Then, the disc table 2 is removed from the rotational shaft 1 a of the spindle motor 1 , and the disc mounting surface 2 a of the disc table 2 is machined to reduce the run-out.
[0006] Specifically, half-blanking is carried out to form three projecting portions from the back side of the disc mounting surface 2 a of disc table 2 . The three projections are disposed equidistantly in a circle defined at the same radial distance on the back surface of the disc mounting surface 2 a. A plane defined by the three points of these projecting portions is adjusted so as to become perpendicular to the axis S of the rotational shaft 1 a.
[0007] [0007]FIG. 6 shows a CD drive which requires less mechanical rotational precision than the DVD drive. Thus, a general-purpose brushed motor (a motor with a brush), etc. can be used as a spindle motor 1 A and the manufacturing cost can be reduced accordingly.
[0008] That surface of the spindle motor 1 A, from which a rotational shaft 1 a projects, is placed on a chassis 4 and fixed by attachment screws 5 . A disc table 2 a is fitted on the rotational shaft 1 a by means of press-fitting, etc.
[0009] In this CD drive, as shown in FIG. 7, in order to eliminate the surface run-out, a cutting process is performed to make a disc mounting surface 2 a of disc table 2 A perpendicular to the axis S of the rotational shaft 1 a in the state in which the disc table 2 A is fitted on the rotational shaft 1 a that has been removed from the spindle motor 1 A. Thereafter, the rotational shaft 1 a with the disc table 2 A is assembled into the spindle motor 1 A.
[0010] In the case of the DVD drive shown in FIG. 5, however, the manufacturing cost increases because the run-out of the disc mounting surface 2 a is measured once the DVD drive has been assembled, following which the DVD drive is disassembled, the disc table 2 is machined and the drive is assembled once again. Furthermore, since the expensive brushless motor is used as spindle motor 1 , the manufacturing cost increases.
[0011] On the other hand, in the case of the CD drive shown in FIG. 6, when a commercially available optical disc with low precision of the center of gravity is mounted and rotated, even if a high-prevision brushed motor is used, the rotational shaft 1 a is rotated with an elastic deformation caused by centrifugal force due to mass eccentricity of the optical disc. As a result, the precision in rotation deteriorates and satisfactory reproduction/recording cannot be performed.
BRIEF SUMMARY OF THE INVENTION
[0012] A first object of the present invention is to provide a disc drive, such as a DVD drive requiring high rotational precision, which is realized with a simple, inexpensive structure like a CD drive.
[0013] According to an aspect of the invention, there is provided an apparatus for manufacturing a disc drive, the apparatus comprising: urging means, put in contact with a disc table engaged with a rotational shaft of a drive motor via an engaging portion, for varying an inclination of the disc table which is swingable with a point of support at the engaging portion; detection means for detecting, in a non-contact state, the inclination of the disc table varied by the urging means; control means for receiving a detection signal from the detection means and stopping rotation of the drive motor when the inclination of the disc table has decreased to a predetermined value or less; and fixing means for fixing the disc table to the rotational shaft of the drive motor which has been stopped by the control means.
[0014] According to the present invention, even in a case of a disc drive requiring high rotational precision, a disc table can be fixed to a rotational shaft of a spindle motor while the position of the disc table is being adjusted. Therefore, a mechanism with a simple, inexpensive structure can be obtained.
[0015] A second object of the invention is to provide an optical disc drive wherein, even when an optical disc such as a disc with mass eccentricity, which may deteriorate precision in rotation, is to be driven, run-out of the disc table can be exactly limited and high rotational precision is maintained, and therefore the reliability in information reproduction/recording can be enhanced.
[0016] According to another aspect of the invention, there is provided an optical disc drive comprising: a drive motor; a disc table for mounting of an optical disc, the disc table being fixed to a rotational shaft of the drive motor; reproducing/recording means for effecting information reproduction/recording by radiating a laser beam to the optical disc; a chassis fixed to a rotational shaft projection surface of the drive motor; and a bearing member, provided on the chassis, for supporting the rotational shaft of the drive motor, which is located near the disc table.
[0017] According to the invention, the rotational shaft is supported at two points within the motor body and it is also supported at a third point by the bearing member. Therefore, the occurrence of centrifugal force due to mass eccentricity of the disc can be prevented.
[0018] Additional objects and advantages of the invention will be set forth in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. The objects and advantages of the invention may be realized and obtained by means of the instrumentalities and combinations particularly pointed out hereinafter.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
[0019] The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate presently preferred embodiments of the invention, and together with the general description given above and the detailed description of the preferred embodiments given below, serve to explain the principles of the invention.
[0020] [0020]FIG. 1 shows a schematic structure of a disc table attachment/adjustment apparatus according to an embodiment of the present invention;
[0021] [0021]FIG. 2 illustrates an engaging portion of a disc table in the embodiment;
[0022] [0022]FIG. 3 is a cross-sectional view of a main part of a disc drive according to the embodiment;
[0023] [0023]FIG. 4 is an exploded, perspective view showing the main part of the disc drive according to the embodiment;
[0024] [0024]FIG. 5 is a cross-sectional view of a main part of a conventional disc drive;
[0025] [0025]FIG. 6 is a cross-sectional view of a main part of another conventional disc drive; and
[0026] [0026]FIG. 7 illustrates a step of increasing the surface precision of the disc table.
DETAILED DESCRIPTION OF THE INVENTION
[0027] [0027]FIG. 1 shows a schematic structure of a disc table attachment/adjustment apparatus according to an embodiment of the present invention. This apparatus operates to attach a disc table 11 constituting a part of a disc drive to a rotational shaft 10 a of a drive motor 10 , and to keep high surface precision of a disc mounting surface 11 a of the disc table 11 relative to an axis S of the motor rotational shaft 10 a.
[0028] A spindle motor constituting the drive motor 10 of the disc drive is a general-purpose brushed motor. The disc table 11 is fixed to the rotational shaft 10 a, as will be described later.
[0029] As is shown in FIG. 2, the disc table 11 has an engaging portion 12 . The engaging portion 12 is engaged with the rotational shaft 10 a of spindle motor 10 . The engaging portion 12 comprises a hole portion formed at a center area of the disc table 11 . The engaging portion 12 is fitted on the rotational shaft 10 a in a “light press-fitting state.” In the “light press-fitting state” in this context, the position of the engaging portion 12 relative to the rotational shaft 10 a is varied only when an external force of a predetermined level or more is applied. In other words, this position of the engaging portion 12 is maintained in normal cases, while the angle of the disc mounting surface 11 a to the axis S of the rotational shaft 10 a is variable.
[0030] The spindle motor 10 is connected to a circuit 14 including a power supply unit 13 for supplying power to the spindle motor 10 . The circuit 14 also includes a variable resistor 15 for controlling the number of revolutions of the spindle motor 10 .
[0031] An adjusting element 16 holding a roller such as a cam follower is disposed in contact with an outer peripheral portion of the disc table 11 , which is fitted on the rotational shaft 10 a of spindle motor 10 by means of light press-fitting. The adjusting element 16 is supported by a bracket 17 . The adjusting element 16 constitutes urging means which is slightly moved by a moving mechanism 30 in a thrust direction (indicated by a double-headed arrow T).
[0032] On the other hand, a non-contact displacement measuring unit 18 is disposed near the disc table 11 . The non-contact displacement measuring unit 18 constitutes detection means for emitting a laser beam onto the disc mounting surface 11 a of disc table 11 and receiving the reflection beam therefrom, thereby measuring the precision relating to run-out of the disc mounting surface 11 a in a non-contact state.
[0033] In addition, an adhesive supply unit 19 constituting fixing means is disposed near the disc table 11 . The adhesive supply unit 19 has a dispenser 19 a for applying a proper amount of adhesive. The dispenser 19 a has a supply port directed to a point between the engaging portion 12 of disc table 11 and the motor rotational shaft 10 a.
[0034] A control unit 40 constituting control means is connected to the power supply unit 13 , the variable resistor 15 , the moving mechanism 30 supporting adjustment element 16 , the non-contact displacement measuring unit 18 and the adhesive supply unit 19 . The control unit 40 provides necessary controls to these elements. Specifically, the control unit 40 is an adjusting unit functioning when the disc table 11 is to be attached to the rotational shaft 10 a. The control unit 40 performs adjustments not only for fixing the disc table 11 to the rotational shaft 10 a but also for maintaining the precision in run-out of the disc mounting surface 11 a of the disc table 11 relative to the axis S of the rotational shaft 10 a.
[0035] More specifically, the spindle motor 10 is rotated at very low speed and the adjusting element 16 is moved in the direction T and brought into contact with the outer periphery of the disc table 11 . Then, the adjusting element 16 is further moved by a slight amount.
[0036] The non-contact displacement measuring unit 19 always detects the precision in run-out, or displacement, of the disc mounting surface 11 a of disc table 11 and feeds the displacement data to the control unit 40 . The control unit 40 controls the movement of the adjusting element 16 so that the displacement represented by the displacement data may decrease to a minimum.
[0037] When the displacement, or run-out, of the disc table 11 has decreased to a minimum, the control unit 40 stops the rotation of the spindle motor 10 . In fact, the adjusting element 16 is unable to effect positioning with a predetermined resolution or less. Thus, a specific displacement value may be set in advance, and if the measured value decreases below the specific displacement value, the spindle motor 10 may be stopped even if the measured value is not a minimum value.
[0038] After the rotation of the spindle motor 10 has completely stopped, the adhesive supply unit 19 is driven to apply adhesive through the dispenser 19 a. Thus, the disc table 11 is fixed to the rotational shaft 10 a. Where the adhesive is of ultraviolet-setting type, ultraviolet is radiated for fixation.
[0039] In this way, the disc table 11 is inclinably fitted on the spindle motor rotational shaft 10 a. Then, the spindle motor 10 is driven to rotate the disc table 11 , while the disc table 11 is being slightly urged. When the displacement data has indicated a minimum value, the spindle motor 10 is stopped and the disc table 11 is fixed to the rotational shaft 10 a. Thus, time-consuming, complex machining is not needed for the disc table 11 , and high rotational precision is obtained by a relatively simple structure and work.
[0040] In this type of brushed motor, a distance between a rotational shaft projection surface 10 b of the motor and the disc mounting surface 11 a of disc table 11 is standardized. The axial length of the rotational shaft 10 a is greater than that of the spindle motor 10 itself. The disc table 11 is attached to a distal end portion of the rotational shaft 10 a.
[0041] At a glance, the rotational shaft 10 a has a considerably “long neck” shape. Even where a high-precision brushed motor is used, if a commercially available disc with low precision of the center of gravity is mounted and rotated, the rotational shaft 10 a is rotated with an elastic deformation caused by centrifugal force due to mass eccentricity of the disc.
[0042] In other words, even if the disc table 11 is precisely fixed to the rotational shaft 10 a using the above-described disc table attachment/adjustment apparatus, if the rotational shaft 10 a rotates with an elastic deformation in actual use, run-out will occur with respect to the disc mounting surface 11 a of disc table 11 .
[0043] To solve this problem, as shown in FIG. 3, the rotational shaft projection surface 10 b of spindle motor 10 is fixed to a chassis 20 , and the chassis 20 is provided with a bearing member 21 to support the rotational shaft 10 a.
[0044] The bearing member 21 has such a length as to span the distance between the upper surface of the chassis 20 and the lower surface of the disc table 11 . An actual bearing portion 21 a for the rotational shaft 10 a is provided at a distal end portion of the bearing member 21 , which is located near the disc table 11 . In FIG. 3, reference numeral 50 denotes a light pickup unit 50 for radiating a laser beam L to the disc 3 to effect information reproduction/recording.
[0045] [0045]FIG. 4 shows structural elements of a centering mechanism for centering when the disc 3 is to be mounted on the disc table 11 . The centering mechanism comprises a centering spring 22 , a center ring 23 and a clamp magnet 24 .
[0046] In ordinary drive motors including the above-described spindle motor 10 , the rotational shaft is supported at two points within the motor body. A third support point, however, is provided by the above-described bearing member 21 . Accordingly, even where the commercially available disc with low precision of the center of gravity is mounted on the disc table 11 and rotated, it is possible to prevent the occurrence of centrifugal force due to mass eccentricity of the disc. Therefore, no elastic deformation of the rotational shaft 10 a occurs, run-out of the disc table 11 is prevented, and high rotational precision is maintained.
[0047] Needless to say, the present invention is not limited to the above-described embodiment, and various modifications can be made without departing from the spirit of the invention.
[0048] Additional advantages and modifications will readily occur to those skilled in the art. Therefore, the invention in its broader aspects is not limited to the specific details and representative embodiments shown and described herein. Accordingly, various modifications may be made without departing from the spirit or scope of the general inventive concept as defined by the appended claims and their equivalents.
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An apparatus for manufacturing a disc drive comprises an adjusting element, put in contact with a disc table engaged with a rotational shaft of a drive motor via an engaging portion, for varying an inclination of the disc table which is swingable with a point of support at the engaging portion, a non-contact displacement measuring unit for detecting, the inclination of the disc table varied by the adjusting element, control unit for receiving a detection signal from the non-contact displacement measuring unit and stopping rotation of the drive motor when the inclination of the disc table has decreased to a predetermined value or less, and an adhesive supply unit for fixing the disc table to the rotational shaft of the drive motor which has been stopped by the control unit.
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The present patent application is a continuation-in-part of U.S. patent application Ser. No. 10/912,324, filed Aug. 5, 2004, now U.S. Pat. No. 7,318,493, and entitled “Hybrid Remote Control Lawn Mower.” Ser. No. 10/912,324 is related to Provisional No. 60/492,687, filed Aug. 5, 2003.
BACKGROUND OF THE INVENTION
Lawn mowers are well known in the art. Typically, lawn mowers are used to cut grass in a lawn to a desired height.
SUMMARY OF THE INVENTION
The present invention provides a hybrid remote control lawn mower that allows an operator to control the hybrid remote control lawn mower from a remote location. Additionally, the hybrid remote control lawn mower may include other embodiments to provide use in all seasons. The embodiments may include a wagon, a spreader, a dethacher, a leaf collector, a leaf blower, a lawn trimmer, an edger, a hedge trimmer, a snow plow blade, a snow blower, or any other suitable attachment. The hybrid remote control lawn mower allows an operator to stay at a safe distance away from the hybrid remote control lawn mower in dangerous places such as on steep hills. Additionally, the hybrid remote control lawn mower allows a physically challenged operator to control the hybrid remote control lawn mower from a stationary location.
BRIEF DESCRIPTION OF THE DRAWINGS
The features of the present invention will best be understood from a detailed description of the invention and a preferred embodiment thereof selected for the purposes of illustration and shown in the accompanying drawings in which:
FIG. 1 illustrates a perspective view of a hybrid remote control lawn mower according to the present invention;
FIG. 2 illustrates a perspective view of a frame of the hybrid remote control lawn mower of the hybrid remote control lawn mower of FIG. 1 ;
FIG. 3 illustrates a perspective view of a deck apparatus of the hybrid remote control lawn mower of FIG. 1 ;
FIG. 4 illustrates a perspective view of the frame of FIG. 2 , the deck apparatus of FIG. 3 , an alternator apparatus, a right rear motor apparatus and a left rear motor apparatus;
FIG. 5 illustrates a perspective view of the hybrid remote control lawn mower;
FIG. 6 illustrates a diagramatic view of a charger system;
FIG. 7 illustrates a front view of a remote transmitter apparatus;
FIG. 8 illustrates a diagramatic view of a brain control system;
FIG. 9 illustrates a diagramatic view of the brain control system including MOSFETs;
FIG. 10 illustrates a side view of a MOSFET cooling apparatus;
FIG. 11 illustrates a perspective view of another embodiment of a hybrid remote control lawn mower including a front bumper, a rear bumper, a headlight, wireless video cameras, a pattern recognition system, a wireless video receiver, and a virtual reality glasses apparatus;
FIG. 12 illustrates a side view of a hill with another embodiment of the hybrid remote control lawn mower wherein the hybrid remote control lawn mower includes a counterweight apparatus;
FIG. 13 illustrates a side view of the hybrid remote control lawn mower wherein the hybrid remote control lawn mower includes the counterweight apparatus of FIG. 12 and an anti-tipping assembly to prevent tipping over of the hybrid remote control lawn mower;
FIG. 14 illustrates a side view of the hybrid remote control lawn mower of FIG. 13 , wherein the anti-tipping assembly is preventing the hybrid remote control lawn mower from tipping over;
FIG. 15 illustrates a side view of another embodiment of a hybrid remote control lawn mower, wherein the hybrid remote control lawn mower includes a seat assembly for an operator and a transmitter support assembly to secure the remote transmitter apparatus of FIG. 7 to the hybrid remote control lawn mower;
FIG. 16 illustrates a plan view of another embodiment of a hybrid remote control lawn mower including a deck apparatus including more than one lawn mower blade;
FIG. 17 illustrates a side view of a hitch assembly attached to the hybrid remote control lawn mower;
FIG. 18 illustrates a side view of another embodiment of a hybrid remote control lawn mower, wherein a wagon apparatus is coupled to the hybrid remote control lawn mower;
FIG. 19 illustrates a side view of another embodiment of a hybrid remote control lawn mower, wherein a spreader apparatus is connected to the hybrid remote control lawn mower;
FIG. 20 illustrates a side view of another embodiment of a hybrid remote control lawn mower, wherein a dethatcher apparatus is connected to the hybrid remote control lawn mower;
FIG. 21 illustrates a side view of another embodiment of a hybrid remote control lawn mower, wherein a lawn clippings collection apparatus is connected to the hybrid remote control lawn mower;
FIG. 22 illustrates a front view of another embodiment of a hybrid remote control lawn mower, wherein a weed trimmer apparatus is attached to the hybrid remote control lawn mower;
FIG. 23 illustrates a side view of the hybrid remote control lawn mower including the weed trimmer apparatus of FIG. 22 ;
FIG. 24 illustrates a front view of another embodiment of a hybrid remote control lawn mower, wherein an edge trimmer apparatus is attached to the hybrid remote control lawn mower;
FIG. 25 illustrates a side view of the hybrid remote control lawn mower including the edge trimmer of FIG. 24 ;
FIG. 26 illustrates a front view of another embodiment of a hybrid remote control lawn mower, wherein a hedge trimmer apparatus is attached to the hybrid remote control lawn mower;
FIG. 27 illustrates a side view of another embodiment of a hybrid remote control lawn mower, wherein a track apparatus provides movement upon a support surface;
FIG. 28 illustrates a front view of the hybrid remote control lawn mower of FIG. 27 ;
FIG. 29 illustrates a side view of another embodiment of a hybrid remote control lawn mower including a rear track drive apparatus;
FIG. 30 illustrates a side view of another embodiment of a hybrid remote control lawn mower including a blade apparatus attached to the hybrid remote control lawn mower;
FIG. 31 illustrates a side view of another embodiment of a remote control lawn mower including a fluid blade apparatus;
FIG. 32 illustrates a front view of the fluid blade apparatus of FIG. 31 , including fluid exhaust ports; and
FIG. 33 illustrates a side view of another embodiment of a remote control lawn mower including a snow blower apparatus attached to the remote control lawn mower.
DETAILED DESCRIPTION OF THE INVENTION
Although certain preferred embodiments of the present invention will be shown and described in detail, it should be understood that various changes and modifications may be made without departing from the scope of the appended claims. The scope of the present invention will in no way be limited to the number of constituting components, the materials thereof, the shapes thereof, the relative arrangement thereof, etc., and are disclosed simply as an example of the preferred embodiment. The features and advantages of the present invention are illustrated in detail in the accompanying drawings, wherein like reference numerals refer to like elements throughout the drawings. Although the drawings are intended to illustrate the present invention, the drawings are not necessarily drawn to scale.
FIGS. 1 , 2 , 3 , 4 and 5 , illustrate a hybrid remote control lawn mower 10 . The hybrid remote control lawn mower 10 includes a frame 12 , a right rear motor apparatus 14 , a left rear motor apparatus 16 , a right rear wheel apparatus 18 , a left rear wheel apparatus 20 , a right front free swiveling wheel apparatus 22 , a left front free swiveling wheel apparatus 24 , a deck apparatus 26 , an engine 28 , a deck suspension apparatus 30 , a lawn mower blade 32 , an alternator apparatus 34 , a battery 36 , a voltage regulator 38 , a remote transmitter apparatus 40 , a receiver apparatus 42 , and a brain control system 44 . The engine 28 may include any suitable engine such as a gasoline engine, a diesel engine, a liquid petroleum gas engine, a bio fuel engine, a hydrogen engine, a fuel cell engine, or any other suitable engine.
As illustrated in FIG. 1 , the engine 28 may further include an emission control system 46 . The emission control system 46 may include any suitable system such as a catalytic converter, lean burn system, or any other suitable system. The emission control system 46 enables the engine 28 to meet federal or state mandated air pollution emission standards. Additionally, as illustrated in FIG. 1 the engine 28 may include an exhaust silencer system 48 to keep noise levels below federal or state mandated noise levels. The engine 28 is attached to the deck apparatus 26 . As illustrated in FIG. 5 , the engine 28 includes a rotating drive shaft 50 . The lawn mower blade 32 is attached to the rotating drive shaft 50 and rotates and cuts through lawn 52 .
As illustrated in FIG. 3 , the alternator apparatus 34 is attached to the deck apparatus 26 . A mounting arm 54 is rigidly attached to the deck apparatus 26 . The alternator apparatus 34 rotates about a pivot bolt 56 attached to the mounting arm 54 . A tensioning arm 58 is rigidly attached to the deck apparatus 26 . The tensioning arm 58 includes an adjustment slot 60 . A fastening device 62 such as a nut and bolt passes through the adjustment slot 60 and may secure the alternator apparatus 34 to the tensioning arm 58 at any location along the slot 60 . As illustrated in FIG. 5 , a drive belt 62 may couple a drive pulley 66 with an alternator pulley 64 . The drive pulley 66 is mounted on the rotating drive shaft 50 of the engine 28 . The alternator pulley 64 provides rotation to the alternator apparatus 34 to generate electric power. Tension in the drive belt 62 is adjusted by sliding the fastening device 62 along the adjustment slot 60 until a desired belt 62 tension is obtained. Then the fastening device 62 is tightened onto the tensioning arm 58 , thus maintaining the desired drive belt 62 tension. Alternatively, the alternator apparatus 34 may be connected with the engine 28 by any suitable means (e.g., gears, engine drive shaft 50 , etc.).
As illustrated in FIG. 4 , the deck apparatus 42 is suspended from the frame 12 by a deck suspension apparatus 30 . The deck suspension apparatus 30 includes an adjustment lever arm 68 and an adjustment plate 70 . The adjustment plate 70 is rigidly attached to the frame 12 . The adjustment plate 70 includes a set of holes 72 . A pin 74 is slid through the adjustment lever arm 68 and into one of the set of holes 72 . An operator may swing the adjustment lever arm 68 to adjust the height between the deck apparatus 34 and the frame 12 . Then the operator may slide the pin 74 through the adjustment lever arm 68 and through one of the set of holes 72 to maintain a desired height.
As illustrated in FIG. 4 , the right rear motor apparatus 14 is attached to the frame 12 . The left rear motor apparatus 16 is attached to the frame 12 . The right rear motor apparatus 14 includes a motor 74 R, a gearbox 76 R and a wheel drive shaft 78 R. The left rear motor apparatus 16 includes a motor 74 L, a gearbox 76 L and a wheel drive shaft 78 L. The motors 74 R and 74 L may include any suitable motors such as DC electric motors. As illustrated in FIG. 5 , the right rear wheel apparatus 18 includes a right rear wheel 80 R and a right rear tire 82 R. The left rear wheel apparatus 20 includes a left rear wheel 80 L and a left rear tire 82 L. The right rear wheel 80 R is attached to the wheel drive shaft 78 R. The left rear wheel 80 L is attached to the wheel drive shaft 78 L. As illustrated in FIG. 5 , the right rear tire 82 R and the left rear wheel 82 L rest upon a support surface 84 . The right rear tire 82 R and the left rear tire 82 R may include any suitable tread pattern (e.g., smooth, knobby, V shaped, etc.). The motor 74 R provides rotation through the gearbox 76 R which provides rotation through the wheel drive shaft 78 R to the right rear tire 82 R. The motor 74 L provides rotation through the gearbox 76 L which provides rotation through the wheel drive shaft 78 L to the left rear tire 82 L. The gear boxes 76 R and 76 L may include any suitable gear ratios that do not overload the motors 74 R and 74 L. For a tire with a diameter of about 12 inches a suitable gear ratio is about 25 or higher.
FIG. 1 illustrates the right front free swiveling wheel apparatus 22 and the left front swiveling wheel apparatus 24 . The right front free swiveling wheel apparatus 22 includes a wheel support 85 R and a tire 88 R. The wheel support 85 R is rotatably attached to the frame 12 . The tire 88 R rotates about a shaft 90 R. The tire 88 R rests upon the support surface 84 . The left front free swiveling wheel apparatus 24 includes a wheel support 85 L and a tire 88 L. The wheel support 85 L is rotatably attached to the frame 12 . The tire 88 L rotates about a shaft 90 L. The tire 88 L rests upon the support surface 84 .
FIG. 1 illustrates the receiver apparatus 42 and the brain control system 44 . The receiver apparatus 42 includes a receiver antenna 92 . The remote transmitter apparatus 40 includes input control modules 94 A, 94 B and 94 C. Additionally, the remote transmitter apparatus 40 includes a transmitter antenna 96 . The operator may input desired command control signals (e.g., such as direction, speed, starting, stopping, etc.) through the input control modules 94 A, 94 B and 94 C. The remote transmitter apparatus 40 translates the operator command control signals and transmits the control signals through a radio wave signal 98 . The radio wave signal 98 is received through the receiver antenna 92 of the receiver apparatus 42 . The receiver apparatus 42 sends the command control signals to the brain control system 44 . The brain control system 44 sends speed and direction signals to the right rear motor apparatus 14 and the left rear motor apparatus 16 . The hybrid remote control lawn mower 10 is then propelled in a desired direction and speed on the support surface 84 . FIG. 8 shows a loss of radio wave signal detector 147 included in the brain control system 44 . When the loss of radio wave signal detector 147 detects a loss of radio wave signal 98 between the remote transmitter apparatus 40 and the receiver apparatus 42 , the brain control system 44 turns the engine 28 off and stops the power to the motors 74 L and 74 R. FIG. 9 shows a current sensor device 149 to measure the current going to the right rear motor 74 R and the left rear motor 74 L. The current sensor device 149 may be any suitable device (e.g., Hall effect sensor, current transformer, etc.). To protect the right rear motor 74 R and the left rear motor 74 L, the brain control system 44 shuts off the engine 28 and the current to the motors 74 R and 74 L when the current exceeds a preset current level.
FIG. 6 includes a diagrammatic view of a charger system 100 . FIG. 6 illustrates the battery 36 , the alternator apparatus 34 , a voltage regulator 102 and the brain control system 44 . The alternator apparatus 34 includes an alternator rotor 104 and an alternator stator 106 . The alternator rotor 104 rotates and the alternator stator 106 provides electrical power 108 . The voltage regulator 102 regulates the electrical power to any suitable voltage level (e.g., 12 volts, 24 volts, etc.). The brain control system 44 sends desired electrical power 108 to the right rear motor apparatus 14 and the left rear motor apparatus 16 . The battery 36 may include any suitable voltage (e.g., 12 volts, 24 volts, etc.).
FIG. 7 illustrates a front view of the remote transmitter apparatus 40 . The remote transmitter apparatus 40 includes the transmitter antenna 96 and the input control modules 94 A, 94 B and 94 C. Input control module 94 A includes an input control stick 110 . The operator may push the input control stick 110 in any desired direction to control the direction of the hybrid remote control lawn mower 10 . For example if the operator pushes the input control stick 110 towards a right direction (direction arrow 111 ) the hybrid remote control lawn mower 10 will steer towards the right. If the operator pushes the input control stick 110 towards a left direction (direction arrow 114 ) the hybrid remote control lawn mower 10 will steer towards the left. If the operator pushes the input control stick 110 towards a forward direction (direction arrow 116 ) the hybrid remote control lawn mower 10 will steer in a straight forward direction. If the operator pushes the input control stick 110 towards a rear direction (direction arrow 118 ) the hybrid remote control lawn mower 10 will steer in a straight backward direction. Additionally, any movement of the input control stick 110 in an intermediate direction will cause the hybrid remote control lawn mower 10 to steer in that direction. For example, if the operator pushes the input control stick 110 in a direction (direction arrow 120 , the hybrid remote control lawn mower 10 would steer in the corresponding direction 120 .
The operator may control the speed of the hybrid remote control lawn mower 10 by how far the operator pushes the input control stick 110 towards the circle 112 . If the operator releases the input control stick 110 , the input control stick 110 returns to a position at the center 121 of the circle 112 and the hybrid remote control lawn mower 10 comes to a stop with no movement. An outer boundary of a precision low speed control region 122 is indicated by a dotted circle 124 . When the operator moves the input control stick 110 within this precision low speed control region 122 , the speed of the hybrid remote control lawn mower 10 is limited to a very slow speed. This enables the operator to safely maneuver the hybrid remote control lawn mower 10 at very slow speeds. Without this precision low speed control region 122 the hybrid remote control lawn mower could suddenly move an unwanted distance when the operator slightly moved the input control stick 110 . This precision low speed control region 122 allows the operator to maneuver the hybrid remote control lawn mower 10 in tight spaces such as when parking in a garage. When the operator pushes the input control stick 110 outside of the outer boundary 124 of the precision low speed control region 122 , the hybrid remote control lawn mower 10 is allowed to move at higher speeds. The precision low speed control region 122 is controlled in the brain control system 44 . Additionally, when the engine 28 is not running, the hybrid remote control lawn mower 10 motors 74 R and 74 L the brain control system 44 and the battery 36 are still fully operational so that the operator may still drive the remote control lawn mower 10 in any desired direction. This is useful when the operator desires to park the unit in a garage without the engine 28 running.
FIG. 7 illustrates the input control module 94 B including an input control stick 126 . The operator may push the input control stick 126 towards a right direction (direction arrow 128 ) to start the engine 28 . The engine may include an electric starter (not shown) to automatically start the engine 28 . The operator may push the input control stick 126 towards a left direction (direction arrow 130 ) to turn the engine 28 off. When the operator releases the input control stick 126 , the input control stick 126 returns to a center position 132 . As an option, when the engine 28 is turned off and not running, the operator may push the input control stick 126 towards the left (direction arrow 130 ) twice in rapid sequence and this signals the brain control system 44 to implement a system reset. This is only used when for some reason the brain control system 44 needs to reset.
FIG. 7 illustrates the input control module 94 C including a safety button 134 . As an option, the safety button 134 may be provided such that the operator must keep the safety button 134 depressed in order for the hybrid remote control lawn mower 10 to operate and move. If the operator releases the safety button 134 the hybrid remote control lawn mower 10 would immediately stop and turn off.
Additional control modules 94 or control channels may be added to provide additional remote operating features to the hybrid remote control lawn mower 10 .
FIG. 8 illustrates a diagramatic view of the remote transmitter apparatus 40 , the receiver apparatus 42 , the brain control system 44 and the right rear motor apparatus 14 and the left rear motor apparatus 16 . The brain control system 44 includes a microprocessor 146 and a propulsion control system 148 . The operator provides control signals (e.g., direction, speed, starting, stopping, etc.) through the input control modules 94 A, 94 B and 94 C of the remote transmitter apparatus 40 ( FIG. 7 ). The remote transmitter apparatus 40 sends command signals (e.g., direction, speed, starting, stopping, etc.) to the receiver apparatus 42 . The receiver apparatus 42 sends command signals to the microprocessor 146 . The microprocessor 146 sends command signals to the propulsion control system 148 to operate the speed and direction of the right rear motor apparatus 14 and the left rear motor apparatus 16 . FIG. 9 illustrates a diagramatic view of the microprocessor 146 , the propulsion control system 148 , the right rear motor apparatus 14 and the left rear motor apparatus 16 . A forward direction is indicated by a direction arrow 81 F as shown in FIG. 1 . A backward direction is indicated by a direction arrow 81 B as shown in FIG. 1 . To travel in the forward direction 81 F the right rear wheel 80 R and the left rear wheel 80 L rotate in the same forward direction 81 F to provide forward movement to the hybrid remote control lawn mower 10 . To travel in the backward direction 81 B the right rear wheel 80 R and the left rear wheel 80 L rotate in the same backward direction 81 B to provide backward movement to the hybrid remote control lawn mower 10 . To travel in a straight line the right rear wheel 80 R and the left rear wheel 80 L rotate at the same speed. When traveling forward and turning right, the left rear wheel 80 L rotates faster than the right rear wheel 80 R. When traveling forward and turning left, the right rear wheel 80 R rotates faster than the left rear wheel 80 L. To provide zero turning radius to the right, the left rear wheel 80 L rotates in the forward direction 81 F while the right rear wheel 80 R rotates in the backward direction 81 B To provide zero turning radius to the left, the right rear wheel 80 R rotates in the forward direction 81 F and the left rear wheel 80 L rotates in the backward direction 81 B. Additionally, the brain control system 44 turns the motors 74 R and 74 L into generators when the hybrid remote control lawn mower is coasting down a hill or slowing down. In this mode of operation, the electric power generated by the motors 74 R and 74 L is stored in the battery 36 . This electric power stored in the battery 36 may be used to provide power to the motors 74 R and 74 L. Thus, energy is conserved and decreases the amount of fuel used by the engine 28 .
FIG. 9 illustrates MOSFETs 150 A and 150 B which provide control of electric current supplied to the left motor 74 L. MOSFETs 150 C and 150 D provide control of electric current supplied to the right motor 74 R. Electric current may cause overheating of the MOSFETs 150 A, 150 B, 150 C and 150 D. FIG. 10 illustrates a side view of a MOSFET 150 cooling apparatus 152 . The cooling apparatus 152 includes a top clamping plate 154 , a heat sink 158 and fasteners 156 A and 156 B. The MOSFET 150 is clamped between the top clamping plate 154 and the heat sink 158 by any suitable fasteners 156 A and 156 B (e.g., nuts and bolts, screws, etc.). The heat sink 158 may be any suitable material (e.g., aluminum, copper, etc.). A conductive grease 160 may be applied between the MOSFET 150 and the heat sink 158 . The MOSFET 150 may be clamped with at least 10 newtons of force but preferably with about 150 newtons of force. The heat sink 158 may also include any other suitable means of cooling (e.g., fins, fan, liquid cooling, thermoelectric Peltier, etc.). The heat sink 158 carries heat away from the MOSFET 150 and enables the MOSFET 150 to carry large currents without failure. A temperature sensor 161 is attached to the MOSFET 150 to measure the MOSFET 150 temperature. Alternatively, the temperature sensor 161 may be attached to the heat sink 158 at a location near the MOSFET 150 . The temperature sensor 161 may be any suitable temperature sensor (e.g., thermistor, thermocouple, RTD, etc.). If the temperature of the MOSFET 150 exceeds a predetermined temperature, the brain control system 44 shuts off the engine 28 and shuts off power to the motors 74 R and 74 L. The predetermined temperature may be but is not limited to about 60 degrees C. The brain control system 44 allows the engine 28 and motors 74 R and 74 L to restart and resume normal operation after the temperature of the MOSFET 150 lowers to a safe operating level.
FIG. 11 illustrates another embodiment of a hybrid remote control lawn mower 10 B including a front bumper 164 , a rear bumper 166 , a headlight 168 , a wireless video camera 170 A, a wireless video camera 170 B, a pattern recognition system 177 , a wireless video receiver 174 , a video display unit 176 and a virtual reality glasses apparatus 178 . The operator inputs desired commands to the hybrid remote control lawn mower 10 B through the remote transmitter apparatus 40 .
If the front bumper 164 contacts an object, a signal is sent to the brain control system 44 and the brain control system 44 causes the hybrid remote control lawn mower 10 B to stop moving. If the rear bumper 166 contacts an object, a signal is sent to the brain control system 44 and the brain control system 44 causes the hybrid remote control lawn mower 10 B to stop moving.
The headlight 168 provides illumination at night. The wireless video cameras 170 A and 170 B provide views ahead and behind the hybrid remote control lawn mower 10 B. The wireless video cameras 170 A and 170 B may be any suitable wireless video camera (e.g., 2.4 GHz, 5.8 GHz, infrared, color, etc.). The wireless video cameras 170 A and 170 B include antennas 180 A and 180 B respectively. The wireless video receiver 174 includes an antenna 182 . The wireless video receiver 174 may be located at a remote distance from the wireless video cameras 170 A and 170 B. The wireless video cameras 170 A and 170 B send video signals through the antennas 180 A and 180 B. The antenna 182 of the wireless video receiver 174 , receives the video signals from the antennas 180 A and 180 B. The videos from video cameras 170 A and 170 B are then displayed on the video display unit 176 . Each video signal from camera 170 A and 170 B may be displayed and observed by the operator while the operator controls the hybrid remote control lawn mower 10 B using the remote transmitter apparatus 40 . Optionally, the video signals from the wireless video cameras 170 A and 170 B may be displayed and observed by the operator using a virtual reality glasses apparatus 178 . The operator wears the virtual reality glasses apparatus 178 like a pair of eyeglasses and can see the video views.
The pattern recognition system 177 ( FIG. 11 ) includes viewing devices 182 and 184 . The pattern recognition apparatus 177 may swivel to look ahead of or behind the hybrid remote control lawn mower 10 B. The brain control system 44 processes the signals from the viewing devices 182 and 184 and learns the locations of significant objects in a yard (e.g., houses, trees, bushes, etc.). The brain control system 44 then prevents the hybrid remote control lawn mower 10 B from contacting these objects.
FIG. 12 illustrates a side view of a hill 190 with another embodiment of a hybrid remote control lawn mower 10 C. FIG. 12 illustrates the hybrid remote control lawn mower 10 C following a contour line 192 (shown as dashed line) of the hill 190 . A desired direction of travel is shown by direction arrow 194 . FIG. 12 illustrates a center of gravity location 196 of the hybrid remote control lawn mower 10 C. The center of gravity location 196 is located at a distance “A” in front of a center 199 of the left rear wheel 80 L. A counterweight assembly 198 is attached to the frame 12 of the hybrid remote control lawn mower 10 C. FIG. 12 illustrates a center of gravity location 200 of the counter weight assembly 198 and mass of the hybrid remote control lawn mower 10 C behind the left rear wheel 80 L. The center of gravity of the counter weight assembly 198 and mass of the hybrid remote control lawn mower 10 C behind the left rear wheel 80 L is located at a distance “B” behind the center 199 of the left rear wheel 80 L. A force “FA” due to the weight of the hybrid remote control lawn mower 10 C ahead of the left rear wheel 80 L acts through the center of gravity location 196 . A force “FB” due to the weight of the counter weight assembly 198 and the mass of the hybrid remote control lawn mower 10 C acts through the center of gravity of location 198 . If the moment due to the force “FA” multiplied by the distance “A” is larger than the moment due to the force “FB” multiplied by the distance “B”, then the hybrid remote control lawn mower 10 C will travel along a path indicated by direction arrow 202 ( FIG. 12 ). If the moment due to force “FA” multiplied by the distance “A” is significantly larger than the moment due to the force “FB” multiplied by the distance “B”, the hybrid remote control lawn mower 10 C will not be able to follow the desired direction of travel 194 along the contour line 192 . Mass is added to the counter weight assembly 198 until the moment due to the force “FA” multiplied by the distance “A” and the force “FB” multiplied by the distance “B” are about equal. Then the hybrid remote control lawn mower 10 C will be able to follow the desired direction of travel 194 along the contour line 192 .
FIG. 13 illustrates the hybrid remote control lawn mower 10 C including the counterweight assembly 198 and a anti-tipping assembly 204 . The anti-tipping assembly 204 is attached to the frame 12 of the hybrid remote control lawn mower 10 C. The anti-tipping assembly 204 includes a skid 206 . The operator inputs desired commands to the remote control lawn mower 10 C through the remote transmitter apparatus 40 .
FIG. 14 illustrates how the anti-tipping assembly 204 prevents the hybrid remote control lawn mower 10 C from flipping over in a backwards direction (direction arrow 208 ). The skid 206 contacts and pushes against the support surface 84 and prevents the hybrid remote control lawn mower 10 C from flipping over in the backwards direction (direction arrow 208 ).
FIG. 15 illustrates a side view of another embodiment of a hybrid remote control lawn mower 10 D. The hybrid remote control lawn mower 10 D includes a seat assembly 210 , the anti-tipping assembly 204 and a remote transmitter support assembly 212 . The seat assembly 210 is attached to the frame 12 of the hybrid remote control lawn mower 10 D. An operator (not shown) may sit on the seat assembly 210 . The remote transmitter support assembly 212 is attached to the frame 12 of the hybrid remote control lawn mower 10 D. The remote transmitter apparatus 40 is removably attached to the remote transmitter support assembly 212 . When the remote transmitter apparatus 40 is attached to the remote transmitter support assembly 212 , the operator may sit on the seat assembly 210 and operate the hybrid remote control lawn mower 10 D using the input control modules 94 A, 94 B and 94 C of the remote transmitter apparatus 40 . As a safety precaution, when mowing on a steep incline or hill, the operator may get off of the hybrid remote control lawn mower 10 D and remove the remote transmitter apparatus 40 from the remote transmitter support assembly 212 . Next, the operator may carry the remote transmitter apparatus 40 (shown in dashed lines) to a safe distance away from the hybrid remote control lawn mower 10 D. Then the operator can use the input control modules 94 A, 94 B and 94 C of the remote transmitter apparatus 40 to operate the hybrid remote control lawn mower on the steep incline or hill. Then in case the hybrid remote control lawn mower 10 D slips down the hill, the operator is at a safe distance away from the unit and has no risk of falling off of the hybrid remote control lawn mower 10 D.
FIG. 16 illustrates a plan view of another embodiment of a hybrid remote control lawn mower 10 E. The hybrid remote control lawn mower 10 E includes a deck apparatus 26 E. The deck apparatus 26 E includes a plurality of lawn mower blades 32 A, 32 B and 32 C. The lawn mower blades 32 B and 32 C are rotatably connected with the drive shaft 50 of the engine 28 (not shown). The lawn mower blade 32 A is directly attached to the rotating drive shaft 50 . Any suitable means of connection (e.g., belts, gears, etc.) may be used to rotatably connect the lawn mower blades 32 B and 32 C to the shaft 50 of the engine 28 . For illustration purposes, belts 213 B and 213 C are shown connecting the lawn mower blades 32 B and 32 C to the rotating shaft 50 . The drive belt 62 is shown connecting the alternator assembly 34 with the rotating drive shaft 50 of the engine 28 .
FIG. 17 illustrates a side view of a hitch assembly 214 attached to the hybrid remote control lawn mower 10 . The hitch assembly 214 includes a hitch support arm 216 , a hitch pin 218 and a tow bar 220 . The hitch support arm 216 is attached to the frame 12 of the hybrid remote control lawn mower 10 . The hitch support arm 216 includes a mounting hole 224 . The hitch pin 218 passes through the mounting hole 224 . The hitch pin may be any suitable form (e.g., hitch ball, straight pin, etc.). It was discovered that hitching the metallic tow bar 220 to the metallic frame 12 and to the metallic hitch pin 218 and to the metallic hitch support arm 216 would create radio wave signal 98 interference between the remote transmitter apparatus 40 and the receiver apparatus 42 . To solve this interference problem it was discovered that electrical insulation must be provided somewhere in the path between the hitch support arm 216 and the tow bar 220 . One solution is to provide electrical insulation between the hitch support arm 216 and the hitch pin 218 . This insulation may include any suitable material (e.g., ceramic, acetal resin plastic, nylon, polyethylene, etc.). Another solution is to have the hitch pin 218 made from an electrical insulation material. The insulation material may include any suitable material (e.g., ceramic, acetal resin plastic, polyethylene, etc.). Another solution is to have the tow bar 220 include an insulation portion 222 . This insulation portion 222 may include any suitable material (e.g., wood, fiberglass, polyethylene, etc.).
FIG. 18 illustrates a side view of another embodiment of a hybrid remote control lawn mower 10 F. The hybrid remote control lawn mower 10 F includes the hitch assembly 214 and a wagon apparatus 226 connected to the hybrid remote control lawn mower 10 F. The wagon apparatus 226 may be used to carry any suitable material (e.g., dirt, sand, plants, etc.). The tow bar 220 of the wagon apparatus 226 may be demountably connected to the hitch pin 218 of the hitch assembly 214 . The hybrid remote control lawn mower 10 F may pull or push the wagon apparatus 226 along the support surface 84 . The operator inputs desired commands to the remote control lawn mower 10 F through the remote transmitter apparatus 40 .
FIG. 19 illustrates a side view of another embodiment of a hybrid remote control lawn mower 10 G. The hybrid remote control lawn mower 10 G includes the hitch assembly 214 and a spreader apparatus 228 connected to the hybrid remote control lawn mower 10 G. The spreader apparatus 228 may be used to spread any suitable material 230 (e.g., fertilizer, seed, deice, etc.) upon the support surface 84 . The tow bar 220 of the spreader apparatus 228 may be demountably connected to the hitch pin 218 of the hitch assembly 214 . The hybrid remote control lawn mower 10 G may pull the spreader apparatus 228 along the support surface 84 . The operator inputs desired commands to the remote control lawn mower 10 G through the remote transmitter apparatus 40 .
FIG. 20 illustrates a side view of another embodiment of a hybrid remote control lawn mower 10 H. The hybrid remote control lawn mower 10 H includes the hitch assembly 214 and a dethatcher apparatus 232 connected to the hybrid remote control lawn mower 10 H. The dethatcher apparatus 232 may be used to remove thatch from the lawn 52 . The tow bar 220 of the dethatcher apparatus 232 may be demountably connected to the hitch pin 218 of the hitch assembly 214 . The hybrid remote control lawn mower 10 H may pull the dethatcher apparatus 232 along the support surface 84 . The operator inputs desired commands to the remote control lawn mower 10 H through the remote transmitter apparatus 40 .
FIG. 21 illustrates a side view of another embodiment of a hybrid remote control lawn mower 10 I. The hybrid remote control lawn mower 10 I includes the hitch assembly 214 and a lawn clippings collector apparatus 234 connected to the hybrid remote control lawn mower 10 I. The tow bar 220 of the lawn clippings collector apparatus 234 may be demountably connected to the hitch pin 218 of the hitch assembly 214 . A lawn clippings conduit 236 connects a lawn exhaust port 238 with a lawn clippings collector port 240 . The lawn exhaust port 238 is an opening in the deck apparatus 26 . The lawn clippings collector port 240 is an opening in the side of a collection bin 242 . Ground up lawn clippings 244 are blown through the lawn exhaust port 238 , through the lawn clippings conduit 236 and through the lawn clippings collector port 240 into the collection bin 242 . The lawn mower blade 32 chops up the lawn 52 into ground up lawn clippings 244 and the air pressure built up in the deck apparatus 26 blows the ground up lawn clippings 244 from the deck apparatus 26 , through the lawn clippings conduit 236 and into the collection bin 242 . Optionally, a supplemental air blower device 246 (shown in dotted lines) may be added to provide additional air flow to blow the lawn clippings 244 up through the lawn clippings conduit 236 into the collection bin 242 . The hybrid remote control lawn mower 10 I pulls the lawn clippings collector apparatus 234 along the support surface 84 . Use of the hybrid remote control lawn mower 10 I with the lawn clippings collector apparatus 234 is not limited to lawn clippings but may be used in a similar manner for grinding up and collecting leaves. The operator inputs desired commands to the remote control lawn mower 10 I through the remote transmitter apparatus 40 .
Another embodiment of the hybrid remote control lawn mower 10 I including a leaf blower apparatus 248 is illustrated in FIG. 21 . The leaf blower apparatus 248 may be demountably attached to the frame 12 of the hybrid remote control lawn mower 10 I. The leaf blower apparatus 248 includes a blower 250 , a conduit 252 and an exhaust nozzle 254 . The blower 250 provides pressurized air 251 . The pressurized air 251 flows through the conduit 252 and ejects from the exhaust nozzle 254 onto the support surface 84 . The blower 250 may include any suitable power means including an internal combustion engine or an electric motor. The electric motor may be powered by the battery 36 of the hybrid remote control lawn mower 10 I. The pressurized air ejecting from the exhaust nozzle 254 of the leaf blower apparatus 248 may be used to blow lawn clippings 244 or leaves from a support surface 84 . While the leaf blower apparatus 248 is operating the hybrid remote control lawn mower 10 I may be controlled to travel along any desired path while the leaf blower apparatus blows lawn clippings 244 or leaves away from the support surface 84 . The operator inputs desired commands to the hybrid remote control lawn mower 10 I through the remote transmitter apparatus 40 . These commands may include turning on and off the blower 250 of the leaf blower apparatus 248 .
FIG. 22 illustrates a front view of another embodiment of a hybrid remote control lawn mower 10 J. The hybrid remote control lawn mower 10 J includes a support frame apparatus 255 and a weed trimmer apparatus 254 . The support frame apparatus 255 is attached to the frame 12 of the hybrid remote control lawn mower 10 J. The weed trimmer apparatus 254 may be demountably attached to the support frame apparatus 255 . The weed trimmer apparatus 254 includes a motor 256 , a drive shaft 258 and a trimmer blade 260 . The motor 256 spins the drive shaft 258 which spins the trimmer blade 260 . The trimmer blade 260 is positioned to trim lawn 52 . The trimmer blade 260 may be any suitable cutting blade (e.g., string cutter, metallic blade, etc.). The motor 256 may be any suitable motor (e.g., gasoline, electric, etc.). The electric motor may be powered by the battery 36 of the remote control lawn mower 10 J. While the weed trimmer apparatus 254 is operating, the hybrid remote control lawn mower 10 I may be controlled to travel along any desired path while the weed trimmer apparatus 254 trims the lawn 52 or weeds. Optionally, a counter balance weight 262 (shown with dotted lines) may be demountably attached to the support frame 12 . The counter balance weight 262 may be used to counterbalance the weight of the weed trimmer apparatus 254 to prevent the hybrid remote control lawn mower 10 J from tipping. FIG. 23 illustrates a side view of the weed trimmer apparatus 254 demountably attached to the support frame apparatus 255 . The operator inputs desired commands to the hybrid remote control lawn mower 10 J through the remote transmitter apparatus 40 . These commands may include turning on and off the motor 256 of the weed trimmer apparatus 254 .
FIG. 24 illustrates a front view of another embodiment of a hybrid remote control lawn mower 10 K. The hybrid remote control lawn mower 10 K includes a support frame apparatus 255 A and an edge trimmer apparatus 263 . The support frame apparatus 255 A is attached to the frame 12 of the remote control lawn mower 10 K. The edge trimmer apparatus 263 may be demountably attached to the support frame apparatus 255 A. The edge trimmer apparatus 263 includes a motor 256 A, a drive shaft 258 A and an edger blade 264 . The motor 256 A spins the drive shaft 258 A which spins the edger blade 264 . The edger blade 264 is positioned to trim lawn 52 at an edge of a walkway 268 . The edger blade 264 may be any suitable cutting blade (e.g., string cutter, metallic blade, etc.). The motor 256 A may be any suitable motor (e.g., gasoline, electric, etc.). The electric motor may be powered by the battery 36 of the hybrid remote control lawn mower 10 K. While the edger apparatus 263 is operating, the hybrid remote control lawn mower 10 K may be controlled to travel along any desired path while the edger trimmer apparatus 263 trims the lawn 52 or weeds along the edge of the walkway 268 . Optionally, the counter balance weight 262 (shown with dotted lines) may be demountably attached to the support frame 12 . The counter balance weight 262 may be used to counterbalance the weight of the edge trimmer apparatus 263 to prevent the remote control lawn mower 10 K from tipping. FIG. 25 illustrates a side view of the edge trimmer apparatus 263 demountably attached to the support frame apparatus 255 . The operator inputs desired commands to the hybrid remote control lawn mower 10 K through the remote transmitter apparatus 40 . These commands may include turning on and off the motor 256 A of the edge trimmer apparatus 263 .
FIG. 26 illustrates a front view of another embodiment of a hybrid remote control lawn mower 10 L. The hybrid remote control lawn mower 10 L includes a support frame apparatus 255 B and a hedge trimmer apparatus 270 . The support frame apparatus 255 B is attached to frame 12 of the hybrid remote control lawn mower 10 L. The hedge trimmer apparatus 270 may be demountably attached to the support frame apparatus 255 B. The hedge trimmer apparatus 270 includes a motor 256 B, a drive shaft 258 B and a hedge trimmer blade 272 . The motor 256 B spins the drive shaft 258 B which drives the hedge trimmer blade 272 . The hedge trimmer blade 272 is positioned to trim a hedge 274 . The hedge trimmer blade 272 may be any suitable blade (e.g., single sided, double sided, etc.). The motor 256 B may be any suitable motor (e.g., gasoline, electric, etc.). The electric motor may be powered by the battery 36 of the hybrid remote control lawn mower 10 L. While the hedge trimmer apparatus 270 is operating, the hybrid remote control lawn mower 10 L may be controlled to travel along any desired path along the surface 84 while the hedge trimmer blade 272 is cutting along the hedge 274 . Optionally, the counter balance 262 may be demountably attached to the support frame 12 . The counter balance weight 262 may be used to counter balance the weight of the hedge trimmer apparatus 270 to prevent the hybrid remote control lawn mower 10 K from tipping. The operator inputs desired commands to the hybrid remote control lawn mower 10 L through the remote transmitter apparatus 40 .
FIGS. 27 and 28 illustrate another embodiment of a hybrid remote control lawn mower 10 M. FIG. 27 illustrates a side view of the hybrid remote control lawn mower 10 M. FIG. 28 illustrates a front view of the hybrid remote control lawn mower 10 M. The hybrid remote control lawn mower 10 M includes a track drive apparatus 275 . The track drive apparatus 275 includes a left front wheel assembly 276 L, a left track 278 L, a left rear drive wheel assembly 280 L, a right front wheel assembly 276 R, a right track 278 R and a right rear wheel drive assembly 280 R. As illustrated in FIG. 27 , the left front wheel assembly 276 L is attached to the frame 12 of the hybrid remote control lawn mower 10 M. The left rear drive wheel assembly 280 L is connected with the left rear motor apparatus 16 . The left track 278 L couples the left rear drive wheel assembly 280 L with the left front wheel assembly 276 L. As illustrated in FIG. 28 , the right front wheel assembly 276 R is attached to the frame 12 of the hybrid remote control lawn mower 10 M. The right rear drive wheel assembly 280 R is connected with the right rear motor apparatus 14 . The right track 278 R couples the right rear drive wheel assembly 280 R with the right front wheel assembly 276 R. In a similar manner as described in the remote control lawn mower 10 ( FIGS. 1-5 ) the right rear motor apparatus 14 may drive the right rear drive wheel assembly 280 R in a forward (direction arrow 81 F) or in a backwards direction (direction arrow 81 B). The left rear motor apparatus 16 may drive the left rear drive wheel assembly 280 L in the forward (direction arrow 81 F) or in the backwards direction (direction arrow 81 B). To travel in the forward direction 81 F the right rear drive wheel assembly 280 R and the left rear drive wheel assembly 280 L rotate in the same forward direction 81 F to provide forward movement to the hybrid remote control lawn mower 10 M. To travel in a backward direction 81 B the right rear drive wheel assembly 280 R and the left rear drive wheel assembly 280 L rotate in the same backward direction 81 B. To travel in a straight line the right rear drive wheel assembly 280 R and the left rear drive wheel assembly 280 L rotate at the same speed. When traveling forward and turning right, the left rear drive wheel assembly 280 L rotates faster than the right rear drive wheel assembly 280 R. When traveling forward and turning left, the right rear drive wheel assembly 280 R rotates faster than the left rear drive wheel assembly 280 L. To provide zero turning radius to the right, the left rear drive wheel assembly 280 L rotates in the forward direction 81 F while the right rear wheel drive assembly 280 R rotates in the backward direction 81 B. To provide zero turning radius to the left, the right rear wheel drive assembly 280 R rotates in the forward direction 81 F and the left rear wheel drive assembly 280 L rotates in the backward direction 81 B. The operator inputs desired commands to the hybrid remote control lawn mower 10 M through the remote transmitter apparatus 40 .
FIG. 29 illustrates a side view of another embodiment of a hybrid remote control lawn mower 10 N. The hybrid remote control lawn mower includes a left rear track drive apparatus 282 L and a right rear track apparatus 282 R. The left rear track drive apparatus 282 L ( FIG. 29 ) replaces the left rear wheel apparatus 20 ( FIG. 1 ) of the embodiment of the hybrid remote control lawn mower 10 . The right rear track drive apparatus 282 R ( FIG. 29 ) replaces the right rear wheel apparatus 18 ( FIG. 1 ) of the first embodiment of the hybrid remote control lawn mower 10 . The left rear track drive apparatus 282 L includes a left rear track drive wheel 286 L, a left rear idler wheel 288 L, a left rear idler wheel 290 L and a left rear track 292 L. The right rear track drive apparatus 282 R includes a right rear track drive wheel 286 R, a right rear idler wheel 288 R, a right rear idler wheel 290 R and right rear track 292 R. The left rear track drive wheel 286 L is connected to the left rear motor apparatus 16 . The right rear track drive wheel 286 R is connected to the right rear motor apparatus 14 . The left rear track 292 L couples the left rear track drive wheel 286 L with the left rear idler wheel 288 L and the left rear idler wheel 290 L. The left rear track 292 L rests upon the support surface 84 . The right rear track 292 R couples the right rear track drive wheel 286 R with the right rear idler wheel 288 R and the right rear idler wheel 290 R. The right rear track 292 R rests upon the support surface 84 . A forward direction (direction arrow 81 F) and a backward direction (direction arrow 81 B) are shown in FIG. 29 . The left rear motor apparatus 16 may rotate the left rear track 292 L in a forward 81 F or backward direction 81 B. The right rear motor apparatus 14 may rotate the right rear track 292 R in a forward 81 F or backward 81 B direction. The left rear track 292 L and the right rear track 292 R provide forward and rear propulsion to the hybrid remote control lawn mower 10 N. The hybrid remote control lawn mower 10 M further includes the left front free swiveling wheel apparatus 24 and the right front swiveling wheel apparatus 22 . Details of the left front free swiveling wheel apparatus 24 and the right front swiveling wheel apparatus 22 are shown in FIG. 1 and described in the previous description of the first embodiment of the hybrid remote control lawn mower 10 . The hybrid remote control lawn mower 10 N steers and operates in a similar manner as included in the description of the embodiment of the remote control lawn mower 10 . The operator inputs desired commands to the hybrid remote control lawn mower 10 N through the remote transmitter apparatus 40 .
FIG. 30 illustrates a side view of another embodiment of a hybrid remote control lawn mower 10 P. The hybrid remote control lawn mower 10 P includes a blade apparatus 294 . The blade apparatus 294 includes a mounting member 296 and a blade 298 . The blade 298 is rigidly attached to the mounting member 298 . The mounting member 298 may be demountably attached to the frame 12 of the hybrid remote control lawn mower 10 P. The blade 298 may be any suitable shape (e.g., concave, flat, etc.). The blade 298 rests upon the support surface 84 . The hybrid remote control lawn mower 10 P pushes the blade 298 towards a pile of loose material 300 (e.g. snow, dirt, sand, etc.). When the hybrid remote control lawn mower 10 P moves in the forward direction (direction arrow 81 F), the blade pushes the loose material 300 in the forward direction 81 F). In this manner the hybrid remote control lawn mower 10 P may push loose material 300 to any desired location. The operator inputs desired commands to the hybrid remote control lawn mower 10 N through the remote transmitter apparatus 40 .
FIG. 31 illustrates a side view of another embodiment of the hybrid remote control lawn mower 10 Q. The hybrid remote control lawn mower 10 Q includes a fluid blade apparatus 304 . The fluid blade apparatus 304 includes a fluid blade 306 , a mounting element 308 and a pressurized air conduit 310 . The fluid blade 306 is rigidly attached to the mounting element 308 . The mounting element 308 may be demountably attached to the frame 12 of the hybrid remote control lawn mower 10 A.
The fluid blade 306 includes at least one fluid exhaust port 312 A, 312 B and 312 C as illustrated in a front view FIG. 32 of the fluid blade 306 . The deck apparatus 26 includes an air exhaust port 314 . Pressurized air 316 is built up in the deck apparatus by the spinning lawn mower blade 32 . The pressurized air conduit 310 connects the air exhaust port 314 with the at least one blade port 312 A, 312 B and 312 C. Pressurized air 316 travels from the deck apparatus 42 through the air exhaust port 314 , through the pressurized air conduit 310 and through the at least one fluid exhaust port 312 A, 312 B and 312 C. The remote control lawn mower 10 Q pushes the fluid blade apparatus 304 in the forward direction (direction arrow 81 F) towards the pile of loose material 300 (e.g., snow, dirt, sand, leaves, etc.). The pressurized air 316 builds up between a front blade surface 318 and the pile of loose material 300 . The pressurized air 316 reduces friction between the front blade surface 318 and the pile of loose material 300 and helps push the pile of loose material 300 in the forward direction 302 . Optionally, a pressurized air source apparatus 320 (shown in dotted lines FIG. 31 ) may supply pressurized air 316 to the pressurized air conduit 310 . The pressurized air source apparatus 320 may include any suitable power blower 322 (e.g., driven from the engine 28 , electric motor, etc.).
As illustrated in FIG. 32 an optional set of wheel assemblies 324 L and 324 R may be attached to the fluid blade 306 . The wheel assembly 324 L includes a wheel 326 L. The wheel assembly 324 R includes a wheel 326 R. The wheels 326 L and 326 R roll along the support surface 84 and may support the fluid blade 306 slightly above the support surface 84 , thereby reducing the friction between the support surface 84 and the fluid blade 306 . The operator inputs desired commands to the hybrid remote control lawn mower 10 P through the remote transmitter apparatus 40 .
FIG. 33 illustrates a side view of another embodiment of a hybrid remote control lawn mower 10 R. The hybrid remote control lawn mower 10 R includes a snow blower apparatus 330 . The snow blower apparatus 330 includes a tow bar apparatus 220 A, a handle assembly 334 and a main body apparatus 336 . The main body apparatus 336 includes a snow blower motor 338 , a main housing 339 , a drive wheel assembly 340 , a front snow inlet section 342 , a snow ejection apparatus 344 and a snow discharge chute apparatus 347 . The handle assembly includes a main handle 335 and a blower control handle 337 . The hybrid remote control lawn mower 10 R includes a hitch assembly 214 A. The hitch assembly 214 A is similar to the hitch assembly 214 as shown in FIG. 17 and as previously described in the specification relating to FIG. 17 . The hitch support arm 216 is attached to the frame 12 of the hybrid remote control lawn mower 10 R. The hitch pin 218 is attached to the hitch support arm 216 . The hitch pin 218 may be any suitable form (e.g., hitch ball, straight pin, etc.). The tow bar apparatus includes a hitch pin connector 348 , a tow arm 350 and a clamp 352 . The hitch pin connector 348 is rigidly attached to the tow arm 350 . The clamp 352 is demountably attached to the main handle 335 of the handle assembly 334 . The clamp 352 may include any suitable means of clamping (e.g., hose clamp, bolt and nut, etc.). Alternatively, the clamp 352 may be demountably attached to the main body housing 339 of the snow blower apparatus 330 . The hitch pin connector 348 may be demountably attached to the hitch pin 218 . As previously described, electrical insulation may be provided somewhere in the path between the hitch pin support arm 216 and the tow arm 350 . This is described in the specification section relating to FIG. 17 . The snow discharge chute apparatus 347 includes a snow outlet chute 346 and a chute rotation apparatus 356 . The snow blower motor 338 provides power to the snow ejection apparatus 344 . The snow blower motor 338 may include any suitable motor (e.g. gasoline, electric, diesel, etc.). The battery 36 in the hybrid remote control lawn mower 10 R may provide power to an electric snow blower motor 338 . The snow ejection apparatus 344 may include any suitable means of blowing snow (e.g., single stage impeller, dual stage auger with impeller, etc.). Snow 352 enters the front snow inlet section 342 and the snow ejection apparatus 344 blows the snow through the snow outlet chute 346 . The chute rotation apparatus 356 provides a means of rotating the snow outlet chute 346 to blow snow in any selected direction (e.g., forward, to the right, to the left, etc.) away from the snow blower apparatus 330 . The chute rotation apparatus 356 may include an electric chute motor 358 to rotate the snow outlet chute 346 . The electric chute motor 358 is controlled by the brain control system 44 . A cable 360 electrically connects the brain control system 44 with the electric chute motor 358 . The brain control system 44 sends electrical signals to the electric chute motor 358 to enable the electric chute motor to rotate the snow outlet chute 346 in a desired direction. FIG. 7 illustrates a front view of the remote transmitter apparatus 40 . If the operator pushes the input control stick 126 in an upward direction (direction arrow 362 FIG. 7 ), the snow outlet chute 346 will rotate in a clockwise direction (direction arrow 370 FIG. 33 ). If the operator pushes the input control stick 126 in a downward direction (direction arrow 366 FIG. 7 ), the snow outlet chute 346 will rotate in a counter clockwise direction (direction arrow 372 FIG. 33 ). If the operator releases the input control stick 126 , the input control stick 126 returns to the center position 132 ( FIG. 7 ) and the snow outlet chute 346 stops rotating. Optionally, the remote control lawn mower 10 R may include the wireless video camera 170 A and the wireless video camera 170 B ( FIG. 11 and FIG. 33 ). The wireless video camera 170 A provides a video view in a direction (direction arrow 380 ) away from the snow blower apparatus 330 . The wireless video camera 170 B provides a video view in a direction (direction arrow 382 ) towards the snow blower apparatus 330 . The operator may view the video views from the video cameras 170 A and 170 B on the video display unit 176 .
The operator starts the snow blower motor 338 and depresses the blower control handle 337 in a downward direction (direction arrow 384 ). When depressed the blower control handle 337 causes the snow ejection apparatus 344 to operate and to blow snow 352 through the snow outlet chute 346 . The blower control handle 337 is locked in the downward direction (direction arrow 384 ) to keep the snow ejection apparatus 344 in continuous operation. A drive wheel 386 of the snow blower apparatus 330 is free wheeling and provides no movement to the snow blower apparatus 330 . Thus the snow blower apparatus 330 is free to move along the support surface 84 . The operator uses the remote transmitter apparatus 40 to start the engine 28 of the hybrid remote control lawn mower 10 R. Detailed descriptions including the operation of the hybrid remote control transmitter apparatus 40 are included in a previous description relating to FIG. 7 . The operator uses the remote transmitter apparatus 40 to send a command to rotate the snow outlet chute 346 to a desired direction. Then the operator uses the remote transmitter apparatus 40 to command the hybrid remote control lawn mower apparatus 10 R to move in a direction (direction 382 ) towards the pile of snow 352 . The snow 352 enters the front snow inlet section 342 and the snow ejection apparatus 344 blows snow through the snow outlet chute 342 and away from the support surface 84 . The operator may use the remote transmitter apparatus 40 to send commands to the hybrid remote control lawn mower apparatus 10 R to steer in a direction to the right or to the left. Additionally, the operator may use the remote transmitter apparatus 40 to command the hybrid remote control lawn mower apparatus 10 R to move in direction (direction arrow 380 ) away from the pile of snow 252 . Then the front snow inlet section 342 is pulled away from the pile of snow 252 . The operator may be at a location in a building away from the remote control lawn mower 10 R. The operator uses the remote transmitter apparatus 40 to send commands to the remote control lawn mower 10 R. At the same time, the operator may look at the video display unit 176 to see video display views in the direction 380 away from the snow blower apparatus and in a direction 382 towards the snow blower apparatus. These video views allow the operator to see which way to steer the hybrid remote control lawn mower 10 R. To turn off the hybrid remote control lawn mower 10 R, the operator releases the blower control handle 337 to stop the snow ejection apparatus 344 . Then the operator turns off the snow blower motor 338 . Next the operator uses the remote transmitter apparatus 40 to command the hybrid remote control lawn mower 10 R to drive near a desired parking location. If desired, the operator may use the remote transmitter apparatus 40 to turn off the engine 28 of the hybrid remote control lawn mower. Then the operator may use the remote transmitter apparatus 40 to send commands to the hybrid remote control lawn mower 10 R to use the battery powered right rear motor apparatus 14 and the left rear motor apparatus 16 to steer and propel the remote control lawn mower 10 R to the desired parking location.
The foregoing description 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 form disclosed, and many modifications and variations are possible in light of the above teaching. For example, the remote transmitter apparatus 40 and the receiver apparatus 42 may include any number of channels. Additional channels may be used for any suitable application such as engine 28 speed control, switching power on and off to other devices (e.g., leaf blower 248 , weed trimmer 254 , edge trimmer 263 , hedge trimmer 270 , etc.). Such modifications and variations that may be apparent to a person skilled in the art are intended to be included within the scope of this invention as defined by the accompanying claims.
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A hybrid remote control lawn mower that includes embodiments to provide use in all seasons. These embodiments include, a wagon, a spreader, a dethacher, a leaf collector, a leaf blower, a lawn trimmer, a lawn edger, an edger, a hedge trimmer, a snow plow blade, a snow blower, etc. The hybrid remote control lawn mower allows an operator to stay at a safe distance away from the hybrid remote control lawn mower in dangerous places such as on steep hills.
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BACKGROUND OF THE INVENTION
This invention relates generally to heat exchangers and more particularly to the structure of plate-type air-to-air heat exchangers. Numerous types of heat exchangers have been utilized to effect the transfer of heat from one stream of gases to another. As heat energy becomes increasingly expensive, a wide range of applications is being found for air-to-air heat exchangers. Many of these applications involve a process or application that contaminates the air, requiring that it be exhausted after being heated and that fresh air be supplied and heated. Examples of this situation include the traditional single pass of air through clothes dryers and forced air heated buildings, in which fresh, ambient air of relatively low humidity is heated and circulated through the dryer or building. As the air is circulated, it is humidified and acquires solid contaminates such as dust and lint. Conventionally, the air is then exhausted to the outside, with a resultant loss of its energy content.
It would be preferable to recover a portion of this energy by heat transfer to the incoming replacement air. Unfortunately, most prior attempts to do so have proven economically infeasible. It is possible to design a heat exchanger having a relatively high heat transfer efficiency, measured only in terms of heat recovered. However, the effectiveness of such heat transfer has proven marginal at best when measured additionally in terms of the value of the heat recovered in proportion to the cost of the apparatus to effect recovery.
A primary problem in the design of air-to-air heat exchangers is to transfer as much input heat as possible from the exhaust airflow path to the incoming airflow path while minimizing the energy required to pump the air through the system. A preferred form of heat exchanger for air-to-air heat transfer is the plate-type counterflow heat exchanger. Plate type parallel and cross-flow heat exchangers have also been used, such as disclosed in U.S. Pat. No. 2,959,400 to Simpelaar, but are less efficient than counterflow heat exchangers. The counterflow arrangement yields higher heat transfer efficiencies but heretofore has required complex and awkward header arrangements such as those of U.S. Pat. No. 2,019,351 to Lathrop, U.S. Pat. No. 2,937,856 to Thomson, and U.S. Pat. Nos. 3,581,649 and 4,184,538 to Rauenhorst.
Such arrangements create bends or folds in the airflow path which cause momentum changes in the airflows. Consequently, added pumping energy is required to move the airflows through the heat exchanger. Abrupt changes of direction also encourage accumulations of solid contaminants within the heat exchanger. Such accumulations lead to plugging thereby reducing the efficiency of the heat exchanger and further increasing its operating cost due to impedence of the airflows through the device. Additionally, such devices are extremely difficult to clean. As a result, a primary design goal for counterflow heat-type exchangers has been to attain a plate arrangement and header configuration which yields high heat transfer efficiencies and yet minimizes the required fan energy, to compensate for pressure drop across the heat exchanger. The need to minimize bending of airflows and changes of cross-sectional area have also been recognized. However, no prior design of parallel plate-type heat exchanger has succeeded in achieving these goals.
Also of importance is the mass producibility of the device, particularly the ease of manufacturing and assembling the plates and headers. U.S. Pat. No. 2,937,856 utilizes complicated stampings. U.S. Pat. No. 2,019,351 utilizes a complicated enclosure and seals. Physical size changes in most type of heat exchangers for each application require custom design and manufacturing of many sizes of the various components. Consequently, the design, manufacture and assembly of heat exchangers is too expensive for many applications in which the value of heat recovered is low in proportion to the cost of recovery.
Accordingly, a need remains for an air-to-air heat exchanger which is both efficient and cost effective, even for relatively low-value energy recovery applications, such as to hot air dryers and forced air heating systems in buildings.
SUMMARY OF THE INVENTION
One object of the invention is to provide an improved plate-type air-to-air heat exchanger.
A second object of the invention is to arrange a counterflow plate-type heat exchanger to maximize heat transfer efficiency with a minimum of pressure losses through the heat exchanger and duct airways.
Another object is to minimize the susceptibility of air-to-air plate-type heat exchangers to accumulations of contaminants, and to make such heat exchangers easy to clean.
A further object is to simplify the design of air-to-air, plate-type heat exchangers so that they can be inexpensively manufactured and assembled.
Yet another object is to provide a modular design of air-to-air, plate-type heat exchanger which can be readily changed in size, without redesigning the size and configuration of components, to handle different volumes of airflow.
An air-to-air plate heat exchanger in accordance with the invention comprises a plurality of similar elongated plates arranged in a parallel array and spaced apart to define one or more pairs of adjoining enclosed elongated passageways. Each pair includes an incoming airway and an exhaust airway. Each plate in the array has pointed opposite ends, each end terminating at an apex along a widthwise midline extending lengthwise of the passageways. A first means defining an air inlet conduit is connected at one end of the array of plates, on one side of the midline, for conveying air into one of the airways. A second means defining an air discharge conduit is similarly connected to a diagonally opposite end of the array of plates.
In a preferred embodiment, in which the plates are uniformly spaced, the midline is identical to a widthwise centerline of the plates. However, the midline is not identical to the centerline in the case of skew-symmetric plates. In such plates, each pointed end is defined by two edges of different lengths equal to the lengths of diagonally opposite edges of the opposite end of the plates. The latter arrangement might be used to transfer heat between gas flows of different densities or flow rates through adjacent airways of different plate spacings.
In one aspect of the invention, the inlet and discharge conduits extend parallel to the midline so that airflows from the inlet conduit through one airway in isolation from the other airway and out the outer discharge conduit with a minimum change of momentum. Both airways have separate air inlet and outlet ducts connected thereto, all preferably extending parallel to the airways. Alternate passageways in the heat exchanger are connected to one of the conduits while an intervening passageway is closed to communication with that conduit by an end closure means extending along one side of the pointed end of the array. The end closure means shunts an airflow widthwise of the intervening passageway to an opposite side of the midline. The latter passageway communicates with the adjoining conduit through a staggered opening on the opposite side of the pointed end of the plate array. The end closure means is preferably shaped to streamline the airflow into and out of the plate array to minimize turbulence of the air entering and exiting the passageways.
A second aspect of the invention is that the conduits are sized to provide each conduit with a cross-sectional area equal to the total cross-sectional area of the airways to which such conduit is connected. The openings into and out of the passageways preferably have a dimension parallel to the plates which equals the width of the passageway, measured widthwise of the plates.
Another aspect of the invention is a heat exchanger plate arrangement, wherein a first plate comprises a rectangular planar elongated plate member having parallel opposite widthwise edges and lengthwise ends which are diagonally truncated so that the plates are pointed at each end. The end portions of the plate members have terminal edges which obliquely intersect the widthwise edges of the plate member and intersect at an apex along the lengthwise midline of the plate member. Interconnecting means connect the first plate along one widthwise edge to an adjoining edge of a second plate and along the opposite widthwise edge to an adjoining edge of a third plate. The second and third plates are spaced from the first plate on opposite sides thereof. Preferably, the interconnecting means comprise a marginal portion of each widthwise edge of the plate member which is folded out of the plane of the plate member to nest with complementary folded marginal portions of the second and third plates. The size of the folded marginal portions determines the spacing of the plates. Preferably, the marginal portions are rolled in opposite directions so as to define in cross-section an S-shape in one plate and a reverse S-shape in the other plate. The pointed end portions likewise have their edges rolled in opposite directions, diagonally opposite edge portions being rolled in the same direction so that, upon assembly, such plates are all interlocked together.
For use in transferring heat from the exhaust of a hot air dryer, which contains small solid contaminates even after passage through a filter, a preferred plate spacing is about 1/4" and a preferred heat exchanger length is about 54".
The foregoing and other objects, features and advantages of the invention will become more readily apparent from the following detailed description which proceeds with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front elevational view of a hot air clothes dryer incorporating an air-to-air counterflow plate heat exchanger in accordance with the invention.
FIG. 2 is an enlarged vertical-lengthwise sectional view of the heat exchanger portion of FIG. 1, portions of the interior plate structure being cut away to show airflows.
FIG. 3 is a transverse sectional view taken along line 3--3 in FIG. 2.
FIG. 4 is a transverse sectional view taken along line 4--4 in FIG. 2.
FIG. 5 is a transverse sectional view taken along line 5--5 in FIG. 2.
FIG. 6 is a schematic perspective view of the heat exchanger of FIGS. 1 and 2.
FIG. 7 is a top plan view taken along line 7--7 in FIG. 2, portions of the duct and housing being cut away to show interior details of the heat exchanger, and the manner of division and recombination of incoming and exhaust airflows.
FIG. 8 is a plan view of a single plate of the type used in the heat exchanger of FIG. 1, shown at an intermediate stage of fabrication.
FIG. 9 is a plan view showing the plate of FIG. 8 rolled along its margins to form a right hand plate.
FIG. 10 is a plan view showing the plate of FIG. 8 rolled along its margins to form a left hand plate.
FIG. 11 is a cross-sectional view taken along lines 11--11 in FIGS. 9 and 10, showing adjoining portions of the right and left hand plates, nested together to interconnect the plates and define a side of an airway of the heat exchanger of FIG. 1.
DETAILED DESCRIPTION
Referring to FIG. 1, an air-to-air counterflow plate-type heat exchanger 10 in accordance with the invention is connected at one end to a conventional, industrial-type clothes dryer 12 via a fresh air inlet duct 14 and a warm air discharge duct 16. These ducts or conduits are connected to the dryer in conventional fashion to convey warmed fresh air 18a into the dryer through duct 14 and to discharge warm, moist exhaust air 20 from the dryer via duct 16. At the opposite end of heat exchanger 10 from the dryer, an incoming air duct 22 and fan 22a induces fresh ambient air 18 into the heat exchanger, to flow ultimately into the dryer through duct 14 as warmed fresh air 18a. An exhaust outlet duct 24 is connected to the heat exchanger above the fan for conveying to an outside outlet exhaust air 20a, cooled by the transfer of heat in the heat exchanger into the incoming fresh air 18. The duct pairs 14, 16 and 22, 24 are horizontally divided adjacent their connections to the heat exchanger by common horizontal divider walls 15 and 23, respectively. A condensate drain tube 26 with a water trap elbow 26a is connected to the underside of discharge duct 16 adjacent heat exchanger 10. Tube 26 collects moisture condensed from the moist exhaust air and conveys it to any suitable drain outlet, such as to a drain pipe serving an adjacent washing machine (not shown). An air filter 28 is positioned in exhaust air duct 16 between the dryer and the heat exchanger to filter sizeable solid contaminats, such as dust and lint, out of the exhaust air flow before it enters to heat exchanger.
The overall structure of heat exchanger 10, and its manner of interconnection to ducts 14, 16 and 22, 24, is best understood by reference to the schematic diagram of FIG. 6 and the longitudinal sectional view of FIG. 2. Th heat exchanger comprises an array of similar parallel spaced heat exchanging plates 30, 32. The array of plates 30, 32 is housed within a sheet metal enclosure defined by top and bottom walls 34, 36 and opposite side walls 38, 40, best seen in FIGS. 3-5. Surrounding connector flanges 42, 44 (FIG. 1) connect the heat exchanger at opposite ends of the housing to the pairs of ducts 16, 18 and 22, 24. A portion of the pairs of ducts immediately adjacent each end of the heat exchanger extends parallel to the walls of the heat exchanger housing. The common walls 15, 23 of such ducts are aligned with a midline 11 extending lengthwise of the heat exchanger. In the particular embodiment shown, wherein the heat exchanger plates are symmetrical in shape, midline 11 is the same as the lengthwise centerline of the plates of the heat exchanger.
Plates 30, 32 are all similarly sized and shaped in accordance with the shape of an elongated hexagon, as better seen in FIGS. 9 and 10. Thus, each plate has a pair of elongated opposite edges 46, 48 defining the widthwise dimension of the plates. End portions 50, 52 of each plate are diagonally truncated to define pointed ends of the plates. The end portions 50, 52 each have a diagonal upper edge 54, 55 and a diagonal lower edge 56, 57, repsectively. The diagonal edges each intersect their respectively adjacent widthwise edges 46, 48 of the plate body at an angle 58, preferably of 30°. The diagonal edges of each end of plates 30, 32 also intersect an an apex at an angle of 60°.
The plates 30, 32 and housing side walls 38, 40 define pairs of airways 60, 62 carrying opposite direction airflows 18, 20, respectively. Staggered on upper and lower sides of the ends 50, 52 of the plate array are alternating inlet openings 64, 66 and discharge openings 65, 67. Openings 65, 66 are positioned on the upper and lower sides, respectively, of the end of the heat exchanger adjacent the dryer. Openings 64, 67 are similarly located at the end remote from the dryer. Alternating between the end openings on each upper and lower side of the pointed ends of the plate array are staggered end closure elements 68, 70, which close off airflow communication between alternate airways and one of the ducts. For example, as shown in FIG. 6, opening 64 provides airflow communication between airway 60 and conduit 22 so that incoming air 18 can flow from the duct into the heat exchanger on the underside of the leftward pointed end of the heat exchanger. Similarly, opening 66 provides airflow communication between airway 62 and duct 24 so that exhaust air 20 can flow from the heat exchanger into the exhaust duct. Closure means 68 prevents air from flowing out of airway 60 into duct 24. A similar closure means 70 on the underside of the end of airway 62 similarly prevents airflow from airway 62 into duct 22.
Consequently, fresh ambient air 18 flowing in through duct 22 enters openings 64, flows through airways 60, and flows out of openings 65 at the opposite end of the heat exchanger into duct 14 (now as heated fresh air 18a) to be carried by duct 14 into the dryer. Simultaneously, warm moist exhaust air 20 flows from the dryer via duct 16 into the heat exchanger through inlet openings 66 staggered along the underside of end 52 of the array of plates. The warm air then flows through airways 62, losing heat through plates 30, 32 to the fresh air in airways 60. Finally, the exhaust air is discharged into conduit 24 from the heat exchanger through openings 67, staggered along the upper side of end 54 of the array of plates, at a reduced temperature due to the loss of heat to the incoming fresh air.
FIGS. 8-11 show the manufacturing development and assembly of plates 30, 32 in further detail. Initially, a plate blank 30 is stamped or cut out of flat sheet metal to the shape previously described generally and specifically as shown in FIG. 8. An excess narrow marginal portion 72 is provided along each edge of the plate. The marginal portion is notched at each intersection 74 between the widthwise edges 46, 48 and the diagonal edges 54-57 of the end portions of the plate. The marginal portions meet at the point or apex of each end of the plate to form a blunt end 76. The blunt ends can be slotted along midline 11 to receive a marginal end portion of the common walls 15, 23.
Referring to FIGS. 9 and 10, the marginal portions of plate blank 31 of FIG. 8 are rolled as next described to form mirror image right and left hand plates 30, 32. In FIG. 9, the right hand plate 30 has its upper widthwise margin 46a rolled clockwise, as shown in FIG. 11. Its lower widthwise marginal portion 48a is likwise rolled clockwise to the opposite side of the plate. Referring to FIG. 10, the upper and lower margins, 46b, 48b of plate 32 are rolled in the opposite directions of margins 46a, 48a.
The marginal portions of the plates are rolled in semicircles of different radii so that adjoining edges 46a, 46b of plates 30, 32 can be nested together, as shown in FIG. 11. The rolled margins thereby connect plates 30, 32 together and enclose one side of airway 62 therebetween. Each plate 30 has, in cross-section, an S-shape and each plate 32 a reverse S-shape, as best seen in FIG. 4. The lower marginal portions 48a, 48b are likewise rolled to different radii so that each plate has an edge portion of the larger radius and an edge portion of the smaller radius. The lower edge portion 48b of plate 32 is thus sized to receive the lower edge portion 48a of a second right hand plate 30.
An array of three such plates 30, 32, 30 nested together thus defines a pair of airways 60, 62 which are enclosed along opposite edges 46, 48 to segregate the opposite incoming and exhaust airflows 18, 24. This arrangement can be repeated indefinitely to increase the lateral width of the plate array as needed to match the volume of airflow which needs to be processed by the heat exchanger.
Referring back to FIGS. 9 and 10, the upper diagonal edges 54, 55 of the end portions of the plates are rolled in directions opposite from one another and in accordance with the same radius as their respective adjoining widthwise edge of the plate body. Accordingly, upper diagonal edge 54a of plate 30 is rolled in the same direction and at the same radius as upper widthwise edge 54a and upper diagonal edge 55a, at the opposite end of plate 30 is rolled in the opposite direction of edge 46a but in accordance with the same radius. Upper edges 54b, 55b of plate 32 are rolled in accordance with the same radius as widthwise edge 46b, but diagonal edge 55b is rolled in the opposite direction. Similarly, the lower diagonal edges 56a, 57a are rolled to the same radius as widthwise edge 48a, with edge 57a being oppositely rolled, and the lower edges 56b, 57b of plate 32 are rolled in the opposite directions in accordance with the smaller radius of widthwise edge 48b.
Consequently, in the plate array of FIGS. 3 and 5, the rolled diagonal edges of different radii nest together to interconnect the end portions of the plates. Because each plate has diagonal edge portions rolled in opposite directions, along both the upper and lower edges of the plate, the plates interlock with adjoining plates on both sides. As a result, a plurality of such plates fitted together to form an array interlock and thereby avoid the necessity of welding, riveting or screwing the plates together.
To fit right and left hand plates together, the plates are initially positioned diagonally, with the left hand plate atop the right hand plate and end 52b spaced below and directed toward edge 46a. Then, the left hand plate 32 is slid parallel to right hand plate 30 toward end portion 52a to nest the upper edge portion 46b of the left hand plate within the upper margin 46a of the right hand plate and to nest the lower diagonal edge 57b of plate 32 into the lower diagonal edge 57a of plate 30. A second right hand plate 30 is then positioned atop the left hand plate, with its end portion 52a spaced above and directed toward the lower margin 48b of plate 32. It is then slid rightwardly until margin 48a is received in margin 48b and margin 55a is received in margin 55b. This process is repeated until a sufficient number of plates have been assembled into an array to accommodate the volume of air to be processed for a particular situation.
Referring to FIG. 7, it can be seen that the rounded diagonal edges at the pointed ends of th plates provide curved or rounded shapes at the ends of the heat exchanger. These shapes streamline the incoming airflow 18 as such airflow divides around the ends of the plates to enter openings 64 on the underside of the end of the plate array. Similarly, such shape streamlines the recombination of airflows 20a flowing from openings 67 along the upper side of the end of the plate array. Although a semicircular shape of such ends is utilized for simplicity, one skilled in the art would recognize that the air foil characteristics of the plate ends can be further optimized.
It is preferable to make the spacing of the plates as narrow as possible. It should not be apparent that the radii of the edges of the plates determines plate spacing. By increasing such radii, plate spacing is increased and conversely by reducing the radius, plate spacing is reduced. For use in exchanging heat between airflows wherein one airflow contains solid contaminants, I have discovered that there is a minimum plate spacing, below which build-up of contaminants occurs and rapidly reduces the efficiency of the heat exchanger. For use in a hot air dryer system, I have found that that minimum spacing is about 1/4". Accordingly, for such application the preferred spacing is 0.28". The plate spacing affects the efficiency of heat exchange in an inverse functional relationship to the length of the heat exchanger. I have found that the most effective heat transfer occurs in my heat exchanger, with the plates spaced 0.28" apart, when the length of the heat exchanger along edges 46, 48 is about 54". A preferred width for the plates is 111/2".
Referring back to FIGS. 2 and 6, the airflows from the ducts into and out of the heat exchanger follow a nearly straight line. This arragement minimizes changes of momentum of the gases flowing through the heat exchanger and thereby reduces resultant pressure losses compared to prior forms of counterflow heat exchangers. Also, each airflow path has a constant cross-sectional area through the ducts and heat exchanger, and thereby avoids contacting or expanding the gases and thus reduces resistance losses in pressure. Particularly important is the fact that the dimensions of the openings 64, 65, 66, 67 are the same as the vertical sectional dimensions of the passageways 60, 62. In other words, edges 54-57, when rolled, have a length twice the widthwise dimension of the passageways within the plates. The ducts have a vertical dimension equal to half of the vertical width of the passageways, but the useful horizontal dimension of such ducts is twice as great, because only half of the airways feed into each duct. Finally, airflow losses due to eddies and turbulence are minimized by the rolled edges 54-57 which streamline the airflows as they divide and recombine upon entering and leaving the heat exchanger.
Having illustrated and described the principles of my invention in a preferred embodiment, it should be readily apparent that the invention can be modified in arrangement and detail without departing from such principles. Accordingly, I claim all modifications coming within the scope and spirit of the following claims:
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A parallel plate air-to-air counterflow heat exchanger employs a parallel array of spaced plates of similar elongated hexagonal shape. A pair of inlet and outlet ducts is connected to each lengthwise pointed end of the array. Each duct communicates with alternate airways via rectangular openings staggered on opposite sides of the ends of the array. The ducts extend parallel to a lengthwise midline of the array to enable air flow through the heat exchanger and ducts with minimal change of momentum and turbulence. The plates each have parallel widthwise margins which are oppositely rolled to different, complementary radii and adjacent plates are mutual mirror images. The plate margins nest together to interconnect the plates and enclose one side of each airway. A housing around the array encloses the opposite side of each airway. Opposite margins of the pointed end portions of the plates are rolled oppositely to interlock the plates, to define the staggered rectangular openings of their respective adjoining plate margins, and smoothly to divide and recombine the airflows into and out of each airway. A standard plate size is used and the number of plates is varied to accommodate different total volumes of airflow.
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TECHNICAL FIELD
The apparatus of the present invention relates generally to material transfer devices. The material transferred might include, but not be limited to, semiconductor wafers, such as Silicon, Gallium Arsenide, semi conductor packing substrates, such as, High Density Interconnects, semiconductor manufacturing process imaging plates, such as masks or recticles, and large area display panels, such as Active Matrix LCD substrates.
The invention further relates to vacuum robot drive technologies for handling wafers or flat panels and relates more particularly to improvements in such technologies whereby electrical power can be brought to the robot arm for purposes of, wafer sensing, wafer gripping and or other sensory applications while nevertheless allowing robot arm angular movement to achieve unlimited rotation through 360 degrees.
Current vacuum robot drive technology for handling wafers or flat panels does not allow electrical power to be brought to the robot arm while simultaneously allowing for unlimited rotation of the drive joint. Providing continuous theta axis rotation to the rotating drive arms in a robot as set forth above to provide unlimited rotational drive, except for example, as limited by the geometry of the robot arms themselves, has been a long felt need. It has always been conceived that if electrical power could be brought from the robot drive to the robot arm, sensing, clamping or measurement devices could be added to the arm linkage.
However, one concern of the electrical feed through was that it would limit the rotation of the arm. If a limit on shaft rotation was placed in such a robotic device, the advantage of the added devices, e.g. sensing, clamping and measuring, would decrease the present capabilities of the device and make them less appealing in the market place.
Accordingly, it is an object of the present invention to provide an unlimited rotation robot drive which allows electrical power to be brought from outside the atmosphere side of the drive unit and into the arms which reside in a vacuum environment.
It is further object of the invention to provide an unlimited angular movement robot drive capable of unlimited angular rotation for the purpose of providing electrostatic wafer clamping, wafer sensing, arm positioning measurement, arm acceleration measurement and wafer position measurement.
It is still a further object of the invention to provide a system which enables unlimited angular rotations of the coaxial drive vacuum robot which is capable of being modified existing coaxial drive structures.
Further objects and advantages of the invention will become apparent from the following disclosure independent claims.
SUMMARY OF THE INVENTION
The invention resides in a coaxial for use in wafer handling and relates more specifically to an improvement therefor whereby the drive is capable of angular rotations fully in a 360 degree circle without interference from electrical connections.
More specifically, the invention resides in a coaxial drive having one part exposed to atmosphere and another part exposed to vacuum. The drive comprises a base member secured to a housing extending vertically therefrom along a central axis, and a drive member having a generally hollow internal confine is disposed over the base member for rotation in either rotational direction with a gap extending therebetween. The drive member and the base include a circumferentially disposed contact means concentrically located about the central axis and the base and the drive members having a contact leads which are located coincidentally with the contact means and in contact therewith along 360° relative rotation between the base member and the drive member. A seal is carried by the drive member and is located thereon between the atmosphere and the vacuum environments and prevents atmosphere from entering the vacuum environment.
DESCRIPTION OF THE DRAWINGS
The foregoing aspects and other features of the invention are explained in the following description taken in connection with the accompanying drawings, wherein
FIG. 1 is a schematic top plan view of a substrate processing apparatus having a substrate transport incorporating features of the present invention;
FIG. 1 a is a perspective view of the same substrate transport drive assembly used in the apparatus used in FIG. 1;
FIG. 2 is a perspective view of the rotational drive assembly shown in FIG. 1 a.
FIG. 3 is a vertical sectional view of the drive assembly taken along line 3 — 3 in FIG. 2 .
FIG. 4 is a schematic isolated view of the inner coaxial shaft of the feed through part of the drive assembly.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIG. 1, there is shown in a schematic top view of a substrate processing apparatus 10 . The apparatus 10 includes a substrate transport 12 , substrate processing modular 14 and load lock 16 . A similar substrate processing apparatus is disclosed in U.S. Pat. No. 4,715,921 which is hereby incorporated by reference in its entirety. U.S. patent application Ser. No. 08/048,833 discloses an articulated arm transfer device which is also hereby incorporated by reference in its entirety. The apparatus 10 is adapted to process substrates, such as, semiconductor wafers or flat panel displays, as is known in the art.
The transport 12 includes a housing 18 , a moveable arm assembly 20 and a drive assembly 22 . The processing modules 14 and load locks 16 are attached to sides of the housing 18 . The housing 18 forms a vacuum chamber in which the arm assembly 20 can transport substrates between and or among the load lock 16 and the processing modules 14 . The arm assembly 20 can be similar to that described in U.S. patent application Ser. No. 08/048,833 with substrates supporting and effectors 24 . In alternative embodiments, other types of housings and/or moveable arm assemblies could be used in conjuction with the present invention.
Referring now to FIG. 1 a , the drive assembly 22 is shown. The drive assembly 22 includes a frame 26 , a rotational drive assembly 28 , a vertical drive 30 , and a controller 32 . The drive assembly 22 is mounted to the underside U of the housing 18 . The frame 26 includes a top flange 34 which is stationarily attached to the mounting flange 35 which is secured to the bottom U of the housing 18 . A carriage driveably connected to the vertical drive 30 and disposed along ways on the frame 26 is controllably vertically moveably positionable between upper and lower positions as required by use. A top flange 34 as seen in FIG. 1 a has a circular opening 48 and a portion of the drive shaft assembly of the rotational drive assembly 28 projects through the hole 48 and through a hole through the bottom U of the housing 18 into the vacuum chamber formed by the housing. A bellows 50 is provided between the underside U of the housing 18 and the drive assembly 28 to maintain the vacuum in the vacuum chamber, but allows the rotational drive assembly 28 to be moveable vertically relative to the housing 18 .
Referring now to FIG. 2, and the rotational drive assembly 28 . The rotational drive assembly 28 includes two rotational drive units 74 and 76 . A positioning signaling device 82 may be provided thereon for determining the real time position of the robot arms. The two units 74 and 76 are substantially identically identical to one another and are attached to one another in reverse orientation in a stacked vertical arrangement. Each unit 74 , 76 has a housing 88 which are suitably sized and shaped to be located within the cage frame 26 . The units 74 and 76 are fixedly connected to each other to form a modular unit that is secured to the carriage of the drive assembly 22 driven by the vertical drive 30 . Each unit 74 , 76 is adapted to independently angularly rotate one of two drive shafts 92 , 94 of the driveshaft assembly 90 . The two driveshafts, outer and inner, 92 and 94 , are coaxially mounted to the rotational drive assembly 28 coincidentally about the central axis CA, and the top ends of the shafts 92 and 94 are each connected to a member of the moveable arm assembly 20 such that rotation of the driveshafts in a given angular direction causes a robot arms to rotate together, while rotation of the shafts 92 , 94 in opposite directions causes the extension/retraction of the arms in a frog leg type manner.
Referring now to FIG. 3, it should be seen that the drive assembly shown therein are coaxially disposed along the central access CA of FIG. 4 within the drive units of 74 , 76 respectively. The radially outwardly disposed outer driveshaft 94 has an annular flange 100 disposed thereabout and has a set of permanent magnets 201 attached to the flange 100 and placed in juxtaposition relative to circumferentially surrounding coils (not shown) within the unit 74 . Likewise, the radially inwardly located inner driveshaft 92 connects through a plurality of axially extending bolts placed through openings 102 , which threadily engage with a lower inner coaxial shaft 104 such that both the lower inner coaxial shaft 104 and the inner driveshaft 92 are nonrotatably connected with one another in axial confrontation about the central access CA.
Adjacent the bottom end of the lower inner coaxial shaft 104 is a second annularly extending flange 106 on which is disposed a set of permanent magnets 202 which are in juxtaposition with coils (not shown) mounted to the lower housing 76 for the purpose of controllably rotating the inner driveshaft 92 between angular orientations. The lower inner axial shaft 104 and the outer coaxial driveshaft 94 are axially separated from one another by a separating flange 110 disposed therebetween, and as between the outer coaxial driveshaft 94 and the separating flange 110 with a bearing plate 112 interposed therebetween.
In accordance with the invention, it should be seen that a bottom plate 114 is provided at the bottom of the unit 76 . The bottom plate 114 has an opening or hole 118 which is exposed to atmosphere and is disposed coincidentally with the central axis CA. The isolation cup 120 is fixedly mounted to the bottom plate 114 about the hole 118 with an 0 -ring seal 122 therebetween. The isolation cup 120 is secured against movement to the bottom plate 114 through the intermediary of a plurality of connecting screws and locating pins 123 , 123 . Rotatably disposed coaxially about the isolation cup 120 is the lower inner shaft 104 . The units 74 and 76 support the component parts shown in FIG. 3 in such a way, using suitable bearing means, that a vertically extending annular gap 140 is provided between the isolation cup 120 and the lower inner axial shaft 104 .
The isolation cup 120 has a hollow inner chamber 124 which extends coaxially about the central axis CA through between the upper and lower ends 124 U, 124 L thereof. The isolation cup 120 narrows towards its top end to define a generally cylindrical tubular collar portion 126 . Within the tubular collar portion 126 is located an electrical connector 125 . The electrical connector 125 is of a tubular shape and has a base 113 in which is formed an opening 119 through which wires 111 are passed which ultimately electrically connect to the robot arm. The connector 125 is secured by bolts 117 to the cup 120 in the manner illustrated.
Also disposed within the hollow tubular confines of the tubular collar portion 126 is a central contact shaft 130 which is nonrotatably and sealingly connected to the isolation cup 120 through the intermediary of a spline connection or a transverse fastening pin and seals. At bottom end of the central contact shaft 130 is disposed an electrical connector 128 which is configured to axially mate with the connector part 125 . The electrical connector 128 is secured against axial movement, such as by an annular groove and snap ring, to the shaft 130 . Since the electrical connector 128 is secured within an atmospheric environment which is allowed to pass through and beyond the connector 128 , the connection can be made using any suitable type of connection, such as by the snap-fit, or adhesive connection because the forces acting upon the connector will not be exaggerated, such as found in the case where atmosphere and vacuum interface exists. Thus, the shaft 130 is axially and rotatably immovable relative to the isolation cup 120 , and the frame of the assembly thereby preventing twisting of the electrical wires 111 which are fed upwardly through the hollow portion 132 of the shaft 130 . In this way, the feed through connection 125 / 128 and its associated wires can be removeable without disassembly of the robotic drive mechanism. Thus, the wires 111 connect to the connector 128 by the mating of the connector 125 inserted therewithin.
As illustrated in FIG. 4 the interiorly disposed driveshaft 92 has a coaxially disposed stepped opening 136 formed therein. The top end of the interiorly disposed driveshaft 92 has a seal cap 133 which provides an end wall and locks the opening 136 from vacuum. The stepped opening seal 136 is defined by a first cylindrical portion 135 having a diameter D 1 and a second cylindrical portion 137 having a diameter D 2 which is less than that of the first portion 135 . The first cylindrical portion 135 is correspondingly sized and shaped to receive a ferrofludic seal 139 which is disposed circumferentially and axially secured against movement about the central contact shaft 130 . The interior surface of the inner coaxial shaft 92 defining the second cylindrical portion 137 is correspondingly sized and shaped to receive for relative rotation therewith the upper end portion 130 U of the central contact shaft 130 .
As previously mentioned, the outer surface of the isolation cup 120 and the inner surface of the lower inner shaft 104 are spaced apart by the gap 140 which exposes the lower end 141 of the seal 136 to the vacuum within the chamber of the handling apparatus. Thus, as illustrated by the arrow line in FIG. 4, vacuum is presented against the end 141 of the seal 139 while the upper inner end 143 of the seal 139 is exposed to atmosphere thereby providing the required differential in pressure necessary for effecting proper functioning of the ferrofluidic seal 139 . It should be understood that the ferrofluidic seal 139 is one that is readily commercially available and sold for example by Ferrofluidics, Inc., of Naushua, N.H. and is known in the industry.
Referring now in greater detail to FIGS. 3 and 4, and to the means 151 for rotatatably maintaining an electrical connection between the top end of the shaft 130 and the inner coaxial shaft 92 , it should be seen that this means is comprised of a plurality of slip-rings and include a plurality of vertically spaced circumferentially disposed grooves 142 a-h formed in the inner cylindrical surface of the second cylindrical portion 137 of the opening 136 . Each groove extends radially outwardly into the surface of the cylindrical opening portion 137 of the inner coaxial shaft 92 . Within each of these grooves is located an annular metallic contact 175 electrically connected and secured to the central contact shaft 130 . At the top end of the central contact shaft 130 and in the confronting surface of the inner surface of the cylindrical portion 137 of the interior drive shaft 92 is located a plurality of transversely extending openings 150 a - 150 h (see FIG. 4) each located in alignment with an associated one of the contact grooves 142 a-h . Within each of the transverse openings 150 a - 150 h is located a lead (not shown) corresponding and connected to one of the contact brushes 175 which are fixed to the shaft 130 . Each lead is further connected to a corresponding lead on the connector 128 . In the case of the drive member 92 , each of the contact brushes 175 corresponds to an electrical device in the robot arm. The grooves 142 a-h in the surface 137 connect to the robot arm by lines within a conduit 171 (see FIG. 4) in the shaft 92 which communicate with a chamber 200 in the member 92 . The brushes 175 of the central contact shaft 130 maintain sliding point contact with the associated one of the annular metallic contact grooves 142 a-h while those of the other part may have a fixed connection therewith. Electrical contact is thus maintained in a full 360 degrees circle by the sliding contact of the leads with the contact rings.
By the foregoing an improved coaxial drive electric contact has been described by way of the preferred embodiment. However, numerous modifications and substitutions may be had without departing from the spirit of the invention. For example, it is well within the purview of the invention to provide contact rings about the outer surface of the central shaft 130 such that pint contact is effected by the leads of either or both the inner coaxial shaft 982 and/or the central.
Accordingly the invention has been described by way of illustration rather than limitation.
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A coaxial drive employs a base member which is secured to a housing and is open to atmosphere and mounts rotatably an interior drive shaft about said base member so that rotation of the drive member in either direction in a full 360° circle. An electrical slip ring is provided between the base and the drive member with a ferrofluidic seal disposed proximate the lower end of the interior drive shaft such that atmospheric pressure passing through the base member and through the electrical slip ring is blocked by the ferrofluidic seal which has an opposite end disposed to the vacuum in the central processing apparatus.
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BACKGROUND
U.S. Pat. No. 2,714,541 describes a physician examination table in which stirrups are longitudinally slidable along a leg support bar 23 for adjusting the longitudinal length of the stirrups. Such construction has a tremendous disadvantage in that when the stirrups are adjusted very close to the examination table, the protruding ends of the supporting bars 23 can be continually bumped into by the physician as he moves about examining the patient. Although these foot support bars 23 can swivel from side to side as shown in the FIG. 5 embodiment, they are of a constant length. When not in use, they can be swung downwardly and tucked beneath the table top, as shown in FIG. 5.
U.S. Pat. No. 3,318,596 describes a surgical table with an elaborate motor system for swinging the leg supports outwardly, such as for gynecology examinations. However, both leg supports are pivotally pinned, as shown in FIG. 2 at 16 to transverse rod 15. Although rod 15 can move forwardly and rearwardly a very short distance in slot 19, this gives no adequate nor independent adjustment to the leg supports. Both leg supports move forwardly and rearwardly together as rod 15 is moved. This is a serious disadvantage in that sometimes a physician will want one leg in an extended stirrup while the other one is in a retracted stirrup for a particular examination position of the patient.
The assignee of the present application also is the assignee of U.S. Pat. No. 3,871,637. In FIGS. 1 and 2 of this patent, there appears to be a slight horizontal swinging motion of limb support bar 25 when compared to FIG. 2. The table described in this patent has no mechanism for combined lateral swinging and longitudinal sliding. As explained in the specification of this patent, the limb support bar structure (hidden from view) is the same as disclosed in Ser. No. 329,380 which later became U.S. Pat. No. 3,944,205. It is clear from such reference disclosure that the limb support bars slide only longitudinally and do not laterally swivel. Such reference does not describe any structure within the table for supporting or controlling lateral swivel and longitudinal motion.
SUMMARY OF THE INVENTION
The present invention overcomes the problems described above and provides a unique support structure for simultaneous movement of a limb support bar in a lateral swivel direction and also in a longitudinal sliding direction. The structure includes a pair of swivel supports that can independently swivel in a horizontal direction, and a limb support bar longitudinally slidable in such swivel support. Preferably, a limb receiver or stirrup is secured to the limb support bar at a fixed location so as to move with the limb support bar. Preferably, the swivel support is a pivoting collar which slidingly receives the limb support bar, and can be hidden from view within the table.
THE DRAWINGS
FIG. 1 is a side elevational view of a patient examination table;
FIG. 2 is a fragmentary top view of the right end of the patient examination table of FIG. 1 showing different positions of the foot stirrups and limb support bars;
FIG. 3 is an enlarged fragmentary view of the limb support bar longitudinally slidable in its swivel collar;
FIG. 4 is a view taken along line 4--4 of FIG. 3 showing the swivel lock construction; and
FIG. 5 is a view taken along line 5--5 of FIG. 3 showing the longitudinal lock structure.
DETAILED DESCRIPTION
In FIG. 1, a patient examination table is shown with a body 1 that can have a series of drawers such as 2 and 3. An accent panel 4 can include an electrical outlet as shown on the panel's upper portion. A patient cushion 6 can have 1 or more elevating sections. Other constructions of the examination table could be used for connection with the adjustable limb support structure which forms the basis for the present invention.
A foot stirrup, shown generally at 10, can include a foot cup section 11, an upstanding column member 12, and a pivot member 13. As shown by the curved arrow 14, the stirrup can fold down against a limb supporting bar 15. The limb supporting bar 15 can then be longitudinally pushed into a recess in body 1 of the examination table, as shown in dotted line in FIG. 1.
It is often the case that the physician desires to independently adjust the foot stirrups both in a lateral swivel position and in a longitudinal length position. Heretofore, the structure of such limb support bars and stirrups did not lend themselves to this particular adjustment. As shown in FIG. 2, limb support bar 15 can be moved longitudinally and pivotally. Hidden within the table is a swivel collar 16 with a pivot member 17. A swivel lock construction 18 holds the angular position of the limb support bar 15. Longitudinal movement of the limb support bar 15 is accomplished by the sliding relationship within swivel collar 16. The structure of the swivel lock 18 also permits this longitudinal sliding. A pin 50 can abut the swivel lock 18 to prevent the support bar from being pulled out of the table.
As can be seen from the structure shown in FIG. 2, the foot stirrup 10 can be moved to practically any desired position within a generally horizontal plane. It is important to note that the stirrup can always be at the end of the limb support bar 15 so that the physician is not continually bumping into a long exposed bar when the stirrup is adjusted to a short position, as is the right stirrup of FIG. 2.
The left stirrup 20 is also supported by a similarly adjustable limb support bar 25 which is longitudinally slidable in swivel collar 26 that has a pivot pin 27. A swivel lock 28 is similar to a swivel lock of 18. Thus, either limb support bar can be independently lengthened, shortened, swiveled sideways, or placed in parallel relationship with the other limb support bar. This provides great flexibility to the examining physician.
The enlarged fragmentary view of the limb support bar 15, as shown in FIG. 3, perhaps best shows the relationship of the limb support bar 15 and swivel collar 16. The swivel collar can have a generally rectangular shape with pivot means 17 and 30 which engage structure on the table. Other types of pivot means could be used, if desired. The swivel collar has a transverse pin 31 at an upper rear portion and a transverse pin 32 at a lower front portion. Thus, as the patient applys the weight of the limb downwardly on the outer end of limb support bar 15, pins 31 and 32 cause a wedging action on the limb support bar 15. This causes the limb support bar 15 to longitudinally lock to the swivel collar 16. Simply by lifting up on the outer end of limb support bar 15, the wedging or locking action is disengaged and can slide in swivel collar 16.
The pivot locking mechanism is shown generally at 18 in FIG. 3. Member 18 is preferably secured as by screws 34 and 35 to table structure that includes depending sections 36 and 37. Thus, a series of slot-like apertures 38, 39, and 40 are created adjacent depending teeth-like members 41 and 42. Alternatively, depending members 36 and 37 could be integrally formed with stop member 18. Also, a different number of adjustment slots could be provided. Three adjustment slots are shown in the present embodiment of the invention. It is also preferred to include a slight gap, as shown at numeral 39, so that the swivel stop 18 does not interfere with the longitudinal wedging action of pins 31 and 32.
For smooth sliding action, it is preferable to make the swivel stop member 18 of a lubricious thermoplastic material such as high density polyethylene. For strength requirements, the swivel collar 16, limb support bar 15, and stirrup 10 are made of a metal material, as are wedge pins 31 and 32. As shown in the drawings, the complete structure of the swivel collar, swivel lock, and longitudinal lock are completely encased within the body 1 of the examination table and there is no involved mechanism at the outer end of the foot stirrup structure.
In the foregoing description, a specific example has been used to describe the present invention. However, it is understood by those skilled in the art that certain modifications can be made to this example without departing from the spirit and scope of the invention.
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A medical examination table which has a pair of foot stirrups that are supported and moved by a pair of limb support bars. These limb support bars are longitudinally slidable within independent swivel collars within the table. A swivel lock means is disclosed for locking the limb support bars in a particular angular position, and there is also lock means disclosed for holding each bar at a particular length adjustment.
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FIELD OF THE INVENTION
[0001] The present invention relates to the field of reaction and separation processes. It more particularly relates to an improved method for generating comonomer from monomer. Still more particularly, the present invention relates to improved in-line process for generating 1-hexene and 1-octene from ethylene monomer for subsequent polyethylene polymerization.
BACKGROUND
[0002] Olefin polymerization, especially ethylene polymerization, can benefit from the addition of longer-chain comonomers, such as 1-hexene, and 1-octene, to produce linear low density polyethylene (LLDPE). LLDPE produced from 1-hexene and 1-octene accounts for a large percentage of the polyethylene resin market. In general, polyethylene plants buy hexene and octene, which are produced in separate plants that typically produce a range of even-numbered alpha olefins from ethylene. It can be expensive to purchase these materials, and they add to the complexity of storage and handling. An attractive alternative is to make the comonomer directly from the ethylene, if this can be done cleanly and economically. It would be perhaps most economical to do this in-situ in the polymerization reactor by altering the catalyst, however this is very difficult.
[0003] The review article “Advances in selective ethylene trimerisation—a critical review” by Dixon et al. (J. Organometallic Chemistry 689 (2004) 3641-3668), herein incorporated by reference in its entirety, describes many different catalysts for trimerization. These catalyst systems contain chromium, and with particular ligands, such as aromatic species (e.g. pyrrolyl) or multidentate heteratomic species. The chromium catalysts are typically activated by alkylaluminum and/or alkylaluminoxane activators. The article also describes group 4 and 5 early transition metals, such as Zr, V, Ta and Ti, and group 8 late transition metals, such as Ni, for showing some activity in trimerization.
[0004] Phillips has developed and patented chromium-based catalysts that are selective towards making 1-hexene from ethylene. The major byproduct appears to be 1-decene. SRI Consulting PEP Review 95-1-8 entitled “1-Hexene From Ethylene By the Phillips Trimerization Technology,” available on-line at http://www.sriconsulting.com/PEP/Reports/Phase — 95/RW95-1-8/RW95-1-8.html, herein incorporated by reference in its entirety, describes the Phillips standalone process for making 1-hexene based on Phillips trimerization technology. In this process, ethylene and a homogeneous catalyst in a solvent are fed to a reactor. The reactor is a stirred tank with heat removal coils. This reactor operates at 115 deg. C. and 49 kg/cm2 (˜700 psia), and converts about 75% of the ethylene fed. This reactor is 42,300 gal (5655 ft3). A spare reactor is provided, since waxy buildup on the cooling coils may necessitate lengthy shutdowns for cleaning. The feed is approximately 29,000 lb/hr cyclohexane solvent (with catalyst) plus 36,000 lb/hr ethylene (27,000 fresh feed and 9,000 recycle). It is estimated that the resident time in the reactor is on average 4 to 5 hours. Selectivity in the Phillips process by weight is about 93% to 1-hexene, 1% to other C6s, 1% to octenes, and 5% to decenes. The effluent from the reactor is contacted with octanol to kill the catalyst from further reaction. The effluent then goes to an ethylene column, where unconverted ethylene is taken overhead and recycled to the reactor. Because ethylene is so volatile, an expensive cryogenic column must be used. Four more distillation columns follow to remove hexene, cyclohexane solvent, octene, and decene. Some of these are run under vacuum, which again makes for expensive hardware and operations. The bottoms from the decene tower is a small stream containing mainly octanol and deactivated catalyst. This stream is treated with caustic and then with acid to remove the catalyst by precipitation and by solution in an aqueous phase, which is separated from the organic phase containing the octanol. Octanol may then be recycled.
[0005] U.S. Pat. No. 5,382,738 to Reagen et al., herein incorporated by reference in its entirety, discloses catalyst systems comprising inorganic oxides, modified with a metal alkyl and an unsaturated hydrocarbon, which can be used to support a metal source, such as, for example, chromium, and a pyrrole-containing compound. The resultant catalyst systems can be used to oligomerize and/or trimerize olefins.
[0006] U.S. Pat. No. 5,451,645 to Reagen et al., herein incorporated by reference in its entirety, discloses novel chromium-containing compounds prepared by forming a mixture of a chromium salt, a metal amide, and an ether. These novel chromium-containing, or chromium pyrrolide compounds, with a metal alkyl and an unsaturated hydrocarbon, can be used as a cocatalyst system in the presence of an olefin polymerization catalyst system to produce a comonomer in-situ.
[0007] U.S. Pat. No. 5,523,507 to Regen et al., herein incorporated by reference in its entirety, discloses novel chromium-containing compounds prepared by forming a mixture of the chromium salt, a metal amide, and an ether either supported or unsupported. These novel chromium-containing compounds are activated by non-hydrolyzed alkyl aluminum compound and a Lewis acid.
[0008] U.S. Pat. No. 5,543,375 to Lashier et al., herein incorporated by reference in its entirety, discloses a process to stabilize and/or reactivate an olefin production catalyst system which comprises contacting an olefin production catalyst system, either before or after use, with an aromatic compound, but prior to contacting the system with a reactant.
[0009] U.S. Pat. No. 5,563,312 to Knudsen et al., herein incorporated by reference in its entirety, discloses a process to stabilize and/or reactivate an olefin production catalyst system which comprises contacting an olefin production catalyst system, either before or after use, with an aromatic compound.
[0010] U.S. Pat. No. 5,859,303 to Lashier, herein incorporated by reference in its entirety, discloses a process in which the solvent is the product of the olefin oligomerization process. This novel process uses a catalyst essentially comprising a chromium compound or chromium salt, a pyrrole-containing compound, and an alkyl compound.
[0011] European Pat. No. 0 668 106 to Freeman et al., herein incorporated by reference in its entirety, discloses a process which will effectively deactivate, inhibit, and/or “kill” an olefin production catalyst, and halt polymer production in an olefin production process. It further provides for a process which can remove an olefin production catalyst from the product stream, and recover catalyst by-products for recycle, and/or recovery.
[0012] PCT publication WO 99/19280A1 to Woodard et al., herein incorporated by reference in its entirety, discloses a process in which olefins are trimerized in the presence of a catalyst system comprising a chromium source, a pyrrole containing compound and a metal alkyl. The process is preformed in a reactor and provides for a separator for collection of the desired products.
[0013] PCT publications WO 2004/056478 to Blann et al. and WO 2004/056479 to Blann et al., both hereby incorporated by reference in their entirety, disclose processes and catalysts to prepare an olefinic stream with more than 30% of 1-octene. The catalysts for this system are those that contain chromium or a chromium salt and a heteroatomic ligand
[0014] A need exists for an improved process to generate comonomer in a pre-reactor immediately before the polymerization reactor without isolation of the comonomer. More particularly, a need exists for a reaction/separation process to generate 1-hexene from ethylene immediately before the LLDPE polymerization reactor with no isolation or storage of the hexene produced.
SUMMARY OF THE INVENTION
[0015] It has been discovered that it is possible to generate 1-hexene and other comonomers from ethylene immediately before the polyethylene polymerization reactor with no isolation or storage of the hexene or other comonomer produced.
[0016] According to the present disclosure, an advantageous method for generating 1-hexene and other comonomers immediately before a polyethylene polymerization reactor, includes the steps of: providing an in-line comonomer synthesis reactor and a downstream gas/liquid phase separator prior to a polyethylene polymerization reactor; feeding ethylene monomer and a catalyst in a solvent to the comonomer synthesis reactor; reacting the ethylene monomer and the catalyst in solvent under reaction conditions to produce an effluent stream comprising ethylene monomer and comonomer selected from the group consisting of 1-hexene, 1-octene; 1decene and mixtures thereof; passing the effluent stream from the comonomer synthesis reactor to the downstream gas/liquid phase separator to separate a gas stream from a bottoms stream, wherein the gas stream is a mixture of ethylene monomer, and the comonomer; purging from the bottom stream spent catalyst and purge heavies, and recycling the catalyst in solvent to the comonomer synthesis reactor; and passing the gas stream to the polyethylene polymerization reactor to provide a comonomer source.
[0017] A further aspect of the present disclosure relates to an advantageous method for generating 1-hexene and other comonomers immediately before a polyethylene polymerization reactor, which includes the steps of: providing an in-line comonomer synthesis reactor prior to a polyethylene polymerization reactor, wherein the reactor is a fixed bed type with a catalyst in a fixed position; feeding ethylene monomer to the comonomer synthesis reactor; reacting the ethylene monomer and the catalyst under reaction conditions to produce an effluent stream comprising ethylene monomer and comonomer selected from the group consisting of 1-hexene, 1-octene; 1decene and mixtures thereof; and directing the effluent stream to the polyethylene polymerization reactor to provide a comonomer source.
[0018] Another aspect of the present disclosure relates to an advantageous method for generating 1-hexene and other comonomers immediately before a polyethylene polymerization reactor, which includes the steps of: providing an in-line comonomer synthesis reactor and a downstream gas/liquid phase separator prior to a polyethylene polymerization reactor; feeding ethylene monomer and a catalyst in a solvent to the comonomer synthesis reactor; reacting the ethylene monomer and the catalyst in solvent under reaction conditions to produce an effluent stream comprising ethylene monomer and comonomer selected from the group consisting of 1-hexene, 1-octene; 1-decene and mixtures thereof; passing the effluent stream from the comonomer synthesis reactor to the downstream gas/liquid phase separator to separate a gas stream from a bottom stream, wherein the gas stream is a mixture of ethylene monomer, and the comonomer; and transporting without isolation or storage the gas stream to the polyethylene polymerization reactor to provide a comonomer source.
[0019] Numerous advantages result from the advantageous method of preparing comonomer from monomer immediately before the polymerization reactor disclosed herein and the uses/applications therefore.
[0020] For example, in exemplary embodiments of the present disclosure, the disclosed method for preparing comonomer from monomer immediately before the polymerization reactor provides for substantial capital and operational cost savings over a conventional standalone process for manufacturing comonomer.
[0021] In a further exemplary embodiment of the present disclosure, the disclosed method for preparing comonomer from monomer immediately before the polymerization reactor eliminates the need to store or isolate the monomer produced.
[0022] In a further exemplary embodiment of the present disclosure, the disclosed method for preparing comonomer from monomer immediately before the polymerization reactor provides for range of catalysts for the oligomerization reaction.
[0023] In a further exemplary embodiment of the present disclosure, the disclosed method for preparing comonomer from monomer immediately before the polymerization reactor provides for the capability to produce both hexene and octene through catalyst selection.
[0024] In a further exemplary embodiment of the present disclosure, the disclosed method for preparing comonomer from monomer immediately before the polymerization reactor provides for process simplification, and the associated benefits of such.
[0025] In a further exemplary embodiment of the present disclosure, the disclosed method for preparing comonomer from monomer immediately before the polymerization reactor provides for continual removal of hexene from the comonomer synthesis reactor zone, which reduces the formation of decene byproduct.
[0026] These and other advantages, features and attributes of the disclosed method for preparing comonomer from monomer immediately before the polymerization reactor of the present disclosure and their advantageous applications and/or uses will be apparent from the detailed description which follows, particularly when read in conjunction with the figures appended hereto.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] To assist those of ordinary skill in the relevant art in making and using the subject matter hereof, reference is made to the appended drawings, wherein:
[0028] FIG. 1 depicts an illustrative schematic of the in-line process for comonomer generation utilizing a comonomer synthesis reactor and a downstream gas/liquid phase separator.
[0029] FIG. 2 depicts an illustrative schematic of the fixed bed reactors for in-line comonomer generation without a downstream gas/liquid phase separator in which catalyst is in the tubes with coolant.
[0030] FIG. 3 depicts an illustrative schematic of the fixed bed reactors for in-line comonomer generation without a downstream gas/liquid phase separator in which cold shot cooling is utilized.
DETAILED DESCRIPTION OF THE INVENTION
[0031] The present invention relates to an improved reaction and separation process for generating comonomer (e.g. 1-hexene) from monomer (e.g. ethylene). In one exemplary embodiment of the present invention, the improved process may be implemented immediately before the polymerization reactor with no isolation or storage of the hexene produced. Hexene is swept out of the reaction zone or loop along with unconverted ethylene, leaving behind catalyst and heavy solvent. Specific hardware implementations of this concept include a “bubbling pot” and a reactor/knockout pot pumparound.
[0032] In an alternative embodiment of the present invention, 1-octene is produced from ethylene through proper selection of the catalyst for the oligomerization reaction. The improved process of the instant invention is also adaptable to catalysts which produce both hexene and octene.
[0033] FIG. 1 depicts one exemplary process schematic of the improved in-line reaction and separation process 10 of the instant invention. In this configuration, ethylene feed 12 and catalyst feed 14 are fed to a comonomer synthesis reactor 16 (also referred to as an oligomerization reactor). The comonomer synthesis reactor 16 may be of various types, including, but not limited to a stirred tank reactor, more than one agitated vessel in series, and a long, thin tube-like contactor. If the catalyst is in the form of a fixed bed rather than slurry or solution, it may be contained in a contactor type of reactor.
[0034] Catalysts suitable for the present invention are those that comprise a reactive transition metal source catalytically able to selectively trimerize or tetramerize olefins. Exemplary metal sources include, but are not limited to, chromium, vanadium, tantalum, and titanium. Exemplary catalyst types include, but are not limited to, chromium, vanadium, tantalum and titanium trimerization and/or tetramerization catalysts. Preferably the catalytic system comprises a titanium source, more preferably a tantalum source and even more preferably a chromium source for improved catalyst activity and selectivity.
[0035] If a chromium source is used, one or more organic ligands may also be present in addition to any inorganic ligands, wherein the oxidation state of the chromium is from 0 to 6. Exemplary organic ligands are organic radicals having from 1 to 20 carbon atoms per radical, which are selected from the group consisting of alkyl, alkoxy, ether, ester, ketone, phosphine and/or amine. The organic ligands may also include heteroatoms. The organic radicals may be straight chained or branched, cyclic or acyclic, aromatic or aliphatic and any combination may be present in the metal complex. The organic radical may include multiple heteroatoms that are linked by bridging groups to provide for multidentate complexation with the chromium source.
[0036] Preferred organic radicals include “pyrrole-containing” compounds. For the purposes of this invention “pyrrole-containing” compounds refers to those that include a pyrrole molecular fragment or a derivative of hydrogen pyrrolide, i.e. pyrrole (C 4 H 5 N). Non-limiting examples of “pyrrole-containing” compounds include 2,3-dimethylpyrrole, 2,5-dimethylpyrrole, 2,4-dimethyl-3-ethylpyrrole, 2-acetylpyrrole, 3-acetyl-2,5-dimethylpyrrole and ethyl-3,5-dimethyl-2-pyrrolecarboxylate.
[0037] Bridging organic radicals of the present invention include those with one or more phosphorous heteroatoms such as PNP ligands. Non-limiting examples include (2-methyloxyphenyl) 2 PN(methyl)P(2-methyoxyphenyl) 2 , (3-methyloxyphenyl) 2 PN(methyl)P(3-methyoxyphenyl) 2 , (4-methyloxyphenyl) 2 PN-(methyl)P(4-methyoxyphenyl) 2 , (2-methyloxyphenyl) 2 PN(ethyl)P(2-methyoxyphenyl) 2 , (2-methyloxyphenyl) 2 PN(isopropyl)P(2-methyoxyphenyl) 2 , (2-methyloxyphenyl) 2 PN(methyl)P(3-methyoxyphenyl) 2 , (2-methyloxyphenyl) 2 PN-(methyl)P(4-methyoxyphenyl) 2 , (4-fluorophenyl) 2 PN(methyl)P(4-fluorophenyl) 2 , and (2-fluorophenyl) 2 PN(benzyl)P(2-fluorophenyl) 2 .
[0038] Bridging organic radicals of the present invention also include those with a hydrocarbon bridge between the phosphorous heteroatoms. Non-limiting examples include 1-(2-methyoxyphenyl)(phenyl)phosphino-2-(2-methyoxyphenyl)(phenyl)phosphinoethane, 1-di(3-methyoxyphenyl)phosphino-2-(2-methyoxyphenyl)(phenyl)phosphinoethane, 1-(2-methyoxyphenyl)-(phenyl)phosphino-3-(2-methyoxyphenyl)(phenyl)phosphinopropane, 1-(4-methyoxyphenyl) (phenyl)phosphino-2-(4-methyoxyphenyl)(phenyl)phosphino-propane, 1-(2-methyoxyphenyl)(phenyl)phosphino-2-(2-methyoxyphenyl)-(phenyl)phosphinopropane, and 1-diphenylphosphino-2-(2-fluoro-phenyl)(phenyl)phosphinoethane.
[0039] The catalyst system may also include an activator. The activator may be any compound that generates an active catalyst when combined with the transition metal compound and the organic and/or inorganic ligand. Exemplary compounds for activators include, but are not limited to, organoaluminum compounds, organoboron compounds, organic metal salts, and inorganic acids and salts. Preferred activators include alkylaluminum compounds, such as triethylaluminum, trimethylaluminum, triisobutylaluminum and alkylaluminoxanes. Preferred alkylaluminoxanes include methylaluminoxane, ethylaluminoxane and modified alkylaluminoxanes, such as modified methylaluminoxane (MMAO). Ratios of the aluminum activator to the transition metal may be from 1:1 to 10,000:1, preferably from about 1:1 to 5000:1, more preferably from about 1:1 to 1000:1 and even more preferably from about 1:1 to 500:1.
[0040] The comonomer synthesis reactor 16 is separate from the subsequent gas/liquid phase separator 18 , which allows for separate control of reaction and separation conditions. The reactor temperature and pressure are controlled to provide for acceptable reaction rates and selectivities, as well as to provide for phase separation.
[0041] With regard to catalyst solvent, there is flexibility as far as what catalyst solvent, if any, may be used. If a catalyst solvent is used, it should be less volatile than hexene, and preferably less volatile than octene, such that it is not swept out along with hexene product. If decene recovery is desired and the solvent is a hydrocarbon, then the solvent should have volatility different than decene. On the other hand, if a solvent is used that is compatible with the polymerization process (e.g. isobutane), it may be acceptable to allow large amounts of that solvent to leave the oligomerization reactor 16 along with the ethylene and hexene. Examples of other suitable catalyst solvents include C5+paraffins (preferable branched, e.g. isopentane), cycloparaffins, and aromatics. If the catalyst is in the form of a fixed bed or a slurry, it may not require additional extraneous solvent.
[0042] Reaction conditions are selected to give from about 5% to about 75%, preferably from about 10% to about 50% conversion of feed ethylene. Some of the chromium catalysts disclosed by Phillips, for example as disclosed in U.S. Pat. No. 5,543,375, permit a range of conditions. One exemplary, but non-limiting set of conditions, is a reaction temperature of from about 80 to about 150° C., and a reaction pressure of from about 300 to about 700 psi. However, when utilizing an ethylene feed 12 , a reaction temperature of from about 60 to about 110° C. is preferred. Process conditions may be tuned to obtain desired phase separations as well as reactivity. Residence time is flexible, and is chosen to provide a desired level of ethylene conversion. A range of average reaction residence time of from about 30 minutes to about 4 hours is contemplated when using Phillips catalysts with a backmixed or pump around type of comonomer synthesis reactor 16 where most of the catalyst in the reactor 16 at a given time is not “fresh”, but has been circulating around for some time before becoming deactivated. The range of reaction residence times may depend on other factors, such as the nature and amount of the catalyst.
[0043] The effluent 20 from the comonomer synthesis reactor 16 is directed to the gas/liquid phase separator 18 , where the gas stream 22 exits the separator 18 . A catalyst deactivator (e.g. water or alcohol) may be added to effluent 20 . The gas stream 22 contains predominately ethylene along with comonomer, such as 1-hexene or 1-octene. The gas/liquid phase separator 18 may include, but is not limited to, a simple knockout vessel or other one-stage phase separator, but it may also include some trays or packing 24 in the zone where vapor is going up, with reflux liquid flowing down, to sharpen the C6/C8 or C8/C10 separation and also to wash down any catalyst or heavies that were carried upwards. In one embodiment, the ethylene is bubbled through a stirred tank or pot, and exits into a vapor space above the liquid.
[0044] In another alternative embodiment, some ethylene (not shown) is added to the separator 18 below the feed entrance point, to strip out hexene or other comonomer (not shown) from the down-flowing solvent (not shown). The bottoms 26 from the separator 18 , containing the catalyst, decene, and heavy solvent (if any), is predominately pumped back to the reactor 16 . Heat exchangers (not shown) are in-line with the pump around flow. Where waxy buildup is an issue, spare heat exchangers may also be provided. For both the bubbling pot and the pumparound type reactor/separator configurations described above, a small portion of the bottoms stream 26 , containing purge heavies, spent catalyst with heavy solvent (if any) 27 , and decene is directed to an optional catalyst disposal and solvent recovery process 28 . To minimize the load on solvent recovery process 28 , it is desirable to have a catalyst with high productivity (grams of olefin converted divided by grams of catalyst used).
[0045] In the gas stream 22 from the gas/liquid phase separator 18 , ethylene (also referred to as C2) is not recovered in high purity. This saves cryogenic ethylene column costs. Unconverted ethylene may be recycled back to the comonomer synthesis reactor 18 , or sent on to another process (not shown), for example the downstream polyethylene polymerization process. Solvent and catalyst recycle 29 from the bottoms 26 . of the gas/liquid phase separator 18 are sent back to the oligomerization reactor 16 . Most octene products are swept out of the reactor or reactor/separator loop along with unconverted ethylene in the gas stream 22 . The improved in-line reaction and separation process 10 does not include hexene/octene (also referred to as C6/C8) separation because some of the trace octene byproduct is used in the polymerization along with the hexene. Some trace octene may also exit the gas/liquid phase separator 18 in the bottoms stream 26 along with the decene (also referred to as C10) byproduct.
[0046] The improved reaction and separation process of the instant invention for generating monomer in a pre-reactor immediately before the polymerization reactor without isolation of the comonomer greatly simplifies the required process. The exemplary process schematic of FIG. 1 permits the number of separation towers to be reduced versus the standalone concept of producing comonomer. This results in significant operating and capital cost savings over conventional standalone processes for manufacturing comonomers, such as hexene. An additional benefit of the instant invention is that the continual removal of hexene from the comonomer synthesis reactor zone reduces the formation of decene byproduct. The improved reaction and separation process of the instant invention is compatible with a Phillips-type trimerization catalyst, but may also be useful with other homogeneous or heterogeneous selective oligomerization catalysts.
[0047] FIGS. 2 and 3 depict two other exemplary process schematics of improved in-line comonomer generation processes 40 , 60 of the instant invention that do not include a gas/liquid phase separator. These embodiments represent an even more simplified approach. In both FIG. 2 and 3 , fixed bed reactor types are used where the catalyst is in a fixed position, and ethylene is fed past it. Catalyst types may include, but are not limited to, chromium, vanadium, tantalum and titanium trimerization and/or tetramerization catalysts.
[0048] As comonomer (e.g. hexene) is produced, it is swept into the gas phase and carried out of the reactor. The precise form of the catalyst may include, but is not limited to, a solid, including active catalytic species anchored to a support, or in the form of a porous solid bed or monolith, which is wetted with soluble catalyst in a heavy solvent. The solvent with catalyst may be trickled through the bed, to renew the solvent over time.
[0049] In gas/solids systems, temperature control can be an issue. Using 47 kcal/mol hexene for heat of reaction, it can be estimated that for undiluted ethylene, a 10% conversion to hexene would generate about a 110 deg. C. temperature rise if there were no heat removal from the reactor. Also depicted in FIG. 2 and 3 are two exemplary embodiments for managing the reaction heat generated.
[0050] In FIG. 2 , the heat exchange capability is put into the reaction zone, for example, by loading the catalyst in 1″-6″ diameter tubes surrounded by a cooling medium. FIG. 2 depicts a comonomer synthesis reactor 42 with catalyst in tubes 44 with coolant. Coolant enters and exits the comonomer synthesis reactor 42 through the coolant in 46 and coolant out 48 ports respectively. Ethylene (C2 feed) 50 enters the comonomer synthesis reactor 42 and reacts to form a gas stream 52 containing predominately ethylene (C2) along with comonomer, such as 1-hexene or 1-octene, which may be transferred directly to a downstream polyethylene polymerization reactor.
[0051] In FIG. 3 , the reactor is divided into two or more catalyst beds, and cool feed or diluent is injected before each stage. FIG. 3 depicts a comonomer synthesis reactor 62 with cold shot cooling of C2 64 between the first reaction stage 66 and the second reaction stage 68 of the comonomer synthesis reactor 62 . Ethylene (C2) feed 70 enters the comonomer synthesis reactor 62 and again reacts to form a gas stream 72 containing predominately ethylene (C2) along with comonomer, such as 1-hexene or 1-octene, which may be transferred directly to a downstream polyethylene polymerization reactor (not shown).
[0052] Applicants have attempted to disclose all embodiments and applications of the disclosed subject matter that could be reasonably foreseen. However, there may be unforeseeable, insubstantial modifications that remain as equivalents. While the present invention has been described in conjunction with specific, exemplary embodiments thereof, it is evident that many alterations, modifications, and variations will be apparent to those skilled in the art in light of the foregoing description without departing from the spirit or scope of the present disclosure. Accordingly, the present disclosure is intended to embrace all such alterations, modifications, and variations of the above detailed description.
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The present invention relates to an in-line method for generating comonomer, such as 1-hexene or 1-octene, from monomer, such as ethylene. The comonomer generated is directly transported, without isolation or storage, to a polyethylene polymerization reactor. The in-line method for generating comonomer includes the steps of providing an in-line comonomer synthesis reactor and a downstream gas/liquid phase separator prior to a polyethylene polymerization reactor; feeding ethylene monomer and a catalyst in a solvent to the comonomer synthesis reactor; reacting the ethylene monomer and the catalyst in solvent under reaction conditions to produce an effluent stream including ethylene monomer and comonomer; passing the effluent stream from the comonomer synthesis reactor to the downstream gas/liquid phase separator to separate a gas stream from a bottom stream, wherein the gas stream is a mixture of ethylene monomer, and comonomer; and passing the gas stream to the polyethylene polymerization reactor to provide the necessary comonomer input. The in-line method is useful in the production of LLDPE, and other branched polyethylene based polymers. Some benefits include process simplification and reduced capital and operating costs.
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FIELD OF THE DISCLOSURE
This disclosure relates generally to negotiated channel security protocols, and, more particularly, to methods and apparatus to perform associated extensions for negotiated channel security protocols.
BACKGROUND
Traditional security protocols (e.g., Secure Sockets Layer (SSL), Transport Layer Security (TLS), Internet Key Exchange (IKE), etc.) negotiate session keys that are authenticated using digital certificates, keys, or shared secrets (e.g., a pass phrase). The session keys are used to encrypt and decrypt subsequent communications carried across a secured channel.
FIGS. 1A-B illustrate an example prior-art authentication sequence (i.e., an authentication protocol encapsulation block (PEB)) executed between two endpoints A and B to negotiate (i.e., derive) session keys. Endpoints A and B are one of a variety of computing devices or platforms (e.g., a computer, a server, a personal digital assistant (PDA), a cellular phone, an Internet kiosk, etc.) connected together, for example, by a computer network, a bus, a wireless communication link, a serial channel, etc. The endpoints A and B may communicate in a master-slave, a client-server, or a peer-to-peer configuration.
The example authentication PEB of FIGS. 1A-B begins with endpoints A and B exchanging authentication attributes (i.e., identifying information) (block 102 of FIG. 1A ). The exchanged attributes (e.g., public keys, digital signatures, certificates, attestation information, etc.) allow an endpoint to authenticate information received from the other endpoint. For example, endpoint A encrypts (or digitally signs) an attribute (e.g., attestation information) using a private key (that is only known to endpoint A) and sends the encrypted attribute and a public key (that corresponds to the private key which remains known only to endpoint A) to endpoint B.
Next, using received authentication attributes (e.g., public keys), the endpoints A and B authenticate the received attributes (block 104 ). For example, endpoint B uses the public key (received from endpoint A) to decrypt the received encrypted attribute (e.g., attestation information). If the decryption is successful, endpoint B knows that the received attribute is authentic (i.e., sent by endpoint A).
In the example authentication PEB of FIG. 1A , endpoint A then generates a high entropy random number (i.e., nonce A ), digitally signs nonce A (using a private key of endpoint A), encrypts the signed nonce A (using a public key of endpoint B), and sends the encrypted and signed nonce to endpoint B (block 106 ). Endpoint B then decrypts and authenticates (using a private key of endpoint B, and a public key of endpoint A) the received nonce A (block 108 ). Endpoint B then generates a second high entropy random number (i.e., nonce B ), creates a cryptographic combination (e.g., arithmetic addition, exclusive-or, hash, etc.) of nonce A and nonce B , signs and encrypts the nonce combination, and sends the encrypted and signed nonce combination to endpoint A (block 110 ). Endpoint A authenticates the received nonce combination (block 112 ) and sends an encrypted and signed version of nonce B back to endpoint B (block 114 ).
The example authentication PEB continues with block 120 of FIG. 1B . The endpoints A and B determine a master secret from nonce A and nonce B . For example, the master secret may be determined using a cryptographic combination of nonce A , nonce B , and a cryptographic hash of the handshake messages (i.e., exchanged identifying information or authentication attributes) (block 120 ). Using one of a variety of techniques (e.g., “Deriving Keys for use with Microsoft Point-to-Point Encryption (MPPE)”, Internet Engineering Task Force (IETF) Request for Comment (RFC) 3079, March 2001), session keys are derived from the master secret (block 122 ). By exchanging and basing session keys on nonce A and nonce B , the authentication PEB of FIGS. 1A-B reduces the risk of replay attacks, man-in-the-middle attacks, etc.
Using techniques similar to those discussed above, the endpoints A and B exchange some initial data (block 124 ). Each endpoint A and B then determines if the received data is valid (e.g., decrypted correctly) (block 126 ). If the received data is valid (block 126 ), the session is authenticated and secure communications can proceed using the established session (block 128 ). Otherwise, the session is not authenticated, and, thus, secure communication can not properly proceed using the new session (block 130 ).
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1A and 1B illustrates an example prior-art authentication protocol exchange block.
FIG. 2 is a schematic illustration of an example security protocol extender constructed in accordance with the teachings of the invention.
FIG. 3 is a flowchart representative of example machine readable instructions which may be executed to implement the security protocol extender of FIG. 2 .
FIGS. 4 , 5 and 6 are example illustrations of associated protocol extensions resulting from the execution of the example machine readable instructions of FIG. 3 .
FIG. 7 is an example illustration of an associated protocol extension for a protocol endpoint migration.
FIG. 8 is a schematic illustration of an example processor platform that may execute the example machine readable instructions represented by FIG. 3 or the example associated protocol extensions of FIGS. 4-7 to implement the security protocol extender of FIG. 2 .
DETAILED DESCRIPTION
Traditionally, an authentication PEB (e.g., a network access authentication based on the version of anti-virus definitions installed, client configuration status information, and/or attestation information) executed subsequent to a previous authentication PEB is executed independently of the previous authentication PEB. That is, subsequent authentications do not derive their session keys based on information available (e.g., identifying information, a master secret) from a previous PEB. As such, the continuity of authentication, authorization, integrity and attack prevention semantics is not preserved through a chain of authentication and authorization PEBs.
The management of platform and user identities in next generation enterprise topologies, where ad-hoc enterprise environments are created in non-traditional locations (e.g., hotels, other companies, public gathering places, via public networks, etc.), will require enhanced security frameworks. A key element of those security frameworks will be the ability to carry forward identity authentication information (i.e., associated protocol extensions) through a chain of authentication and authorization PEBs.
FIG. 2 is a schematic illustration of an example security protocol extender (SPE) 200 constructed in accordance with the teachings of the invention. The SPE 200 may be a part, or all, of a protocol endpoint. To associate an authentication PEB with a previous authentication PEB and to extend a previously established and authenticated identification, the SPE 200 includes a protocol processor 205 , a protected storage device 210 , and a message handler 215 . The protocol processor 205 is one of a variety of processors or computing devices capable of executing PEBs. For example, the protocol processor 205 could be a general purpose Intel® processor or an Intel® Active Management Technology (AMT) engine.
To transmit encrypted and/or digitally signed information (i.e., messages, packets, etc.), the message handler 215 includes a message encrypter 220 , and a message transmitter 225 . The message encrypter 220 receives from the protocol processor 205 information to encrypt and/or digitally sign, and encryption keys (stored in the protected storage device 210 ). The message encrypter 220 encrypts and/or digitally signs the provided information and provides the encrypted and/or digitally signed message to the message transmitter 225 . The message transmitter 225 transmits the encrypted and/or digitally signed message to another endpoint across, for example, a computer network, a bus, a wireless communication link, a serial channel, etc.
To receive and authenticate encrypted and/or digitally signed messages, the message handler 215 includes a message receiver 235 , and a message authenticator 240 . The message receiver 235 receives messages from another endpoint across, for example, a computer network, a bus, a wireless communication link, a serial channel, etc. The message authenticator 240 decrypts and/or authenticates (using keys provided by the protocol processor 205 ) the received messages. In addition to the decrypted and/or authenticated messages, the message authenticator 240 provides to the protocol processor 205 an authentication status (e.g., authentic or not authentic) for received messages.
The protected storage device 210 stores identifying information, certificates, private keys, etc. exchanged during authentication PEBs, the master secret from previous authentication PEBs, and the current sets of exchanged public and session key(s). The contents of the protected storage device 210 are only accessible to the protocol processor 205 . The protected storage device 210 can be implemented using any variety of random access memory (RAM). Alternatively, all, or a portion, of the protected storage device 210 could be implemented by a Trusted Platform Module (TPM). The TPM may, for example, contain a platform identity that is registered with a public registration agent who then issues a platform identity credential.
FIG. 3 illustrates a flowchart representative of example machine readable instructions that may be executed by a processor (e.g., the processor 810 of FIG. 8 ) to implement the example SPE 200 of FIG. 2 . The machine readable instructions of FIG. 3 , the example SPE 200 , the protocol processor 205 , the message handler 215 , and/or the protected storage device 210 may be executed by a processor, a controller, or any other suitable processing device. For example, the machine readable instructions of FIG. 3 , the example SPE 200 , the protocol processor 205 , the message handler 215 , and/or the protected storage device 210 may be embodied in coded instructions stored on a tangible medium such as a flash memory, or RAM associated with the processor 810 shown in the example processor platform 800 discussed below in conjunction with FIG. 8 . Alternatively, some or all of the machine readable instructions of FIG. 3 , the example SPE 200 , the protocol processor 205 , the message handler 215 , and/or the protected storage device 210 may be implemented using an application specific integrated circuit (ASIC), a programmable logic device (PLD), a field programmable logic device (FPLD), discrete logic, etc. Also, some or all of the machine readable instructions of FIG. 3 , the example SPE 200 , the protocol processor 205 , the message handler 215 , and/or the protected storage device 210 may be implemented manually or as combinations of any of the foregoing techniques. Further, although the example machine readable instructions of FIG. 3 are described with reference to the flowchart of FIG. 3 , persons of ordinary skill in the art will readily appreciate that many other methods of implementing the example SPE 200 , the protocol processor 205 , the message handler 215 , and/or the protected storage device 210 exist. For example, the order of execution of the blocks may be changed, and/or some of the blocks described may be changed, eliminated, or combined.
Prior to the start of the example machine readable instructions of FIG. 3 , the SPE 200 (e.g., endpoint A) has established a secure channel (i.e., a secure communications link) to another endpoint B, by, for example, using the example authentication PEB illustrated in FIGS. 1A-B , TLS, Internet Protocol Security (IPSEC), Institute of Electrical and Electronics Engineers (IEEE) 802.11i, IEEE 802.11EC, etc.
The example machine readable instructions of FIG. 3 begin when SPE 200 starts a new authentication PEB by exchanging information (e.g., attestation information, identification, credentials, etc.) with the endpoint B (block 302 ). Based upon the exchanged information, the SPE 200 determines a secret (block 304 ) from the exchanged information. For example, the secret can be created as a cryptographic hash (e.g., Secure Hash Algorithm—Version 1.0 (SHA-1)) of the exchanged information. Then, the SPE 200 determines a new master secret (block 306 ). For example, the new master secret is determined by applying a privacy randomization function (PRF) to the current master secret and the determined secret. The PRF can be any appropriate cryptographic combination (e.g., arithmetic addition, exclusive-or cryptographic hash, etc.).
Next, using one of a variety of techniques (e.g., IETF RFC 3079), the SPE 200 derives session keys (i.e., re-keys the session) based on the new master secret (block 308 ). Using techniques similar to those discussed above, the SPE 200 exchanges data with the other endpoint (block 310 ). The exchanged data can be, for example, user data to be carried across the new secure session, or identifying information being exchanged as part of a subsequent authentication or authorization PEB. The SPE 200 then determines if received data is valid (e.g., decrypted correctly, valid signature, authentic, etc.) (block 312 ). If the received data is valid (block 312 ), the session is authenticated and secure communications can proceed between the SPE 200 and the other endpoint using the established session (block 314 ). Otherwise, the session is not authenticated, and, thus, secure communication can not properly proceed using the new session (block 316 ). Finally, the SPE 200 ends the example machine readable instructions of FIG. 3 .
FIG. 4 is an example illustration of associated protocol extensions resulting from the execution of the example machine readable instructions of FIG. 3 . Two PEBs are illustrated in FIG. 4 . The first (i.e., phase 1 or outer) PEB establishes a secure channel between the SPE 200 (i.e., endpoint A) and another endpoint B. In the second (i.e., phase 2 or inner) PEB, the SPE 200 exchanges second handshake messages (e.g., attestation information, identification, credentials, etc.) with the endpoint B. Based on the second handshake messages, the SPE 200 determines a secret. Then, based on the determined secret and the master secret from the first PEB, the SPE 200 determines a new master secret. Finally, the SPE 200 derives new session keys (i.e., re-keys the session) based on the new master secret. Because, the second PEB is linked (i.e., associated) to the first PEB (by basing the new session keys on the previous master secret), the security protocol has been extended from the first PEB into the second PEB.
It will be readily apparent to persons of ordinary skill in the art that the example machine readable instructions of FIG. 3 can be repeated, without limit, to extend the security authentication with the first and second PEBs into additional PEBs. For example, a third PEB can be associated to and extended from the second PEB, which itself was associated to and extended from the first PEB.
It will also be readily apparent to persons of ordinary skill in the art that some authentication or authorization PEBs are not intended to result in a new master secret and/or session keys. In this case, the SPE 200 can skip or omit example machine readable instructions associated with one or more of the blocks 304 - 316 of FIG. 3 . However, the identifying information exchanged during the PEB can be incorporated into subsequent authentication or authorization PEBs. In one example, a first PEB (i.e., PEB 0 ) establishes a first secure communication session. A second PEB (i.e., PEB 1 ), by design, only results in exchanged identifying information. A third PEB (i.e., PEB 2 ) then exchanges identifying information and establishes a second secure communication session. The new master secret determined in PEB 2 can be based on the master secret from PEB 0 , the exchanged information from PEB 1 , and the exchanged information from PEB 2 . Thus, the second secure communication established during PEB 2 is associated to and extended from both PEB 0 and PEB 1 .
It will also be readily apparent to persons of ordinary skill in the art that the additional PEBs can realize a variety of authentication functions. For example, the additional PEBS realize a platform attestation or an attestation key registry (e.g., registering a TPM) as illustrated by the example PEBs of FIGS. 5 and 6 , respectively. In the examples of FIGS. 5 and 6 , the following notations and abbreviations are utilized:
[MSG A ]KEY B —indicates that the message MSG (created by endpoint A) is digitally signed (using the public key KEY of endpoint B). {MSG A }KEY A —indicates that the message MSG (created by endpoint A) is encrypted (using the private key KEY of endpoint A). PCR—platform configuration register (e.g., a register in a TPM) AIK—Attestation Identity Key (asymmetric) IML—Integrity Measurement Log PCA—Platform Certificate Authority EK—Endorsement Key (asymmetric) SK—temporal Symmetric Key
The example platform attestation PEB of FIG. 5 relies on a separate (i.e., outer) PEB to establish a secure session between the SPE 200 (i.e., endpoint A) and an endpoint B. However, the PCR values in the example of FIG. 5 are signed by AIK, to authenticate that the configuration data (contained in the PCR) is associated with the platform or device (that includes the SPE 200 ), since it may not have been previously certified that the outer PEB is tied to the same platform as the PCR. For a similar reason, the information exchanged in the example of FIG. 6 is signed using an AIK or PCA.
Protocol endpoint migrations are valuable in Internet services, where one Internet service vectors a secure connection to another Internet service. The methods and apparatus discussed above can also be used to reliably migrate a protocol endpoint (e.g., from endpoint B to C). Endpoint migrations require the mutual agreement of the current endpoints (e.g., the SPE 200 (i.e., endpoint A) and the endpoint B). Normally, an endpoint migration is requested by the endpoint not being migrated (e.g., endpoint A). However, an endpoint migration can be requested by either endpoint (e.g., endpoint A or B).
By applying the methods discussed above to perform endpoint migration, the security attributes of the new connection (e.g., between endpoints A and C) are associated to and extended from the previously established secure connection (e.g., between endpoints A and B). Thus, the endpoint migration retains unambiguous endpoint identification and retains knowledge of the vectoring endpoint (i.e., endpoint B). This retained additional security context permits policy controlled vectoring with an organization. The benefits of policy controlled vectoring include autonomic enterprise connections, worm propagation mitigation, improved forensic history for tracking network intruders, etc.
FIG. 7 illustrates an example protocol endpoint migration from endpoint B to endpoint C. The example endpoint migration of FIG. 7 starts with an established secure connection between endpoints A and B (i.e., PEB AB ) based on a master secret MSR AB . The MSR AB is communicated to endpoint C by endpoint B by establishing a second session (i.e., PEB BC ) between endpoints B and C that results in MSR BC . The MSR BC is communicated to endpoint A by endpoint B allowing endpoint A to be convinced that there is no man-in-the-middle between endpoints B and C. The SPE 200 (i.e., endpoint A) and endpoint C create a third session (i.e., PEB AC ) using endpoint B to relay messages between endpoints A and C. Endpoints A and C determine a new master secret MSR AC based on, among other things, MSR AB and MSR BC . For example, MSR AC could be determined using a PRF to combine the MSR AC , a cryptographic hash of the messages exchanged between A and C, and the MSR AB . The MSR AB and MSR BC represent a cryptographic binding between the associated endpoints. By including the MSR AB , the connection between endpoints A and C is associated to and extended from the secure connection between endpoints A and B.
A history of exchanged messages (e.g., for PEB AB , PEB AC , PEB BC ) (possibly containing specific identification, authentication and authorization/attestation information) can be held in a repository that can be queried by endpoint A or endpoint C to understand the security conditions of the endpointA-to-endpointB connection and/or the endpointB-to-endpointC connection. For example, when endpoint B sends MSR BC to endpoint A, a reference to the repository could be included. The MSR AB , or a derivative key, could then be used to protect the repository link and associated references.
While the disclosed methods and apparatus discussed herein were described with respect to bi-directional authentications and peer-to-peer communications, it will be readily apparent to persons of ordinary skill in the art that the disclosed methods and apparatus apply equally to uni-direction authentication (i.e., authentication of only one endpoint), and master-slave and client-server communications. It will also be readily apparent to persons of ordinary skill in the art that the disclosed methods and apparatus discussed herein are not dependent upon the use of a particular packet processing technique (e.g., asynchronous, synchronous, isochronous), a framing format, a communication technique, a communication link, etc.
FIG. 8 is a schematic diagram of an example processor platform 800 capable of implementing the examples illustrated in FIGS. 3-7 . For example, the processor platform 800 can be implemented by one or more general purpose microprocessors, microcontrollers, etc.
The processor platform 800 of the example of FIG. 8 includes a general purpose programmable processor 810 . The processor 810 executes coded instructions present in main memory of the processor 810 . The processor 810 may be any type of processing unit, such as a microprocessor from the Intel® Centrino® family of microprocessors, the Intel® Pentium® family of microprocessors, the Intel® Itanium® family of microprocessors, the Intel® XScale® family of processors, and/or the Intel® active management technology engine. The processor 810 may implement, among other things, the protocol processor 205 , the message encrypter 220 and/or the message authenticator 240 of FIG. 2 , and the examples illustrated in FIGS. 3-7 .
The processor 810 is in communication with the main memory (including a read only memory (ROM) 820 and a RAM 825 ) via a bus 805 . The RAM 825 may be implemented by Synchronous Dynamic Random Access Memory (SDRAM), Dynamic DRAM, and/or any other type of RAM device. The ROM 820 may be implemented by flash memory and/or any other desired type of memory device. Access to the memory space 820 , 825 is typically controlled by a memory controller (not shown) in a conventional manner. The RAM 825 may be used to implement the protected storage device 210 of FIG. 2 .
The processor platform 800 also includes a conventional interface circuit 830 . The interface circuit 830 may be implemented by any type of interface standard, such as an external memory interface, serial port, general purpose input/output, etc.
One or more input devices 835 are connected to the interface circuit 830 . The input devices 835 may be used to implement the message transmitter 225 of FIG. 2 . One or more output devices 840 are also connected to the interface circuit 830 . The output devices 840 may be used to implement the message receiver 235 of FIG. 2 .
Of course, one of ordinary skill in the art will recognize that the order, size, and proportions of the memory illustrated in the example systems may vary. For example, the user/hardware variable space may be larger than the main firmware instructions space. Additionally, although this patent discloses example systems including, among other components, software or firmware executed on hardware, it should be noted that such systems are merely illustrative and should not be considered as limiting. For example, it is contemplated that any or all of these hardware and software components could be embodied exclusively in hardware, exclusively in software, exclusively in firmware or in some combination of hardware, firmware and/or software. Accordingly, while the above described example systems, persons of ordinary skill in the art will readily appreciate that the examples are not the only way to implement such systems.
Although certain example methods, apparatus and articles of manufacture have been described herein, the scope of coverage of this patent is not limited thereto. On the contrary, this patent covers all methods, apparatus and articles of manufacture fairly falling within the scope of the appended claims either literally or under the doctrine of equivalents.
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Methods and apparatus to perform associated extensions for negotiated channel security protocols are disclosed. A disclosed method to extend a security protocol comprises exchanging identifying information between a first and a second endpoint, determining a secret based on the exchanged identifying information, determining a first master secret based on the determined secret and a second master secret determined in a prior protocol exchange block, and deriving a session key based on the first master secret.
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BACKGROUND OF THE INVENTION
This invention relates to a method for optically transmitting signals in measurement units, and a measurement system employing such optical transmission method.
It has hitherto been a normal method in the production process for television receivers or the like to inspect the assembling state using a plurality of measurement devices. For example, when inspecting the assembled state of television receivers by a plurality of measurement devices placed along a belt conveyor, it becomes necessary to transmit information signals between the measurement devices. For such case, it has been customary to perform signal transmission using communication systems having a RS232C or GPIB signal format.
However, such signal transmission makes use of electric cables, and insulation between the measurement devices cannot be achieved, so that there is a risk of circuit destruction due to the difference in the ground potential between the different measurement devices. Besides, connection by electric cables is not desirable because signal transmission by the cable is performed at a site where the noise is likely to be picked up, such as an assembly line.
In addition, it is difficult to raise the information transfer speed with the above enumerated communication systems, so that, if the number of measurement devices connected to the inspection system is increased, it becomes difficult to achieve smooth signal transmission.
SUMMARY OF THE INVENTION
The present invention a novel measurement device and method employing optical fiber communication. The measurement device for executing the present invention translates the information to be measured into optical signals using a photocoupler and a signal processor having a serial interface enclosed therein, and executes transmission of information signals over an optical fiber cable.
According to the present invention, a plurality of the input/output devices, each including a display device and a signal processing device, are interconnected by an optical fiber cable. The measurement device in the present invention may comprise a television camera, in which case an image processing device may be included in the television camera for providing a more compact system.
The measurement device may be further reduced in size by employing an input/output device in which the display device, the signal processing device and the input keyboard are housed integrally. In such case, the measurement device and the input/output device are interconnected by a fiber cable for light transmission.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a top plan view showing a general layout of signal transmission by plural measurement devices.
FIG. 2 is a schematic block diagram showing a signal processing device shown in FIG. 1.
FIG. 3 is a perspective view showing a photocoupler connected to a serial communication link.
FIG. 4 is a schematic block diagram showing a second embodiment of the measurement device shown in FIG. 1.
FIG. 5 is a partial perspective view showing a measurement system employing plural measurement devices.
FIG. 6 is a schematic block diagram showing a third embodiment of the measurement device.
FIG. 7 is a schematic block diagram showing fourth embodiment of the measurement device.
FIG. 8 is a partial perspective view showing a measurement device according to the fourth embodiment of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to the drawings, illustrative embodiments of the present invention will be explained in detail.
The optical signal communication method with the measurement device according to the present invention is employed for transmission of information signals between plural measurement devices. With the communication method according to the present invention, each measurement device includes a photocoupler and a signal processing unit having an interface enclosed therein. The photocouplers of the measurement devices are interconnected by an optical fiber to execute transmission of the information.
The signal communication method by the measurement device according to the present invention is executed by a signal communication device having measurement units shown in FIG. 1. That is, a plurality of signal processing units 6a, 6b and 6c and a plurality of photocouplers 5a, 5b, 5c, 5d, 5e and 5f are provided in each of a plurality of measurement units 1, 2 and 3.
Each of the signal processing units 6a, 6b and 6c is a signal processor having a 32-bit central processing unit (CPU) 21, as an example, as shown in FIG. 2. Each of the signal processing units 6a, 6b and 6c has a plurality of serial communication links 24 connected to the CPU 21 by a local bus 23.
Each of the signal processing units 6a, 6b and 6c also includes a memory 26 operated under control by the CPU 21, a timer 27 and an external memory interface 25 connected to an external memory, not shown. Thus it is possible for the CPU 21 of each of the signal processing units 6a, 6b and 6c to have communication of information signals with outside over the local bus 23 and the serial communication links 24. Such communication of the information signals is executed by direct memory accessing (DMA) so that transmission of the information at a rate of 20 M bits/sec is possible by bi-directional communication. For the signal processors 6a, 6b and 6c, a transputer manufactured by SGS Thomson Inc. under the trade name of IMST-805 may be employed.
The photocouplers 5a, 5b, 5c, 5d, 5e and 5f, shown in FIG. 3, are connected to each serial communication link 24. Each of the photocouplers 5a, 5b, 5c, 5d, 5e and 5f includes a light emitting section 8 made up of a light emitting diode or a laser diode, and a light receiving section 9 formed by a photodiode or a phototransistor. The light emitting section 8 emits light in a pulsed fashion responsive to digital information signals transmitted from the CPU 21 via the serial communication links 24. The light receiving section 9 receives the light transmitted from outside for translation into digital information signals which are supplied over the serial communication links 24 to the CPU 21.
The light emitting section 8 and the light receiving section 9 are arranged in a socket 10 provided on the front side of a casing member. An optical fiber 4 is coupled via a plug 11 to the socket 10. The photocouplers 5a to 5f execute information transmission, at the above-mentioned rate of 20 M bits/sec, using the non-return to zero (NRZ) code for the transmission signals.
The signal processors 6a, 6b and 6c are connected to measurement sections 7a, 7b and 7c, respectively. A variety of functions may be associated with the measurement sections 7a, 7b and 7c. For example, it is possible for the measurement sections 7a to 7c to measure the length or weight or to capture an image and to exchange signals with the signal processors 6a to 6c connected thereto. That is, the measurement sections 7a to 7c are controlled by control signals from the signal processors 6a to 6c and the measured results are transmitted to the signal processors 6a to 6c.
In this manner, the signal processor 6a, photocouplers 5a, 5b and the measurement section 7a make up the measurement unit 1, while the signal processor 6b, photocouplers 5c, 5d and the measurement section 7b make up the measurement unit 2 and the signal processor 6c, photocouplers 5e, 5f and the measurement section 7c make up the measurement unit 3. Although a sole signal processor and a sole measurement section are included in FIG. 1 in a measurement unit, there may be occasions where a plurality of signal processors and measurement sections are provided in one measurement unit.
A measurement device 28 employing the above-mentioned measurement units is shown in FIGS. 4 and 5. That is, the measurement device 28 includes a control computer 11 and, in an embodiment shown in FIG. 4, the measurement units 1 and 2 are connected via the optical fiber 4 to the control computer 11. The control computer 11 includes an input/output device 12 and a contactor 18 connected to the measurement section of the measurement unit. The input/output device 12 includes an indicator and a keyboard, not shown.
A plurality of the measurement devices 28 are incorporated into a production line, as shown in FIG. 5. A plurality of the input/output devices 12 are mounted on supporting pillars 29. Each of the input/output devices 12 includes a liquid crystal display device (LCD) 30. A plurality of the contractors 18 are connected to a plurality of objects to be measured 17, while being connected to the measurement devices 28 by flexible cables.
The measurement devices 28 are employed for such a case in which the objects to be measured 17, each placed on a palette transported on a belt conveyor 14, are assembled while measurement operations are performed thereon. Meanwhile, a mechanical section 16 includes an electric motor and a plunger for controlling the palette. The measurement devices 28 are supported on the bottom of the belt conveyor 14 and arrayed along the belt conveyor 14. The measurement devices 28 are interconnected by an optical fiber 31 for signal transmission between the measurement devices 28.
Referring to FIG. 4, the measurement device 28 includes a conveyor control section 13 connected to the control computer 11 by the optical fiber 4 for controlling the movement of the belt conveyor 14. Besides, the conveyor control section 13 is connected to a controller 15 by the optical fiber 4. The controller 15 controls the contactor 18, mechanical section 16 and an adjustment driver controller 19 which controls a screw driver 20 adapted for adjusting an adjustment screw of the object to be measured 17.
Meanwhile, the serial communication link shown in FIG. 2 is enclosed within each of the control computer 11, conveyor control section 13 and the adjustment driver controller 19 for enabling light communication at a rate of 20 M bits/sec.
FIG. 6 shows a modification in which the control computer 11 shown in FIG. 5 is integrally formed with the input/output device 12. That is, an input/output device 44 includes a control computer 39 therein and an operating key 46 connected to the control computer 39 via a key interface 47. The control computer 39 controls a display controller 49 to cause an image to be displayed on an LCD 45 along with an output of character generator 48.
As explained in connection with FIG. 4, a signal processor having a serial interface enclosed therein is included in the control computer 39 for having communication with the outside via the photocoupler 5. A cathode ray tube (CRT) may naturally be employed in place of the LCD 45.
In an embodiment shown in FIG. 6, a television camera 40 is employed as a measurement device. The television camera 40 includes an image pickup device 41, an image processing circuit 42 including an A/D converter, and a signal processor 43. The signal processor 43 naturally corresponds to the signal processor shown in FIG. 2 and includes a serial communication link. Thus the video signals produced by the image pickup unit 41 are translated by the image processing circuit 42 into digital signals which are transmitted from the photocoupler 5 to the control computer 39 of the input/output device 44 via the optical fiber 4.
In the embodiment shown in FIG. 6, outputs of plural television cameras 40, 50 are sequentially processed in a pre-set manner by the control computer 39. High-speed image processing may be achieved by providing plural signal processors 65, 66, 67 and 68 in the input/output device 60 as shown in FIG. 7 for parallel processing of digital video signals from television cameras 61, 62, 63 and 64. These signal processors 65 to 68 are connected to a control computer 70 for processing the signals in accordance with the control information from the operating key 46. The results of the processing are displayed on a display device 45.
If a plurality of television camera are employed in this manner, the present invention is employed on the production line as shown in FIG. 8. That is, a plurality of the television cameras 61, 62 and 63 are arranged along the belt conveyor 14. These television cameras 61 to 63 are arranged for imaging a sole object 69 from different angles. The results of measurement are processed by the input/output device 60 having the image processing unit enclosed therein.
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A measurement device includes a measurement unit, a signal processing unit having a serial interface and connected to the measurement unit for processing signals obtained at the measurement unit, and a photocoupler connected to the serial interface of the signal processing unit for converting processed signals into optical information. A measurement system may comprise a plurality of the measurement devices and a method for measuring an object may use the measurement devices.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention is directed to a device to block and divert lateral water spray generated from vehicle tires moving over a wet surface wherein water drops strike against the underside of the vehicle and are sprayed laterally outward.
2. Prior Art
When vehicle tires move across a wet surface, droplets of water will adhere to the tires and are thrown upward from the road. While these water droplets move in various directions, it has been found that a great amount of water is thrown upward against the underside of a vehicle. In the case of large trucks and tractor trailers with multiple large wheels, a large amount of water spray is thrown against the underside of the truck which then produces a spray of water in all directions. Particularly in cases of vehicles moving at fast highway speeds, water is thrown laterally outward from the underside of the vehicle and past the lateral sides of the vehicle. This laterally moving water spray is a problem to vehicles behind, to the side of, and approaching the truck or tractor trailer. Additionally, in winter conditions, salt water spray thrown laterally is damaging to vegetation.
While mudflaps are utilized (and are often required) to block the rearwardly moving water spray, the laterally moving water spray remains a problem.
This laterally moving water spray has been identified as a problem. As an example, Moore et al. (U.S. Pat. No. 3,675,943) discloses a bracket secured to the side of a truck bed and the hub of a wheel in order to create side mudflaps.
Alternate solutions have also been proposed. For example, Stropkay (U.S. Pat. No. 5,277,444) controls the lateral discharge of water spray from truck tires with a hollow body device having channels that direct air flow in order to create an air screen that discourages laterally moving water. Schmidt (U.S. Pat. No. 5,299,831) provides an exhaust suction device.
There remains a need for a simple device that may be attached to the body of a vehicle in order to block the lateral water spray generated from vehicle tires moving over a wet surface and divert it toward the center of the vehicle and downwardly away from the underside of the vehicle toward the ground.
There is also a need for a device to block and divert lateral water spray that may be simply and quickly attached to and detached from existing vehicles.
There is also a need for a device to block and divert lateral water spray which may be used and operated in conjunction with existing mudflaps.
There is also a need for a device to block and divert lateral water spray and discharge the water closer to the ground and toward the center of the vehicle.
SUMMARY OF THE INVENTION
The present invention provides a device to block and divert lateral water spray generated from a vehicle moving over a wet roadway. As the tires of the vehicle rotate, drops of water are adhered to the tires and are thrown upward against the underside of the vehicle. The water droplets are dispersed in all directions, causing a spray, cloud, or mist.
The water spray diverter device includes an elongated first gutter portion which is attached to one lateral side of the vehicle and extends beneath the level of the underside. The first gutter portion is lateral of the vertical plane of the outermost tire.
The first gutter portion may be permanently affixed to the tractor-trailer, or may be removably attached thereto.
The lateral water spray which strikes the underside of the vehicle and moves laterally will be trapped in the first gutter portion. The first gutter portion forms a continuous channel so that water droplets in the channel may move therein. The water droplets will tend to move in the first portion toward the rear of the vehicle.
The first gutter portion is connected at its rearmost end to a second gutter portion which is in fluid communication with the first gutter portion. The second gutter portion likewise forms a channel for direction and movement of water therein. The second gutter portion is angled away from the underside of the vehicle downward toward the roadway. The second gutter portion is also in angular relation to the first gutter portion so that the second gutter portion is angled toward the center of the vehicle.
The second gutter portion terminates in an open end where the water may be discharged. The second gutter portion terminates in front of the existing mudflap so that the second gutter portion discharges the water collected in front of the existing mudflap. Accordingly, the discharge of water is directed downward toward the ground so that it will exit beneath the lower edge of the mudflap. Additionally, the discharge of water is directed toward the center of the vehicle away from the lateral sides.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates a tractor-trailer and car moving across a wet roadway prior to introduction of the present invention;
FIG. 2 illustrates the tractor-trailer and car moving across a wet roadway as shown in FIG. 1 making use of the water spray diverter device of the present invention;
FIG. 3 illustrates a partial view of the tractor-trailer shown in FIG. 2 with the device to block and divert lateral water spray attached thereto;
FIG. 4 illustrates the device to block and divert lateral water spray apart from the tractor-trailer; and
FIG. 5 is a cross-sectional view of the water spray diverter device taken along section line 5--5 of FIG. 4 and FIG. 6 is an alternate embodiment of the water spray diverter device of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to the drawings in detail, FIG. 1 illustrates a view of the prior art without use of the present invention. Two vehicles, a tractor-trailer 12 and car 13 are shown moving across a wet roadway 14. In FIG. 1, the usual flexible mudflaps which extend from the underside of the vehicle toward the roadway 14 have been removed for clarity. The truck includes an underside 17 above the tires 16, a longitudinal center with lateral opposed sides 19 and 21. When large vehicles such as a tractor-trailer 12 move across a wet surface such as roadway 14, a great amount of water will adhere to the tires 16 as they rotate and be lifted and thrown upward from the road surface with force against the underside 17 of the truck 12. Upon striking the underside 17, this action causes a large amount of water spray to be thrown in all directions. As seen in FIG. 1, water causing a spray, cloud, or mist is thrown laterally outward from the underside of the vehicle past the lateral sides of the vehicle as indicated at reference numeral 18. While this spray, cloud, or mist is disbursed in all directions, a great portion of it is disbursed laterally.
It will be observed that the lateral water spray 18 poses a significant visibility problem for vehicles on either side of the tractor-trailer 12, including oncoming vehicles.
The direction of the water from the roadway 14 is initially upward as indicated by arrow 20 from the road surface toward the underside 17 of the tractor-trailer 12. Thereafter, the water droplets are thrown in all directions, including laterally outward as indicated by arrow 22.
FIG. 2 illustrates the tractor-trailer 12 and car 13 moving across a wet roadway 14 with the device to block and divert water spray 30 of the present invention installed. Again, the mudflaps which extend from the underside of the vehicle have been removed from the drawing for clarity. As the tires 16 rotate at great speed, drops of water are adhered to the tires and are thrown upward as shown by arrow 20. The water droplets strike with force against the underside 17 of the tractor-trailer 12. The water droplets may even be caused to be broken into smaller particles causing a spray, cloud, or mist.
Through the use of the present invention, however, the bulk of water droplets and water spray do not move laterally outward as in the description of FIG. 1. Rather, the laterally moving water droplets and spray are trapped in the diverter device 30 and directed downward toward the roadway or ground and also directed in the direction toward the center of the tractor-trailer 12. By directing the water toward the longitudinal center of the vehicle, the amount of water escaping laterally is minimized. This is indicated in FIG. 2 by arrow 32.
FIG. 3 illustrates a partial view of the tractor-trailer 12 with the rear tires 16 clearly visible. The underside 17 is above the level of the tires. The mudflap 34 is shown installed in place behind the rear wheels extending from the underside 17 of the vehicle.
The water spray diverter device 30 of the present invention includes an elongated first gutter portion 36 which is attached to one lateral side 19 of the tractor-trailer 12 and extends beneath the level of the underside 17. Alternatively, the first gutter portion 36 may be attached to the underside 17. The first gutter portion is lateral of the vertical plane of the outermost tire 16.
The first gutter portion 36 may be permanently affixed to the tractor trailer 12 or may be removably attached thereto. The first portion 36 may be removably connected to the tractor-trailer 12 through a clamp or clamps (not shown).
The diverter device 30 is somewhat flexible so that in the event a stone or other material strikes the device, or ice builds up, no damage will be done.
It has been found that a great proportion of the water spray moves laterally within a few inches of the underside. The lateral water spray previously described which strikes the underside 17 of the tractor-trailer 12 and moves laterally will be trapped in the first gutter portion 36. The first gutter portion 36 is slightly offset from the outermost tire so as to trap a substantial portion of the water spray therefrom.
The first gutter portion 36 forms a continuous channel so that water droplets in the channel may move therein. The diverter device 30 is used while the vehicle is moving so that the water droplets will tend to move in the first gutter portion 36 toward the rear of the vehicle. Stated another way, the first gutter portion 36 will be moving with the vehicle so that the water droplets will be directed rearward.
Additionally, the force of air due to the vehicle moving assists in forcing the water in the first gutter portion 36 rearward. The first gutter portion 36 is connected at its rearmost end 37 to an elongated second gutter portion 38 which is in fluid communication with the first portion. The second gutter portion 38 likewise forms a channel for direction and movement of water therein. The second gutter portion 38 is in angular relation to the first gutter portion at between 30 to 45 degrees. The water is thus moved from the lateral side of the vehicle where it is gathered and moved toward the longitudinal center of the vehicle.
Additionally, the second gutter portion is angled away from the underside of the vehicle 12 downward toward the roadway 14. The water gathered is, thus, displaced in two directions.
The second gutter portion 38 terminates in an open end 40 where the water is discharged.
FIG. 4 illustrates the diverter device 30 apart from the tractor trailer 12. The diverter device 30 includes a lip 42 with openings 44 for use in attaching the diverter device 30 to the vehicle. The first and second gutter portions each have arcuate cross sections and as seen in FIG. 5 the cross sections are hemispherical.
With continuing reference to FIG. 3, it will be observed that the open end 40 of the second gutter portion 38 discharges water in front of the existing mudflap 34. Accordingly, the discharge of water is directed downward toward the ground so that it will exit beneath the lower edge 42 of the mudflap.
It will be observed that both the first and second gutter portions are open channels to discourage blockage or ice build-up.
The opposite lateral side 21 would have a similar diverter device to collect and disperse water spray.
FIG. 6 is a view of an alternate embodiment of the diverter device 50 installed for the front tires 48 of a vehicle. A portion of the left front side of the vehicle 12, including the front bumper 52, is visible in FIG. 6. A first portion 54 is attached to the front wheel-well above the tire level. A second portion 56 is in fluid communication with the first portion and is in angular relation thereto. The water spray which would normally emanate from the front wheel-well is trapped and diverted.
Whereas, the present invention has been described in relation to the drawings attached hereto, it should be understood that other and further modifications, apart from those shown or suggested herein, may be made within the spirit and scope of this invention.
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A device to block and divert lateral water spray generated from a vehicle, the vehicle including a plurality of tires and a body having a pair of lateral sides on opposite sides of a center, an underside between said lateral sides, and a rear. The device includes a first gutter portion attached to one said lateral side to trap and direct said water spray toward said rear. A second gutter portion is in fluid communication with the first gutter portion in order to divert the water spray from the lateral side toward the center and away from the underside down toward the ground.
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CROSS REFERENCES TO RELATED APPLICATIONS
[0001] This application in a continuation of U.S. application Ser. No. 14/747,155, filed on Jun. 23, 2015, which is a continuation of U.S. application Ser. No. 14/043,043, filed on Oct. 1, 2013, now issued as U.S. Pat. No. 9,115,529, all disclosures of which are incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to improvements in window opening control devices, and more particularly to a device that is capable of limiting the travel of a casement window.
BACKGROUND OF THE INVENTION
[0003] One safety concern for children, with respect to the windows that may be installed into residential homes and other buildings, are its features that may serve to prevent accidental egress and serious injury from a fall. One preventative feature is the height that the windows are installed above the floor, which prevents toddlers from accidentally falling out, and inhibits small children from creatively seeking to observe the outside view from the sill of the window, which could result in an accidental fall therefrom.
[0004] Opening control devices for windows (WOCDs), which serve to releasably limit the travel that a window may undergo to a relatively small amount, which may be roughly four inches, are another feature that has been employed on sliding sash windows for that reason. They have also been utilized thereon to prevent unauthorized entry into the dwelling from the outside by an intruder. However, preventative measures in the form of WOCDs have not been pursued as vigorously for casement windows, which typically are hingedly connected in some fashion to the master window frame.
[0005] As building codes have sought to regulate the construction industry to improve child safety through the use of such devices (see e.g., ASTM F2090-10: “Standard Specification for Window Fall Prevention Devices with Emergency Escape (Egress) Release Mechanisms”), tradeoffs have been proposed to reduce the height restrictions for window installations where such devices are utilized. But such lessening of these window height requirements only serves to place greater importance on the integrity of the WOCDs, particularly their ability to automatically reset themselves, after having been manually released to open the casement window beyond its restricted range of movement.
[0006] The window opening control device of the present invention is uniquely adapted to not only limit the range of travel of the casement window to prevent accidental falls therefrom, and to automatically reset itself, but to also avoid the necessity of having to remove the screen from the window in order for the device to function properly.
Objects of the Invention
[0007] It is an object of the invention to provide a window opening control device that may releasably limit the travel of a casement window to an amount preventing accidental egress therefrom.
[0008] It is another object of the invention to provide a window opening control device for a casement window that is easily released to permit full travel of the casement window when desired.
[0009] It is a further object of the invention to provide a safety switch for a window opening control device for a casement window that prevents tampering by young children who may seek to impermissibly operate the safety device.
[0010] It is another object of the invention to provide a window opening control device for a casement window that automatically resets the device, after the window has been moved back to the closed position.
[0011] Further objects and advantages of the invention will become apparent from the following description and claims, and from the accompanying drawings.
SUMMARY OF THE INVENTION
[0012] A device may limit opening of a sash window that is hingedly coupled to a master window frame, and may include: a bracket attached to the sash; a first arm having a first end pivotally coupled to the bracket; a second arm having a first end pivotally coupled to the second end of the first arm; a means for biasing the second arm into a retracted position; and a release assembly. The release assembly may be secured within the master window frame and may include a hook member that is pivotable between a first position and a second position.
[0013] With the hook member occupying the first position, the hook portion thereon may be releasably received in an opening in the second end of the second arm, when the first and second arms are in the retracted position, and the sash is closed and received by the master window frame.
[0014] The first arm may normally occupy its retracted position, with respect to the bracket that is fixedly secured to the sash, by rotating downward into a vertically oriented position, and may be limited to that position through the prevention of any over-travel by a stop protruding from the bracket. The second arm may be configured to normally occupy its retracted position, with respect to the vertically oriented first arm and the bracket, by being biased against gravity to rotate upwardly to be positioned, and travel limited by a stop on the first arm, to occupy a somewhat vertical position, being at a small acute angle with respect to the first arm.
[0015] Once the hook portion of the hook member has been releasably received within the opening in the second end of the second arm, as described above, the sash may be opened, and the amount that it may be opened will be travel-limited according to the length of the first and second arms. The sash of the casement window being travel limited in this manner will prevent a small child from accidentally falling through the gap between the sash and the master window frame. When the user desires to open the window even further, the second arm may be disengaged from the hook of the release assembly, by rotating the hook to be in the second position.
[0016] The hook may be configured to extend from a graspable switch member, in order for a user's hand to more easily cause its pivotal movement between the first and second positions. The hook and switch member may be installed directly into a master window frame that is particularly configured to receive its envelope and permit pivotal movement therein, or it may instead be received within a base member that itself is adapted to be received within a simple opening in the master window frame and secured thereat.
[0017] The combination of the switch member and base member may serve to enable additional functionality. The switch member may be configured to receive a spring biased safety button therein, which may be slidable between a protruding position and a depressed position. The safety button may be configured to inhibit pivoting of the switch member and hook combination from its first position, when the button occupies its spring biased outwardly disposed position. When the button is depressed, pivoting of the switch member is no longer inhibited, and it may be pivoted into the second position to release the second arm from the hook member. The helical spring may also have its ends adapted to provide torsional biasing of the switch member relative to the base member, so that when the user releases their grasp of the switch member, it may be biased so that the combination switch member and hook member occupy the first position, and may readily accommodate engagement with the catch assembly.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1 illustrates a perspective view of the window opening control device of the present invention, installed upon a casement window master frame and its sash window, and with the device being used to releasably secure the window sash to prevent further travel of the opened window beyond the safe limit.
[0019] FIG. 2 illustrates the window opening control device and casement window of FIG. 1 , but with the device having been released to permit further travel of the opened window sash.
[0020] FIG. 2A is an enlarged detail view of the release assembly on the window frame and the catch assembly on the sash, as seen in perspective view of FIG. 1 .
[0021] FIG. 2B is an enlarged detail view of the bracket of the catch assembly of FIG. 1 , showing the possible use of backing plates to accommodate installation on a sash with a different profile.
[0022] FIG. 2C is a side view of the release assembly and a portion of the catch assembly, as installed on the casement window of FIG. 1 .
[0023] FIG. 2D is a front view of the release assembly protruding through the master frame of the casement window of FIG. 2C .
[0024] FIG. 2E is a top view of the release assembly of FIG. 2D , shown by itself.
[0025] FIG. 2F is a perspective view of the release assembly of FIG. 2E , but shown with the switch member cut away.
[0026] FIG. 2G is a bottom perspective view of the switch member.
[0027] FIG. 2H is a perspective view of the assembled hook member, the turning switch, and the safety button of the present invention.
[0028] FIG. 3 illustrates the catch assembly and the release assembly of the window opening control device of FIG. 2 , with the casement window omitted from the view, and with the catch assembly releasably secured to the release assembly, the arms of the catch assembly being in the retracted position, and with the sash having been closed with respect to the master frame.
[0029] FIG. 4 illustrates the catch assembly and the release assembly of the window opening control device of FIG. 3 , but with the arms of the catch assembly shown extended, for when the sash is opened with respect to the master frame, and thereby travel limited.
[0030] FIG. 4A illustrates a reverse perspective view of the release assembly of FIG. 4 , where the safety button has not been depressed.
[0031] FIG. 4B is an enlarged detail view of the release assembly retaining the second arm of the catch assembly, as seen in FIG. 4 .
[0032] FIG. 5 illustrates the catch assembly and the release assembly of the window opening control device of FIG. 4 , but with the safety button having been depressed, and the switch member pivoted to release the hook of the release assembly from the opening of the second arm of the catch assembly.
[0033] FIG. 5A illustrates a reverse perspective view of the release assembly of FIG. 5 , where the safety button has been depressed, and the switch member pivoted.
[0034] FIG. 5B is an enlarged detail view of the release assembly shown in FIG. 5 .
[0035] FIG. 6 illustrates the catch assembly and the release assembly of the window opening control device of FIG. 5 , but with arms of the catch assembly moving into the retracted position as a result of spring biasing.
[0036] FIG. 7 is an exploded view of the parts used for assembly and installation of the opening control device of the present invention.
[0037] FIG. 8 is a perspective view of the bracket of the catch assembly of the opening control device of the present invention.
[0038] FIG. 8A is a front view of the bracket of the catch assembly of FIG. 8 .
[0039] FIG. 8B is a side view of the bracket of the catch assembly of FIG. 8 .
[0040] FIG. 8C is an end view of the bracket of the catch assembly of FIG. 8 .
[0041] FIG. 9 is a perspective view of the first arm of the catch assembly of the opening control device of the present invention.
[0042] FIG. 9A is a front view of the first arm of the catch assembly of FIG. 9 .
[0043] FIG. 9B is a side view of the first arm of the catch assembly of FIG. 9 .
[0044] FIG. 9C is an end view of the first arm of the catch assembly of FIG. 9 .
[0045] FIG. 10 is a perspective view of the second arm of the catch assembly of the opening control device of the present invention.
[0046] FIG. 10A is a front view of the second arm of the catch assembly of FIG. 10 .
[0047] FIG. 10B is a side view of the second arm of the catch assembly of FIG. 10 .
[0048] FIG. 10C is an end view of the second arm of the catch assembly of FIG. 10 .
[0049] FIG. 11 is a perspective view of the torsion spring of the catch assembly of the opening control device of the present invention.
[0050] FIG. 11A is a front view of the torsion spring of the catch assembly of FIG. 11 .
[0051] FIG. 11B is a side view of the torsion spring of the catch assembly of FIG. 11 .
[0052] FIG. 11C is an end view of the torsion spring of the catch assembly of FIG. 11 .
[0053] FIG. 12 is a perspective view of the rivet of the catch assembly of the opening control device of the present invention.
[0054] FIG. 12A is a front view of the rivet of the catch assembly of FIG. 12 .
[0055] FIG. 12B is a side view of the rivet of the catch assembly of FIG. 12 .
[0056] FIG. 12C is an end view of the rivet of the catch assembly of FIG. 12 .
[0057] FIG. 13 is a perspective view of the base member of the release assembly of the opening control device of the present invention.
[0058] FIG. 13A is a front view of the base member of the release assembly of FIG. 13 .
[0059] FIG. 13B is a side view of the base member of the release assembly of FIG. 13 .
[0060] FIG. 13C is an end view of the base member of the release assembly of FIG. 13 .
[0061] FIG. 14 is a perspective view of the switch member of the release assembly of the opening control device of the present invention.
[0062] FIG. 14A is a front view of the switch member of the release assembly of FIG. 14 .
[0063] FIG. 14B is a side view of the switch member of the release assembly of FIG. 14 .
[0064] FIG. 14C is an end view of the switch member of the release assembly of FIG. 14 .
[0065] FIG. 15 is a perspective view of the hook member of the release assembly of the opening control device of the present invention.
[0066] FIG. 15A is a front view of the hook member of the release assembly of FIG. 15 .
[0067] FIG. 15B is a side view of the hook member of the release assembly of FIG. 15 .
[0068] FIG. 15C is an end view of the hook member of the release assembly of FIG. 15 .
[0069] FIG. 16 is a perspective view of the safety button of the release assembly of the opening control device of the present invention.
[0070] FIG. 16A is a front view of the safety button of the release assembly of FIG. 16 .
[0071] FIG. 16B is a side view of the safety button of the release assembly of FIG. 16 .
[0072] FIG. 16C is an end view of the safety button of the release assembly of FIG. 16 .
[0073] FIG. 17 is a perspective view of the spring of the release assembly of the opening control device of the present invention.
[0074] FIG. 17A is a front view of the spring of the release assembly of FIG. 17 .
[0075] FIG. 17B is a side view of the spring of the release assembly of FIG. 17 .
[0076] FIG. 17C is an end view of the spring of the release assembly of FIG. 17 .
[0077] FIG. 18A shows the decal of the exploded view of FIG. 7 that may be used to position holes on the sash for proper positioning thereon of the catch assembly of the opening control device of the present invention.
[0078] FIG. 18B shows the decal of FIG. 18B being further used to coordinate the hole positions on the sash with proper positioning of the holes on the master window frame, for proper mounting thereon of the release assembly.
[0079] FIG. 19 is an exploded view of the parts forming a second embodiment of the opening control device of the present invention, including a V-shaped torsion spring.
[0080] FIG. 20 illustrates the catch assembly and the release assembly of the second embodiment of the window opening control device of the present invention, with the casement window omitted from the view, and with the catch assembly releasably secured to the release assembly, the arms of the catch assembly being in the retracted position, and with the sash having been closed with respect to the master frame.
[0081] FIG. 21 illustrates the catch assembly and the release assembly of the window opening control device of FIG. 20 , but with the arms of the catch assembly shown extended, for when the sash is opened with respect to the master frame, and thereby travel limited.
[0082] FIG. 22 is a first perspective view of the base member of the release assembly of the second embodiment of the opening control device of the present invention.
[0083] FIG. 22A is a second perspective view of the base member of FIG. 22 .
[0084] FIG. 22B is a third perspective view of the base member of FIG. 22 .
[0085] FIG. 22C is a fourth perspective view of the base member of FIG. 22 .
[0086] FIG. 22D is a fifth perspective view of the base member of FIG. 22 .
[0087] FIG. 22E is a sixth perspective view of the base member of FIG. 22 .
[0088] FIG. 23 is a front view of the base member of FIG. 22 .
[0089] FIG. 23A is a rear view of the base member of FIG. 22 .
[0090] FIG. 24 is a first side view of the base member of FIG. 22 .
[0091] FIG. 24A is a second side view of the base member of FIG. 22 .
[0092] FIG. 25 is an end view of the base member of FIG. 22 .
[0093] FIG. 26 is a first perspective view of the switch member of the release assembly of the second embodiment of the opening control device of the present invention.
[0094] FIG. 26A is a second perspective view of the switch member of FIG. 26 .
[0095] FIG. 26B is a third perspective view of the switch member of FIG. 26 .
[0096] FIG. 26C is a fourth perspective view of the switch member of FIG. 26 .
[0097] FIG. 26D is a fifth perspective view of the switch member of FIG. 26 .
[0098] FIG. 26E is a sixth perspective view of the switch member of FIG. 26 .
[0099] FIG. 27 is a front view of the switch member of FIG. 26 .
[0100] FIG. 27A is a rear view of the switch member of FIG. 26 .
[0101] FIG. 28 is a first side view of the switch member of FIG. 26 .
[0102] FIG. 28A is a second side view of the switch member of FIG. 26 .
[0103] FIG. 29 is a first end view of the switch member of FIG. 26 .
[0104] FIG. 29A is a second end view of the switch member of FIG. 26 .
[0105] FIG. 30 is a perspective view of the hook member of the release assembly of the second embodiment of the opening control device of the present invention.
[0106] FIG. 31 is a front view of the hook member of FIG. 30 .
[0107] FIG. 32 is a side view of the hook member of FIG. 30 .
[0108] FIG. 33 is an end view of the hook member of FIG. 30 .
[0109] FIG. 34 is a perspective view of the torsion spring of the catch assembly of the release assembly of the second embodiment of the opening control device of the present invention.
[0110] FIG. 35 is a front view of the torsion spring of FIG. 34 .
[0111] FIG. 36 is a side view of the torsion spring of FIG. 34 .
[0112] FIG. 37 is an end view of the torsion spring of FIG. 34 .
DETAILED DESCRIPTION OF THE INVENTION
[0113] FIG. 1 illustrates a perspective view of the catch assembly of the window opening control device of the present invention having been installed upon a master frame and sash of a casement window. The device is being used thereon to releasably secure the sash to the master frame to prevent further travel of the opened window sash beyond the safe limit. Depressing of a safety button and pivoting of a switch member causes release of the device to permit further travel of the opened window sash, as seen in FIG. 2 .
[0114] The two main assemblies of the opening control device of the present invention are seen in the enlarged detail view of FIG. 2A , and consist of the catch assembly 100 , and the release assembly 200 . The catch assembly 100 and release assembly 200 may be secured to the sash window 11 and the master window frame 21 , respectively, and are discussed further hereinafter.
[0115] The catch assembly 100 may consist of a bracket 110 , a first arm 120 , a second arm 130 , and a torsion spring 140 . The bracket 110 is shown in detail within FIGS. 8-8C . Bracket 110 may be a generally flat plate that may be pocketed to reduce weight in-between certain features that are necessary to enable use of the bracket. Bracket 110 may include a pair of mounting holes 111 A and 111 B, which may be formed with a countersink to accommodate flush head mounting screws therein, in order to suitably mount the bracket to the side of the sash 11 . A hole 112 in the bracket 110 may be used for pivotal mounting thereto of the first arm 120 , which may be pivotally mounted using a rivet 159 , or other suitable pivotal fastening means. The bracket 110 may include a protruding stop member thereon, which may be used to limit travel of the pivotally mounted first arm 120 with respect to the bracket, when the arm is in the retracted position. The mounting holes 111 A and 111 B may be symmetrically positioned in the bracket, and may be symmetrically positioned with respect to the hole 112 that is used for pivotal mounting of the first arm 120 , which may be centered therein. With the hole 112 being centrally positioned, the pivotal stop may be located towards one end of the bracket 110 , to reduce loading of those features of the bracket. In order to be able to use the bracket for mounting to either a left-hand or a right-hand sash of the casement window, there may be a first pivotal stop 113 A located at one end of the bracket 110 , and a second pivotal stop 113 B located at the other end of the bracket. Each of the stops 113 A and 113 B of bracket 110 of the catch assembly 100 may have a “V” shaped cavity formed by a slanted surface 113 S ( FIG. 8 ) of the stop, which works for guiding automatic alignment of the first arm 120 when the catch assembly 100 is biased back towards the sash 11 , and thereafter the stop 113 completely inhibits further rotation of the first arm 120 at the fully retracted position with respect to bracket 110 .
[0116] The first arm 120 is shown in detail in FIGS. 9-9C , and may be an elongated thin plate member, which may be formed of plastic, metal, or any other suitable material. Proximate to the first end 121 of the arm 120 may be a hole 123 usable for pivotal mounting of the arm to the hole 112 of bracket 110 . Hole 123 may be an eccentric or slotted hole, through which the first arm 120 is riveted with the bracket 110 of catch assembly 100 via the rivet 159 . It provides free movements of the first arm 120 in all directions when the first arm 120 retracts to the sash 11 when the catch assembly 100 is unlocked from the release member 200 . Proximate to the second end 122 of the first arm 120 may be a hole 124 for the pivotal mounting thereto of the second arm 130 . Also proximate to the second end 122 may be a recess 126 in the side of the plate, which may be generally flat at a central portion. The first arm 120 may have a stop 125 positioned thereon to be in proximity to hole 124 . The stop could simply be a mechanical fastener that is fastened to the plate, such as a rivet or a nut and bolt. Alternatively, the stop could be a protrusion that is integral with the plate or bonded thereto, or the stop could be a portion of the plate being stamped and raised to protrude beyond the flat plane of one side of the arm. The latter option is shown in FIG. 9A , which may be seen to produce a straight edge for the stop that may generally be aligned with the position of the edge of the second arm 130 where it is to be restrained in the retracted position.
[0117] The second arm 130 is seen in detail within FIGS. 10-10C , and may, in general, be constructed similar to first arm 120 . Second arm 130 may be an elongated thin flat plate member, with a hole 133 proximate to its first end 131 , to be usable for pivotal mounting of the second arm to hole 124 of the first arm 120 . At the first end 131 of the second arm 130 , a small protrusion 134 may protrude orthogonally from the side of the arm, and may be formed by any of the means cited above for producing stop 125 . The protrusion 134 shown within FIG. 10 is shown as a small tab at the first end 131 that is bent at roughly a 90 degree angle. The protrusion 134 works as a stop to limit the over rotation of the second arm 130 with respect to the first arm 120 , and is received in the recess 126 of the first arm 120 when the sash is to maximum limit opening position, which his discussed further hereinafter. The second end 132 of the second arm 130 may have a shaped opening 135 therein, which may be generally rectangular, and which may further have a notch 135 N therein, both of which are discussed later as to the operation of the opening control device.
[0118] The pivotal mounting of the second arm 130 to the first arm 120 may utilize a simple rivet or other mechanical fastener, and one of many different varieties of springs, which may be a tension spring or a torsion spring. Merely to be exemplary, use of torsion spring 140 and rivet 150 is utilized herein. An exemplary torsion spring 140 is illustrated within FIGS. 11-11C , and may include a small number of helical windings 140 W or even just a portion of one winding that may terminate in a first end 141 via a radial portion 141 R, and in a second end 142 . The first and second ends 141 and 142 may be used to bias the second arm 130 with respect to the first arm 120 . (An alternative V-shaped torsion spring 340 is disclosed hereinafter discussed alternate embodiment).
[0119] In this exemplary arrangement, a rivet 150 , which is shown in detail within FIGS. 12-12C , may have a first post 151 extending from the head 153 , and a second post 152 telescoping therefrom. Pivotal mounting of the first and second arms 120 and 130 may be achieved by first receiving the helical windings 140 W of the torsion spring 140 upon the first post 151 of rivet 150 , such that its radial portion 141 R of the first end 141 is received through opening 153 P in the head 153 of the rivet 150 (see FIG. 7 and FIG. 3 ). Next, the second arm 130 may be mounted upon the rivet 150 such that hole 133 of the second arm is received upon, and sized to be pivotal with respect to, the first post 151 of the rivet. The first arm 120 may then be mounted upon the rivet 150 such that hole 124 of the arm is received upon its second post 152 . The side of the arm may abut the shoulder ISIS formed by the side of the post 151 and the post 152 . The second end 142 of torsion spring 140 may loop about the side of the elongated flat plate of the first arm, as seen for example in FIG. 4 . The post 152 may then be bucked to fixedly secure the first arm 120 to the shoulder 151 S, so that there will be no relative motion therebetween. Instead of relying upon the bucked post 152 to fixedly secure the first arm 120 to the rivet 150 , the post 152 may have a flat side 152 D, as seen in FIG. 12A , to form a D-shaped profile, which may be mated to a correspondingly keyed opening 124 D ( FIG. 9A ) that may be used instead of the plain round hole.
[0120] Therefore, as seen in FIG. 2A , when the bracket 110 of catch assembly 100 is properly mounted to the sash (i.e., with the bracket generally oriented in the vertical direction and using backing plate(s) 110 A/ 110 B that are shown in FIG. 2B to accommodate different sash/frame profiles), the first arm 120 may normally pivot downwardly (clockwise in the view) about the bracket due to gravity, until reaching the stop 113 A of the bracket. At the same time, torsional biasing provided by torsion spring 140 may cause the second arm 130 to pivot upwardly (counterclockwise in the view), in opposition of the force of gravity, until the side of the second arm contacts the stop 125 on the first arm 120 . Without any forces acting upon the catch assembly 100 , it may normally occupy this retracted position that is illustrated within FIG. 2A .
[0121] An exemplary release assembly 200 is shown separately in FIG. 4A , but in its simplest form it may instead consist of a hook element configured to be pivotally received in the master window frame, where a hook portion of the element may be configured to engage the shaped opening 135 in the second end of the second arm 130 , and be disengaged therefrom through its pivotal motion within the master window frame. This pivotal movement of this hook element that enables engagement within the opening and disengagement therefrom of its hook portion, especially using the notch 135 N in the second arm 130 , may be seen in viewing FIGS. 4B and 5B . This simple version of the hook element may be a slightly modified version of the combination of the hook member 210 and base member 230 that are discussed hereinafter.
[0122] For ease of manufacturing and/or other reasons, this simplified hook element may be replaced by the combination of the separate hook member 210 that is shown within FIGS. 15-15C and the separate graspable switch member 220 that is shown within FIGS. 14-14C .
[0123] The hook member may take many different shapes, however, the exemplary hook member 210 shown in FIG. 15 may be a narrow, thin-shaped material that is formed to have a hook portion 212 extending from one end of its shank 211 . The other end of the shank 211 may have an eye formed thereat, or it may instead be formed with a return flange 214 that extends from a cross-member 213 to create a clasp portion 210 C. The clasp portion 210 C may be fixedly secured to a corresponding retaining member 222 formed within a recess 220 R of the switch member 220 , so that the angled hook portion 210 C of hook 210 protrudes outwardly therefrom (see FIG. 2H ). The length of the shank 211 and its shape may be particularly formed so as to permit the hook portion 212 to be somewhat flexible with respect to the clasp portion 210 C, after it has been secured to the retaining member 222 of the switch member 220 . The clasp portion 210 C of hook member 210 may be fixedly secured within the corresponding recess 220 R of the switch member 220 using a friction fit, or using adhesive, or mechanical fasteners, or any suitable fastening means or combination thereof.
[0124] The shaft 221 of the switch member 220 may be formed to be pivotally received within a corresponding opening in the window master frame, and such an opening may be added to a window that is already installed and in service in a dwelling. However, to more easily accommodate installation of the release assembly 200 within the master frame of a newly manufactured window, and to further accommodate additional features of the opening control device of the present invention, the switch member 220 may instead be formed to be pivotally received within a base member 230 , which is illustrated within FIGS. 13-13C .
[0125] The base member 230 may have a correspondingly shaped shaft 231 that extends from a flange 232 . The flange 232 may have a pair of holes 233 A and 233 B formed therein to receive fasteners for mounting of the base member to the master window frame 21 , as seen in FIG. 2C . FIG. 2D shows the shaft 231 of the base member 230 installed within, and protruding from, the opening in the master window frame.
[0126] The shaft 221 of the switch member 220 may have a stop 223 protruding therefrom ( FIG. 14 ), which may serve to limit pivotal travel of the switch member to 90 degrees of travel within the shaft 231 of the base member 230 ( FIGS. 4A and 5A ). The travel of the switch member 220 may be so limited by a pair of corresponding stops formed within the hollow of the shaft 231 of the base member 230 .
[0127] As an additional safety precaution, to better prevent a mischievous child from rotating the switch member 220 to disengage the opening control device to open the window fully, the device of the current invention may furthermore include a safety button 240 , which is illustrated within FIG. 16-16C , and which may be biased by the helical spring 250 that is shown within FIGS. 17 - 17 C. The safety button 240 may have a cylindrical head portion 240 H, from which may extend two pairs of legs—a first pair of legs, 241 A and 241 B, and a second pair of legs, 242 A and 242 B. The safety button 240 may also have a post 243 protruding away from the bottom of the head portion 240 H, upon which may be received the first end 251 of the helical spring 250 .
[0128] This combination of helical spring 250 and safety button 240 may be received within the opening 224 in the shaft of the switch member 220 , such that the pairs of legs are slidably received within corresponding elongated recesses therein, which may serve to prevent rotation of the safety button with respect to the switch member. The second pairs of legs, 242 A and 242 B, as seen in FIG. 16 , which may be longer than the first pair of legs, may have respective outwardly extending flanges 242 A F and 242 B F .
[0129] Although it may be understood by one skilled in the art that other features may be used to similarly accomplish functional mating of the safety button 240 , the switch member 220 , and the base member 230 , the second pair of legs 242 A and 242 B of the safety button may herein be received through correspondingly shaped openings 225 A and 225 B in the switch member ( FIGS. 7 and 14A ), to secure the safety button to the switch member. The second pair of legs will need to be elastically deflected inwardly in order for the outwardly extending flanges 242 A F and 242 B F of the legs to be received through the opening 224 in the shaft 221 of the switch member 220 . Once having passed therethrough, the legs would naturally deflect back to their undeformed position, as seen in FIG. 16A , and may thereby secure the safety button 240 with respect to the switch member 220 , as a portion of the outwardly extending flanges 242 A F and 242 B F of the legs would now overhang beyond the diametrical periphery of the shaft 221 (see FIGS. 14C and 16B ). The helical spring 250 retained between the safety button 240 and the base member 230 may serve to normally bias the button to have a portion protrude outwardly beyond the graspable handle portion 226 of the switch member 220 ( FIG. 4A ).
[0130] This subassembly—the switch member 220 , the safety button 240 , and the spring 250 —may be coupled with the base member 230 , with the shaft 221 of the switch member being received within the opening 234 of the shaft 231 of the base member 230 . The second pair of legs 242 A and 242 B may again need to be elastically deflected inwardly in order for the outwardly extending flanges 242 A F and 242 B F thereon that protrude beyond the diametrical periphery of the shaft 221 , to be received through the opening 234 in the shaft 231 of the base member 230 . The outwardly extending flanges 242 A F and 242 B F may also be aligned to be received through the correspondingly shaped openings 235 A and 235 B in the base member (see FIG. 7 , and FIGS. 13A, 14A, and 16B ). Once having passed therethrough, the second pair of legs would again naturally deflect outwardly back to their undeformed position and would extend slightly beyond the periphery of the opening 234 ( FIG. 13A ), to thereby secure the subassembly of the switch member 220 , spring 250 , and safety button 240 with respect to the base member 230 . In addition, with the formation of the shaped openings 235 A and 235 B in the base member, the lateral extent of which may protrude in the axial direction to be slightly beyond the point where the outwardly extending flanges 242 A F and 242 B F overhang the periphery of the opening 234 of the shaft 231 , pivoting of the switch member relative to the base member may thereby be inhibited. This functions as a safety—a means of preventing inadvertent actuation of the release member of opening control device, by some person not familiar with the device (i.e., a child-proof safety). However, by depressing the safety button 240 to overcome the biasing by spring 250 , the portion of the outwardly extending flanges 242 A F and 242 B F of the second pair of legs that were still nested within the lateral extent of the openings 235 A and 235 B in the base member, may now protrude beyond its extent, and thus the switch member is then free to pivot until such pivoting is limited by the aforementioned stops, being after roughly 90 degrees of rotation (see FIGS. 2F, 2G, and 2H ).
[0131] Another additional feature that may be incorporated into release assembly 200 may be the further provision that the helical compression spring 250 that is used to normally bias the safety button 240 outwardly from the opening 224 in the switch member 220 , may also be formed to have its first and second ends 251 and 252 be usable for providing torsional biasing of the switch member 220 relative to the base member 230 . The radial over-center portion 253 of spring 250 at its first end 251 ( FIG. 17C ) may be received in the groove 243 G in the post 243 of the head 240 H of the safety button 240 ( FIG. 16 ). Also, the outwardly extending hook portion 254 at the second end 252 of the spring 250 may similarly be restrained within a portion of the base member 230 . Therefore, when the safety button 240 of the release assembly 200 is depressed and the switch member 220 is manually pivoted 90 degrees to thereby also pivot hook portion 212 ( FIG. 5A ), after the user releases his/her grip from the switch member, the dual-biasing spring 250 may then serve to bias the switch member to counter-rotate the 90 degrees, and as well as serve to bias the safety button to translate outwardly to once again be positioned as seen in FIG. 4A .
[0132] Operation of the opening control device of the present invention may thus be understood by initially viewing FIG. 2 . With the catch assembly 100 shown in its normally retracted position on window sash 11 , as described hereinabove, the opened window sash may then be closed, which may serve to bring the catch assembly on the sash into proximity with the release assembly 200 on the master window frame, and cause engagement between the hook portion 212 of the hook member 210 and the shaped opening 135 of the second arm 130 . This is illustrated within FIG. 3 , in which the sash and the master window frame are not shown, to better illustrate the engagement therebetween, which occurs automatically through the mere closing of the window. The flexibility of the shank 211 of the hook 210 may serve to aid in the engagement therebetween, as the approaching side of the second arm 130 may cause the angled hook portion 212 to deflect out of its way, and then it may deflect back, as the opening 135 in the arm reaches the hook portion 212 . The generally rectangular shape of the opening 135 in the second arm 130 may also serve to better accommodate capture of the hook portion 212 of the shank 211 of hook member 210 , which will be protruding substantially orthogonally from the master window frame 21 .
[0133] When the user opens the window, the bracket 110 on the sash moves away from the release assembly 200 on the master window frame. The engagement between the hook portion 212 of the hook member 210 and the shaped opening 135 of the second arm 130 serves to overcome the torsional biasing of the spring 140 , so that increasing distance between the sash 11 and master frame 21 ( FIG. 1 ) results in the extension of the first and second arms 120 and 130 , as seen in FIG. 4 . (Note, recess 126 on first arm 120 and small tab 134 on second arm 130 may prevent over-travel therebetween). The length of the first and second arms 120 and 130 may be sized so that this limited travel of the sash 11 is small enough to prevent a child from accidentally falling through the opening, and may be roughly four inches.
[0134] As seen in FIGS. 1 and 2 , the opening control device may be positioned on an upper part of the sash and master window frame to make it more difficult for a small child to reach the release assembly. When an adult desires to open the window beyond the travel limited position of FIG. 1 , the safety button 240 of the release assembly 200 , as seen in FIG. 4A , may be depressed and the switch member 220 may be rotated, so that it appears as shown in FIG. 5A . This results in the hook portion 212 of hook member 210 moving from its initial engaged position, as seen in FIG. 4B , to the disengage position, as seen in FIG. 5B . Note that the notch 135 N in the opening 135 of the second arm 130 may be shaped as shown in FIG. 10A , so that with the second arm extended as seen in FIG. 4 , rotation of the hook member 210 would not tend to cause its hook portion 212 to jam against the side of second arm, and may freely exit from the opening 135 through the notch, as shown in FIG. 5B . The hook member may thus be freely rotated from its first hooked position, wherein the hook 212 of the release assembly is connected with the second arm of the catch assembly, to its second unhooked or position. Once the hook 210 is disengaged, retraction of the arms may occur, where the force of gravity may cause the first and second arms 120 and 130 to drop vertically, and the second arm may also pivot with respect to the first arm, due to biasing by spring 140 , and both may move away from the release assembly 200 , as seen in FIG. 6 , until reaching the retracted position seen in FIG. 2 . The sash may now be fully opened.
[0135] An alternate embodiment of the catch assembly 100 and release assembly 200 may be catch assembly 101 and release assembly 201 that is formed using component parts being generally the same as those in FIG. 7 , but with some minor adjustments have been made thereto, and with the modified parts being shown within the exploded view of FIG. 19 .
[0136] The torsion spring 140 of FIG. 7 and FIGS. 11-11C may be replaced by torsion spring 340 , which is shown in detail within FIGS. 34-37 . Torsion spring 340 may include a small number of helical windings 340 W that may terminate in a first leg 341 and a second leg 342 . At the end of the first leg 341 being distal from the windings may be formed a hook portion 341 H, and at the end of the second leg 342 may be formed a hook portion 342 H. The first and second legs 341 and 342 may be used to bias the second arm 130 with respect to the first arm 120 . However, with this arrangement, the bias that is applied by torsion spring 340 is applied directly to arms 120 and 130 , whereas, for spring 140 , the bias is applied through the rivet 150 and its connection to the first arm 120 . As seen in FIG. 20 , for catch assembly 101 and release assembly 201 , the hook portion 341 H of the first leg 341 of torsion spring 340 may wrap around the first arm 120 , in proximity to its stop 125 , while the hook portion 342 H of the second leg 342 may wrap around the second arm 130 . When the first arm 120 and second arm 130 are extended by opening of the sash, the torsion spring is elastically deformed, and as seen in FIG. 21 , the first and second legs 341 and 342 of the spring 340 being so deformed apply a biasing force to the arms 120 and 130 . Here again, once the release assembly 201 no longer has its hook secured within the opening 135 of the second arm, the spring 340 will bias the two arms to rotate toward each other until the side of the second arm contacts stop 125 , as seen in FIG. 20 .
[0137] For release assembly 201 , the hook member used therein may take a slightly different shape, and a hook member 410 , which is shown in detail within FIGS. 30-33 , may be used instead of hook 210 . Hook 410 may be formed similar to hook 210 , but may have a hook portion 410 C that is more rectangular in shape, and its return flange 414 may have a bent end flange 415 thereon, which may serve to more positively retain the hook in engagement with the switch member. The release assembly 201 may also use a base member 430 and a switch member 420 , with the features of each being shown in detail within FIGS. 22-25 , and FIGS. 26-29 , respectively.
[0138] The examples and descriptions provided merely illustrate a preferred embodiment of the present invention. Those skilled in the art and having the benefit of the present disclosure will appreciate that further embodiments may be implemented with various changes within the scope of the present invention. Other modifications, substitutions, omissions and changes may be made in the design, size, materials used or proportions, operating conditions, assembly sequence, or arrangement or positioning of elements and members of the preferred embodiment without departing from the spirit of this invention.
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A device may limit opening of a sash hingedly coupled to a master frame, and includes: a bracket attached to the sash; a first arm having a first end pivotally coupled to the bracket; a second arm having a first end pivotally coupled to the first arm's second end; means for biasing the second arm into a retracted position; and a release assembly. The release assembly is secured to the master frame and includes a hook pivotable between a first position and a second position, which, in the first position, may be releasably received in an opening in the second end of the second arm when the second arm is in the retracted position, as the sash is closed and received within the master window frame The second arm is disengaged from the hook, permitting full opening of the sash, when the hook is pivoted into the second position.
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TECHNICAL FIELD
The present invention relates to parental control for accessing an IP Multimedia Subsystem network. More particularly, the invention pertains to means and method for an implicit registration of a number of Private User Identities of a subscriber of an IP Multimedia Subsystem upon an explicit registration of the subscriber in the IP Multimedia Subsystem with a given Private User Identity and a given Public User Identity.
BACKGROUND
3GPP defines an IP Multimedia Subsystem and, more specifically, the IP Multimedia Core Network Subsystem to enable support for IP multimedia applications. For the sake of simplicity, and since the IP Multimedia Subsystem is defined by 3GPP as being access-independent, all references are made throughout this specification to the IP Multimedia Subsystem (hereinafter IMS).
According to 3GPP, a user may register into the IMS network or receive a terminating call to experience IMS services. To this end, such user must be given a subscription to the IMS.
A user with an IMS subscription is given one or more Private User Identities. An IMS Private User Identity (hereinafter IMPI) is assigned by the home network operator, and is used for Registration, that is, for Authorization and Authentication into the IMS network. A user may also have one or more Public User Identities. An IMS Public User identity (hereinafter IMPU) is used by any user as a user's identifier for communications with other users.
Generally speaking, any IMPU of an IMS subscription may be shared by more than one IMPI within the same IMS subscription. In particular, an IMPU may be shared amongst all the IMPI's of an IMS subscription as stated in 3GPP TS 23.228. This feature is called IMPU sharing, and such IMPU is generally known under 3GPP as a ‘shared IMPU’.
In this respect, FIG. 1 illustrates an exemplary IMS subscription in accordance with 3GPP, wherein “Public User Identity—3” and “Public User Identity—4” are both shared by all the IMPI's of the IMS subscription, namely “Private User Identity—1” and “Private User Identity—2”, and are thus both considered ‘shared IMPU's’.
On the one hand, an IMS subscriber may register into the IMS network with an IMPI/IMPU pair selected by the IMS subscriber amongst those IMPI's and IMPU's associated in the IMS subscription of the IMS subscriber. The IMS subscriber thus registers into the IMS with a ‘Register’ message of a Session Initiation Protocol (hereinafter SIP), as defined by 3GPP, and including a selected IMPU/IMPI pair. Moreover, 3GPP further discloses a so-called ‘implicit registration set’ (hereinafter IRS) of more than one IMPU so that, where a given IMPU registered in an IMPI/IMPU pair is included in an IRS, all the IMPU's included in said IRS are considered to be registered as well.
On the other hand, 3GPP TS 24.229 Rel-7 introduces the concept of contact addresses into the IMS network. In this respect, the contact address can be defined as a SIP Uniform Resource Identifier (hereinafter a ‘SIP URI’) containing the IP address of the user equipment (hereinafter UE). Under certain circumstances, a contact address may also contain an instance identifier that uniquely identifies a specific UE amongst all other UEs registered with a same IMPU. For the sake of simplicity, this contact address may indistinctly be referred to as ‘contact address’ or simply as ‘contact’ throughout this specification.
A conventional registration process includes the submission of a ‘SIP Register’ message from the IMS subscriber towards a so-called Proxy Call Session Control Function server (hereinafter P-CSCF), which forwards such message towards an Interrogating Call Session Control Function server (hereinafter I-CSCF) of the IMS network where the destination subscriber belongs to. In particular, this ‘SIP Register’ message includes a given IMPI/IMPU pair to be registered during this registration process, and a contact address associated with the currently used UE. The I-CSCF is in charge of selecting an appropriate Serving Call Session Control Function server (hereinafter S-CSCF) for serving the IMS subscriber, and queries a Home Subscriber Server (hereinafter HSS), which is in charge of subscription data for subscribers of the IMS network where the IMS subscriber belongs to, with the given IMPI/IMPU pair. Assuming that the IMS subscriber had not previously registered the IMPI/IMPU pair, the HSS returns the capabilities required for an S-CSCF to be assigned for serving the IMS subscriber. The I-CSCF receiving such capabilities selects an appropriate S-CSCF fulfilling the capabilities, and forwards the ‘SIP Register’ message with the IMPI/IMPU pair and the contact address thereto. The S-CSCF receiving the ‘SIP Register’ message submits its own registration towards the HSS to indicate it has been assigned for serving the subscriber identified by the IMPI/IMPU pair. The HSS then changes the status of said IMPI and IMPU from ‘not registered’ to ‘registered’, it stores a reference to the S-CSCF as being assigned for serving the IMS subscriber, and it downloads a user profile associated with said IMPU towards the S-CSCF. The S-CSCF receiving the user profile for the IMS subscriber and already having the given IMPI/IMPU pair and the contact address is now ready for serving the IMS subscriber.
In accordance with the current registration mechanism as described in 3GPP, an IMS subscriber is registered in the network with a given IMPU/IMPI pair and with a given contact address. Then, where the IMS subscriber wants to register with another IMPI of the same IMS subscription or with another contact address, the same previous registration mechanism can to be repeated with said another IMPI or another contact address. Regarding the registration of contacts, when the user initiates a new registration attempt, the new contact traverses the network within the SIP header until the ‘SIP Register’ message arrives to the S-CSCF. The S-CSCF stores the contact bound to the IMPU received in the SIP message or to the IRS received from HSS during the registration process.
At present, some network operators propose the concept of a so-called ‘familiar subscription’ as an IMS subscription consisting of several IMPI's identifying the members of the family or even the roles that each member play in the family. For instance, an exemplary ‘familiar subscription’ may consist of a first IMPI identifying the mother, a second IMPI identifying the father, a third IMPI identifying the daughter and a fourth IMPI identifying the son. With this approach, the operators can make special offers to families for contracting an IMS ‘familiar subscription’ and to charge them as a whole rather than independently for every member.
Nowadays, there are quite a few families with kids and teenagers, whose parents would like to have a control of the time their children spend with IMS services.
However, with the currently existing mechanisms for accessing the IMS network and for IMS session establishment, either terminating or originating session, there is no mechanism to exercise a parental control over children's activities in the IMS network.
SUMMARY
The present invention is aimed to at least minimize the above drawback and provides for a new IMS subscription model supporting a hierarchy of IMPI's, the so-called ‘primary’ IMPI's and the so-called ‘secondary’ IMPI's, whereby only the primary IMPI's are allowed to register themselves on their own, whereas the secondary IMPI's are not allowed to register themselves unless they have been previously registered by any primary IMPI. Therefore, a new method and an enhanced HSS are provided to allow the implicit registration of one or more secondary IMPI's upon the explicit registration of an IMS subscriber with a given IMPI/IMPU pair, wherein the given IMPI is a primary IMPI and the given IMPU is associated with a registration set of IMPI's which includes said one or more secondary IMPI's.
In accordance with a first aspect of the present invention, there is provided a new method of registering, during a single registration process in an IP Multimedia Subsystem “IMS”, an implicit registration set of ‘j’ IMPI's.
This method comprises the steps of: configuring at a HSS an IMS subscription for a subscriber with a number ‘n’ of IMPI's and a number ‘m’ of IMPU's, wherein each IMPI is associated with at least one IMPU and each IMPU is associated with at least one IMPI, and wherein an IMPU is shared by more than one IMPI; configuring at the HSS this IMS subscription with an implicit registration set of ‘j’ IMPI's associated with the shared IMPU, wherein the ‘j’ IMPI's are preferably selected amongst the ‘n’ IMPI's in the IMS subscription; configuring at the HSS at least one IMPI as ‘primary’ IMPI and any other IMPI as ‘secondary’ IMPI of this IMS subscription; receiving at the HSS from a S-CSCF, which is currently assigned for serving the subscriber, an indication of a registration of said subscriber with a given IMPU and a given IMPI, and an identifier of said S-CSCF; determining at the HSS whether the given IMPI is configured as a ‘primary’ IMPI or as a ‘secondary’ IMPI; and either downloading from the HSS towards the S-CSCF the implicit registration set of ‘j’ IMPI's, where the given IMPI is a ‘primary’ IMPI and the given IMPU is the shared IMPU associated with the implicit registration set of ‘j’ IMPI's; or rejecting the registration of the subscriber with the given IMPU and given IMPI, where the given IMPI is a ‘secondary’ IMPI not previously registered by a ‘primary’ IMPI within an implicit registration set.
Generally speaking for this method, the shared IMPU associated with the implicit registration set of ‘j’ IMPI's is not necessarily an IMPU shared by all the IMPI's in the IMS subscription, in accordance with the concept of ‘shared IMPU’ stipulated by 3GPP, but simply an IMPU shared by the given IMPI and those IMPI's in the implicit registration set of ‘j’ IMPI's. In particular, the shared IMPU associated with the implicit registration set of ‘j’ IMPI's may be an IMPU shared by all the IMPI's in the IMS subscription, as stipulated by 3GPP.
An advantageous operation may be achieved, where this method further comprises a step of configuring at the HSS each ‘secondary’ IMPI of the IMS subscription as ‘barred’ for registration. In particular, this step of configuring each ‘secondary’ IMPI as ‘barred’ for registration may include a step of barring for own registration the ‘secondary’ IMPI, which is advantageous on the determination on whether the secondary IMPI may register itself or not.
Where the above barring mechanism is implemented, the step of determining in this method that the given IMPI is a ‘primary’ IMPI and the given IMPU is the shared IMPU associated with the implicit registration set of ‘j’ IMPI's further comprises a step of unbarring for own registration those ‘secondary’ IMPI's included in the implicit registration set of ‘j’ IMPI's.
Additionally, and in order to avoid that a kid previously registered by the parents further registers other kid prevented by the parents from registration, the step of configuring each ‘secondary’ IMPI as ‘barred’ for registration may include a step of barring the ‘secondary’ IMPI for registration of the implicit registration set of ‘j’ IMPI's associated with the given IMPU.
Moreover, apart from barring the own registration of a ‘secondary’ IMPI not previously registered by the parents, the parental control may be advantageously complemented by an effective control over call establishment procedures. To this end, the method may further comprise a step of configuring at the HSS each non-shared IMPU associated with each ‘secondary’ IMPI of the IMS subscription as ‘barred’ for call establishment.
Where this barring mechanism is implemented to control the call establishment procedures, the step of determining in this method that the given IMPI is a ‘primary’ IMPI and the given IMPU is the shared IMPU associated with the implicit registration set of ‘j’ IMPI's further comprises a step of unbarring for call establishment the non-shared IMPU's associated with each ‘secondary’ IMPI included in the implicit registration set of ‘j’ IMPI's.
An exemplary IMS familiar subscription may include, apart from the children to be carefully controlled by the parents, other family members responsible for their own registration but whom control of children cannot be given. This may be the case of an older brother who needs accessing the IMS services at any time but who should not be fully responsible of younger brothers. To this end, this method may further comprise a step of configuring at the HSS a ‘primary’ IMPI of the IMS subscription, the one for the exemplary older brother, as ‘barred’ for registration of any implicit registration set of ‘j’ IMPI's associated with a shared IMPU.
With this method, parents make sure that young children cannot access the IMS on their own at any time but only during fixed periods under their direct control or supervision, and this access to IMS services terminates for the young children as soon as the parents deregister the implicit registration set of ‘j’ IMPI's, including those ‘secondary’ IMPI's assigned to the children.
For this purpose, this method may further comprise the steps of: receiving at the HSS an indication of deregistering a subscriber with a given IMPI and a given IMPU from the S-CSCF; determining at the HSS that the given IMPI is a ‘primary’ IMPI and the given IMPU is the shared IMPU associated with the implicit registration set of ‘j’ IMPI's; and deregistering from the HSS all those ‘secondary’ IMPI's included in the implicit registration set of ‘j’ IMPI's with any IMPU they had previously been registered.
Where the above barring mechanism is implemented to control the own registration, the step of deregistering from the HSS all those ‘secondary’ IMPI's included in the implicit registration set of ‘j’ IMPI's may be followed by a step of barring for own registration at the HSS those ‘secondary’ IMPI's (included in the implicit registration set of ‘j’ IMPI's.
Likewise, where the above barring mechanism is implemented to control the call establishment procedures, the step of deregistering from the HSS all those ‘secondary’ IMPI's included in the implicit registration set of ‘j’ IMPI's may be followed by a step of barring for call establishment the non-shared IMPU's associated with each ‘secondary’ IMPI included in the implicit registration set of ‘j’ IMPI's.
Even though the step of downloading from the HSS towards the S-CSCF the implicit registration set of IMPI's associated with the given IMPU may be carried out at any time during or after concluding the registration process, advantages may be obtained in terms of data consistency and simplicity where said step of downloading the implicit registration set is carried out along with the downloading during the registration process, if any, of those IMPU's in an Implicit Registration Set associated with the given IMPU explicitly registered.
The method may be improved with additional steps in order to avoid a terminating call to reach a ‘secondary’ IMPI, which might occur under certain service criteria where said ‘secondary’ IMPI is not registered, since such terminating call may simply address an IMPU associated with the ‘secondary’ IMPI. To this end, this method may further comprise the steps of: receiving a query at the HSS from an I-CSCF, which is in charge of receiving an invitation to communicate with a terminating IMS subscriber, about a subscriber identified by a second given IMPU; determining at the HSS that the second given IMPU is a non-shared IMPU associated with a ‘secondary’ IMPI not previously registered by a ‘primary’ IMPI within an implicit registration set; and rejecting the query about the subscriber with the second given IMPU towards the I-CSCF.
In accordance with a second aspect of the present invention, there is provided a new HSS for holding subscriptions for subscribers of the IMS and arranged to configure and download an implicit registration set of ‘j’ IMS private identities.
This HSS comprises an accessible storage for configuring an IMS subscription for a subscriber with a number ‘n’ of IMPI's and a number ‘m’ of IMPU's, wherein each IMPI is associated with at least one IMPU and each IMPU is associated with at least one IMPI, and wherein an IMPU is shared by more than one IMPI; and wherein this accessible storage is arranged for configuring the IMS subscription for the subscriber with an implicit registration set of ‘j’ IMPI's associated with the shared IMPU, wherein the ‘j’ IMPI's are preferably selected amongst the ‘n’ IMPI's in the IMS subscription, and for configuring at least one IMPI in the IMS subscription as ‘primary’ IMPI and any other IMPI as ‘secondary’ IMPI of the IMS subscription for the subscriber. This HSS also comprises a receiver for receiving from a S-CSCF, which is assigned for serving the subscriber, an indication of a registration of said subscriber with a given IMPI and a given IMPU, and an identifier of said S-CSCF; and a processing unit for determining whether the given IMPU and the given IMPI are associated; wherein this processing unit is arranged for determining whether the given IMPI is a ‘primary’ IMPI or a ‘secondary’ IMPI, whether a ‘secondary’ IMPI has been previously registered within an implicit registration set, and whether the given IMPU is the shared IMPU associated with the implicit registration set of ‘j’ IMPI's. Moreover, this HSS also comprises a sender for downloading towards the S-CSCF the implicit registration set of ‘j’ IMPI's, where the given IMPI is a ‘primary’ IMPI and the given IMPU is the shared IMPU associated with the implicit registration set of ‘j’ IMPI's; or for rejecting the registration of the subscriber with the given IMPU and given IMPI towards the S-CSCF, where the given IMPI is a ‘secondary’ IMPI and the given IMPI has not previously been registered by a ‘primary’ IMPI within an implicit registration set.
As for the above method, and in order to benefit from data consistency and simplicity, the sender of the HSS may be arranged for downloading during the registration process the implicit registration set of ‘j’ IMPI's towards the S-CSCF along with an Implicit Registration Set of IMPU's, if any, associated with the given IMPU.
Aligned with the above method, the accessible storage of this HSS may advantageously include per ‘secondary’ IMPI of the IMS subscription a ‘barring’ indicator configured for barring an own registration of the ‘secondary’ IMPI, and may advantageously include per ‘secondary’ IMPI of the IMS subscription a ‘barring’ indicator configured for barring a registration of an implicit registration set of ‘j’ IMPI's. Where the accessible storage is arranged for barring an own registration of the ‘secondary’ IMPI, the processing unit may advantageously be arranged for unbarring and barring in the accessible storage the own registration of those ‘secondary’ IMPI's included in the implicit registration set of ‘j’ IMPI's.
Also aligned with the above method, the accessible storage of this HSS may advantageously include per each non-shared IMPU associated with each ‘secondary’ IMPI of the IMS subscription a ‘barring’ indicator configured for barring the non-shared IMPU for call establishment. Where the accessible storage is arranged for barring the non-shared IMPU for call establishment, the processing unit may advantageously be arranged for unbarring and barring in the accessible storage the call establishment for the non-shared IMPU's associated with each ‘secondary’ IMPI included in the implicit registration set of ‘j’ IMPI's.
In order to terminate the access to IMS services for the young children, the receiver of this HSS may be arranged for receiving from the S-CSCF an indication of deregistering a subscriber with a given IMPI and a given IMPU; and, responsive to this deregistration, the processing unit of the HSS may be arranged for determining that the given IMPI is a ‘primary’ IMPI and the given IMPU is the shared IMPU associated with the implicit registration set of ‘j’ IMPI's; and, in cooperation with the sender of the HSS, the processing unit may be arranged for deregistering towards the S-CSCF all those ‘secondary’ IMPI's included in the implicit registration set of ‘j’ IMPI's with any IMPU they had previously been registered.
Particularly advantageous for the above method to avoid a terminating call reaching a ‘secondary’ IMPI, the receiver of the HSS may be arranged for receiving a query from an I-CSCF, which is in charge of receiving an invitation to communicate with a terminating IMS subscriber, about a subscriber identified by a second given IMPU; and, responsive to this query, the processing unit of the HSS may be arranged for determining that the second given IMPU is a non-shared IMPU associated with a ‘secondary’ IMPI not previously registered by a ‘primary’ IMPI within an implicit registration set; and the sender of the HSS may be arranged for rejecting the query about the subscriber with the second given IMPU towards the I-CSCF.
In accordance with a third aspect of the present invention, there is provided a new S-CSCF for serving subscribers of the IMS. This S-CSCF comprises a sender for submitting towards a HSS, which holds subscriptions for subscribers of the IMS, an indication of a registration of an IMS subscriber with a given IMPU and a given IMPI, and an identifier of the S-CSCF; a receiver for receiving from the HSS an implicit registration set including a number ‘j’ of IMPI's associated with the given IMPU; a processing unit for determining that the given IMPI is a ‘primary’ IMPI of the IMS subscription; and an accessible storage for storing the ‘primary’ IMPI along with the implicit registration set of ‘j’ IMPI's, and the given IMPU explicitly registered.
In particular, the receiver of this S-CSCF may be arranged for receiving from the HSS an indication per IMPI in the implicit registration set of ‘j’ IMPI's indicating whether such IMPI is a ‘primary’ or ‘secondary’ IMPI of the IMS subscription. Also in particular, the processing unit may be arranged for determining that the given IMPI is a ‘primary’ IMPI of the IMS subscription in cooperation with the receiver receiving the indication per IMPI on whether such IMPI is a ‘primary’ or ‘secondary’ IMPI of the IMS subscription.
Moreover, the receiver of this S-CSCF may be arranged for receiving from the HSS a set with a number ‘k’ of contact addresses to reach those IMPI's currently registered; and the accessible storage may be arranged for storing the set of ‘k’ contact addresses in association with the IMPI's currently registered, and with the given IMPU explicitly registered.
On the other hand, the invention may be practised by a computer program, in accordance with a fourth aspect of the invention, the computer program being loadable into an internal memory of a computer with input and output units as well as with a processing unit, and comprising executable code adapted to carry out the above method steps. In particular, this executable code may be recorded in a carrier medium readable in the computer.
BRIEF DESCRIPTION OF THE DRAWINGS
The features, objects and advantages of the invention will become apparent by reading this description in conjunction with the accompanying drawings, in which:
FIG. 1 basically represents a conventional model of an IMS subscription, in respect of user identities and their relationships, as defined by 3GPP.
FIG. 2 shows a simplified view of an exemplary IMS familiar subscription to better describe embodiments of the invention.
FIG. 3 shows an exemplary configuration at the HSS of ‘primary’ and ‘secondary’ IMPI's along with respective implicit registration sets of contact addresses and ‘barring’ indicators per IMPI basis.
FIG. 4 shows an exemplary configuration at the HSS of implicit registration sets of IMPI's per IMPU basis along with respective implicit registration sets of IMPU's and ‘barring’ indicators.
FIG. 5 illustrates a simplified view of the sequence of actions to be performed to carry out a method of registering, during a single registration process in an IMS network, an implicit registration set of ‘j’ IMPI's, in accordance with an aspect of the present invention.
FIG. 6 illustrates an exemplary implementation of a HSS provided for configuring and downloading an implicit registration set of ‘j’ IMPI's, wherein the accessible storage is provided by an internal memory integrated into the HSS.
FIG. 7 illustrates an exemplary implementation of a HSS provided for configuring and downloading an implicit registration set of ‘j’ IMPI's, wherein the accessible storage is provided by an external database acting as an HSS back-end shared by a plurality of HSS front-ends.
FIG. 8 shows an exemplary data model of implicit registration sets of IMPI's and contact addresses built up at the S-CSCF, and downloaded from the HSS, in accordance with the exemplary IMS subscription illustrated in FIG. 2 .
FIG. 9 illustrates an exemplary implementation of an S-CSCF provided for downloading an implicit registration set of ‘j’ IMPI's, and for building up a data model thereof.
FIG. 10 illustrates a simplified view of the sequence of actions to carry out to avoid a terminating call reaching a ‘secondary’ IMPI not previously registered by a ‘primary’ IMPI within an implicit registration set of ‘j’ IMPI's.
FIG. 11 illustrates a simplified view of the sequence of actions to carry out for deregistering all those ‘secondary’ IMPI's included in the implicit registration set of ‘j’ IMPI's upon deregistration of the ‘primary’ IMPI.
DETAILED DESCRIPTION
The following describes currently preferred embodiments of means and method for registering an implicit registration of one or more secondary IMPI's upon the explicit registration of an IMS subscriber with a given IMPI/IMPU pair, wherein the given IMPI is a primary IMPI and the given IMPU is associated with a registration set of IMPI's which includes said one or more secondary IMPI's.
FIG. 2 illustrates an exemplary IMS familiar subscription 100 for a subscriber of an IMS network, the IMS subscription including a number of IMPI's 101 - 106 assignable for usage to family members, and another number of IMPU's 107 - 115 wherein some of them are exclusive of some family member whereas others are shared by several or all family members. In this exemplary IMS subscription 100 the first IMPU 107 is exclusively associated with the first IMPI 101 assigned to the mother; the second IMPU 108 is exclusively associated with the second IMPI 102 assigned to the father; the third IMPU 109 and the fourth IMPU 110 are shared IMPU's associated with all the IMPI's of the IMS subscription; the fifth IMPU 111 is a shared IMPU associated with the first IMPI 101 assigned to the mother, with the second IMPI 102 assigned to the father, and with the fourth IMPI 104 assigned to the son; the sixth IMPU 112 is exclusively associated with the fourth IMPI 104 assigned to the son; the seventh IMPU 113 is a shared IMPU associated with the first IMPI 101 assigned to the mother, with the second IMPI 102 assigned to the father, and with the fifth IMPI 105 assigned to the daughter; the eighth IMPU 114 is exclusively associated with the fifth IMPI 105 assigned to the daughter; and the ninth IMPU 115 is exclusively associated with the sixth IMPI 106 assigned to an older son.
In accordance with the invention, there is at least one registration set of IMPI's (hereinafter RSI) associated with a shared IMPU and to be implicitly registered upon registration of a given IMPI/IMPU pair, wherein the given IMPI is configured as a ‘primary’ IMPI associated with the given IMPU and the latter being the shared IMPU associated with the RSI.
As illustrated in FIG. 2 for the exemplary IMS familiar subscription 100 , a first RSI 116 is associated with the shared IMPU 109 and including the first IMPI 101 , second IMPI 102 , fourth IMPI 104 and fifth IMPI 105 . Likewise, a second RSI 117 is associated with the shared IMPU 110 and including the fourth IMPI 104 and fifth IMPI 105 ; a third RSI 118 is associated with the shared IMPU 111 and just including the fourth IMPI 104 ; and a fourth RSI 119 is associated with the shared IMPU 113 and just including the fifth IMPI 105 .
Particularly in this exemplary subscription, some shared IMPU's, namely the third IMPU 109 and the fourth IMPU 110 , are shared IMPU's in accordance with the stipulations made by 3GPP whereby a shared IMPU is shared by all the IMPI's in the IMS subscription, whereas other shared IMPU's, namely the fifth IMPU 111 and the seventh IMPU 113 , are shared IMPU's in accordance with a less restrictive concept used throughout this specification in the sense that they are shared by more than one IMPI of the IMS subscription.
Also in this exemplary IMS subscription, there is provided a third IMPI 103 assignable to the parents, being the mother or the father, associated with the third IMPI 103 and fourth IMPI 104 for the purpose of registering at home any of these shared IMPI 103 and fourth IMPI 104 , and usable to allow the implicit registration of IMPI's assigned to the younger kids whilst keeping the parents exclusive IMPI's 101 - 102 in a separate registration status.
FIG. 3 illustrates an exemplary configuration 120 at the HSS with configuration elements 121 - 126 per IMPI basis in accordance with the exemplary IMS subscription 100 illustrated in FIG. 2 . This exemplary configuration 120 per IMPI basis includes information on whether each IMPI is a ‘primary’ or ‘secondary IMPI, and may advantageously include ‘barring’ indicators and respective implicit registration sets of contact addresses where each IMPI may be reachable.
In this respect, and for the sake of simplicity with regard to the exemplary IMS subscription 100 illustrated in FIG. 2 , IMPU's 107 to 115 are supposed to be reachable in contact addresses IP.ad-1 to IP.ad-9, though other arrangements, including more than one contact address per each IMPU, are also possible.
Thus, as illustrated in FIG. 3 , a first configuration element 121 is provided for the first IMPI 101 configured as ‘primary’ IMPI; associated with first IMPU 107 , third IMPU 109 , fourth IMPU 110 , fifth IMPU 111 and seventh IMPU 113 ; having a set of contact addresses comprising IP.ad-3, IP.ad-4, IP.ad-5 and IP.ad-7; and having no barring indicator active. A second configuration element 122 is provided for the second IMPI 102 configured as ‘primary’ IMPI; associated with second IMPU 108 , third IMPU 109 , fourth IMPU 110 , fifth IMPU 111 and seventh IMPU 113 ; having a set of contact addresses comprising IP.ad-3, IP.ad-4, IP.ad-5 and IP.ad-7; and having no barring indicator active. A third configuration element 123 is provided for the third IMPI 103 configured as ‘primary’ IMPI; associated with third IMPU 109 and fourth IMPU 110 ; having a set of contact addresses comprising IP.ad-3, IP.ad-4, IP.ad-5 and IP.ad-7; and having no barring indicator active. A fourth configuration element 124 is provided for the fourth IMPI 104 configured as ‘secondary’ IMPI; associated with third IMPU 109 , fourth IMPU 110 , fifth IMPU 111 and sixth IMPU 112 ; having a set of contact addresses comprising IP.ad-3, IP.ad-4, IP.ad-5 and IP.ad-6; and having a barring indicator active for own registration and for registration of any RSI. A fifth configuration element 125 is provided for the fifth IMPI 105 configured as ‘secondary’ IMPI; associated with third IMPU 109 , fourth IMPU 110 , seventh IMPU 113 and eighth IMPU 114 ; having a set of contact addresses comprising IP.ad-3, IP.ad-4, IP.ad-7 and IP.ad-8; and having a barring indicator active for own registration and for registration of any RSI. A sixth configuration element 126 is provided for the sixth IMPI 106 configured as ‘primary’ IMPI; associated with third IMPU 109 , fourth IMPU 110 and ninth IMPU 115 ; having a set of contact addresses comprising IP.ad-3, IP.ad-4 and IP.ad-9; and having a barring indicator active only for registration of any RSI.
FIG. 4 illustrates an exemplary configuration 130 at the HSS with configuration elements 131 - 139 per IMPU basis in accordance with the exemplary IMS subscription 100 illustrated in FIG. 2 . This exemplary configuration 130 per IMPU basis includes information on whether each IMPU is associated with an RSI, or with an implicit registration set of IMPU's, and may advantageously include ‘barring’ indicators for call establishment.
Thus, as illustrated in FIG. 4 , a first configuration element 131 is provided for the first IMPU 107 , not associated with any implicit registration set of IMPU's; not associated with any RSI; and not barred for call establishment. A second configuration element 132 is provided for the second IMPU 108 , not associated with any implicit registration set of IMPU's; not associated with any RSI; and not barred for call establishment. A third configuration element 133 is provided for the third IMPU 109 , associated with an implicit registration set of IMPU's that includes the third IMPU 109 and the fourth IMPU 110 ; associated with a first RSI 116 that includes the first IMPI 101 , the second IMPI 102 , the fourth IMPI 104 and the fifth IMPI 105 ; and not barred for call establishment. A fourth configuration element 134 is provided for the fourth IMPU 110 , associated with an implicit registration set of IMPU's that includes the third IMPU 109 and the fourth IMPU 110 ; associated with a second RSI 117 that includes the fourth IMPI 104 and the fifth IMPI 105 ; and not barred for call establishment. A fifth configuration element 135 is provided for the fifth IMPU 111 , not associated with any implicit registration set of IMPU's; associated with a third RSI 118 that just includes the fourth IMPI 104 ; and not barred for call establishment. A sixth configuration element 136 is provided for the sixth IMPU 112 , not associated with any implicit registration set of IMPU's; not associated with any RSI; and barred for call establishment, since it is a non-shared IMPU exclusively associated with a ‘secondary’ IMPI such as the fourth IMPI 104 . A seventh configuration element 137 is provided for the seventh IMPU 113 , not associated with any implicit registration set of IMPU's; associated with a fourth RSI 119 that just includes the fifth IMPI 105 ; and not barred for call establishment. An eighth configuration element 138 is provided for the eighth IMPU 114 , not associated with any implicit registration set of IMPU's; not associated with any RSI; and barred for call establishment, since it is a non-shared IMPU exclusively associated with a ‘secondary’ IMPI such as the fifth IMPI 105 . A ninth configuration element 139 is provided for the ninth IMPU 1115 , not associated with any implicit registration set of IMPU's; not associated with any RSI; and not barred for call establishment.
Other combinations and data distributions are also possible in the light of the above exemplary embodiments exemplified with configuration elements 120 and 130 . For example, where no implicit registration set of contact addresses is configured.
In operation, once a subscriber has registered in an access network and has gotten IP connectivity, such subscriber may register into the IMS network. To this end, the method illustrated in FIG. 5 may be followed to register a subscriber with a UE 5 in the IMS network. In this respect, the present specification assumes the exemplary IMS subscription 100 illustrated in FIG. 2 for exemplary describing the sequence of actions to be carried out in an illustrative and non-restrictive manner.
Conventionally, this method includes a step not illustrated in any drawing of configuring at a HSS 1 or 1 a , which holds subscriptions for subscribers of the IMS, the exemplary IMS subscription 100 for a subscriber with a number ‘n’ of IMPI's 101 - 106 and a number ‘m’ of IMPU's 107 - 115 , wherein each IMPI is associated with at least one IMPU and each IMPU is associated with at least one IMPI, and wherein some IMPU's 109 - 111 or 113 may be shared by more than one IMPI.
As illustrated in FIG. 5 , this method starts with a step S- 100 carried out at the HSS 1 or 1 a of configuring the IMS subscription for the subscriber with an implicit registration set 117 of ‘j’ IMPI's associated with a shared IMPU 110 ; and configuring an exemplary number of IMPI's 101 - 103 and 106 as ‘primary’ IMPI's, whereas the other IMPI's 104 - 105 are configured as ‘secondary’ IMPI's of this IMS subscription.
The method illustrated in FIG. 5 continues with the explicit registration of the subscriber with UE 5 into the IMS. To this end, the UE 5 submits a register message during a step S- 105 towards a P-CSCF 4 for accessing the IMS network. This register message includes a given IMPI and a given IMPU to be registered during this registration process, and a contact address associated with the currently used UE 5 . In accordance with the invention, several embodiments are provided depending on whether the given IMPI is a ‘primary’ IMPI or a ‘secondary’ IMPI.
In a first embodiment, the IMS subscriber attempts to register with a given ‘secondary’ IMPI and a given IMPU. For example, where the UE 5 submits a register message during the step S- 105 towards a P-CSCF 4 including a given IMPI 104 and a given IMPU 110 to be registered during this registration process, and a contact address associated with the currently used UE 5 .
The P-CSCF 4 forwards such message during a step S- 110 towards an I-CSCF 3 of the IMS network where the IMS subscriber belongs to. The I-CSCF is in charge of selecting an appropriate S-CSCF for serving the IMS subscriber, and queries during a step S- 115 the HSS 1 or 1 a with the given IMPI/IMPU pair and a network identifier of the P-CSCF 4 .
Assuming that the IMS subscriber had not previously registered with the given IMPI 104 and given IMPU 110 pair, the HSS 1 or 1 a returns during a step S- 120 the capabilities required for an S-CSCF to be assigned for serving the IMS subscriber. The I-CSCF 3 receiving such capabilities selects an appropriate S-CSCF 2 fulfilling the capabilities, and forwards the register message during a step S- 125 with the given IMPI/IMPU pair and the contact address towards said S-CSCF 2 . The S-CSCF 2 receiving the register message submits during a step S- 130 its own registration towards the HSS 1 or 1 a to indicate it has been assigned for serving the subscriber identified by the given IMPI 104 and given IMPU 110 .
The HSS 1 or 1 a , as receiving such indication of a registration of the subscriber with a given IMPU 110 and a given IMPI 104 , and an identifier of said S-CSCF 2 , determines during a step S- 135 whether the given IMPI 104 is configured as a ‘primary’ IMPI or as a ‘secondary’ IMPI; and, since the given IMPI 104 is a ‘secondary’ IMPI not previously registered by a ‘primary’ IMPI 101 - 103 within an implicit registration set, the HSS rejects during a step S- 140 such registration with the given IMPI 104 and given IMPU 110 towards the S-CSCF.
The S-CSCF receiving such rejection for the registration of the IMS subscriber with the given IMPI/IMPU pair, confirms back such rejection to the I-CSCF 3 during a step S- 145 , and this rejection is confirmed back from the I-CSCF towards the P-CSCF 4 during a step S- 150 and from the P-CSCF 4 towards the UE 5 during a step S- 155 .
In a second embodiment, the IMS subscriber attempts to register with a given ‘primary’ IMPI and a given IMPU. In this respect, the same sequence of actions illustrated in FIG. 5 may be followed where the IMS subscriber attempts to register with a given ‘primary’ IMPI and a given IMPU. For example, where the UE 5 submits a register message during the step S- 105 towards a P-CSCF 4 including a given IMPI 103 and a given IMPU 110 of the exemplary IMS subscription 100 illustrated in FIG. 2 , to be registered during this registration process, and a contact address associated with the currently used UE 5 .
The P-CSCF 4 forwards such message during a step S- 110 towards an I-CSCF 3 and the latter queries during a step S- 115 the HSS 1 or 1 a with the given IMPI/IMPU pair and a network identifier of the P-CSCF 4 . Assuming that the IMS subscriber had not previously registered with the given IMPI 103 and given IMPU 110 pair, the HSS 1 or 1 a returns during a step S- 120 the capabilities required for an S-CSCF to be assigned for serving the IMS subscriber. The I-CSCF 3 receiving such capabilities selects the S-CSCF 2 and forwards the register message during a step S- 125 with the given IMPI/IMPU pair and the contact address towards said S-CSCF 2 . The S-CSCF 2 receiving the register message submits during a step S- 130 its own registration towards the HSS 1 or 1 a to indicate it has been assigned for serving the subscriber identified by the given IMPI 103 and given IMPU 110 .
The HSS 1 or 1 a , as receiving the indication of the registration of the subscriber with a given IMPU 110 and a given IMPI 103 , and an identifier of said S-CSCF 2 , determines during a step S- 135 whether the given IMPI 103 is configured as a ‘primary’ IMPI or as a ‘secondary’ IMPI; and, since the given IMPI 103 is a ‘primary’ IMPI, the HSS determines whether the given IMPU 110 is a shared IMPU associated with any implicit registration set of ‘j’ IMPI's. In the present case, the given IMPU 110 is the shared IMPU associated with the implicit registration set 117 of ‘j’ IMPI's, so that the HSS registers the ‘j’ IMPI's 104 - 105 along with the given IMPI 103 and, during a step S- 140 , downloads towards the S-CSCF the implicit registration set 117 of ‘j’ IMPI's.
In addition or complementary to these actions, the HSS may carry out at this stage the conventional steps of marking said IMPI's 103 - 105 and IMPU 110 as ‘registered’, storing a reference to the S-CSCF as been assigned for serving the IMS subscriber, and downloading a user profile associated with the given IMPU 110 towards the S-CSCF. Moreover, this user profile may also include a conventional Implicit Registration Set of IMPU's 109 - 110 associated with the given IMPU, as illustrated in the configuration element 133 of FIG. 4 . Furthermore, the HSS may also download towards the S-CSCF 2 a set of contact addresses IP.ad-3, IP.ad-4, IP.ad-5 and IP.ad-7 associated with the given IMPI 103 , as illustrated in the configuration element 123 of FIG. 3 .
The S-CSCF 2 , as receiving the implicit registration set 117 of ‘j’ IMPI's, may build up a data model 150 , exemplary illustrated in FIG. 8 , and comprising: a set 151 of IMPI's that includes the given IMPI 103 explicitly registered and the implicit registration set of IMPI's 104 - 105 , a set 152 of IMPU's that includes the given IMPU 110 explicitly registered and an Implicit Registration Set of IMPU's 109 - 110 , and a set 153 of contact addresses, if any, for the given IMPI.
The S-CSCF receiving the user profile for the IMS subscriber and already having the given IMPI/IMPU pair and the contact address originally received in the registration message is now ready for serving the IMS subscriber. As illustrated in FIG. 5 , this is confirmed from the S-CSCF 2 back to the I-CSCF 3 during a step S- 145 , and this confirmation is forwarded from the I-CSCF towards the P-CSCF 4 during a step S- 150 and from the latter towards the UE 5 during a step S- 155 .
In order to carry out the method illustrated in FIG. 5 , there is provided an enhanced HSS 1 or 1 a , as illustrated in FIG. 6 and FIG. 7 , and an enhanced S-CSCF 2 , as illustrated in FIG. 9 .
Thus, the HSS 1 or 1 a illustrated in FIG. 6 and FIG. 7 comprises an accessible storage for configuring an IMS subscription for each IMS subscriber, wherein the IMS subscription includes more than one IMPI 101 - 106 and more than one IMPU 107 - 115 , wherein each IMPI is associated with at least one IMPU and each IMPU is associated with at least one IMPI, and wherein at least one IMPU 109 - 111 and 113 is shared by more than one IMPI.
This accessible storage is arranged for configuring the IMS subscription for the subscriber with an implicit registration set 117 of ‘j’ IMPI's associated with the shared IMPU 110 , wherein the ‘j’ IMPI's are preferably selected amongst the ‘n’ IMPI's in the IMS subscription, and for configuring at least one IMPI 101 - 103 or 106 in the IMS subscription as ‘primary’ IMPI and any other IMPI 104 - 105 as ‘secondary’ IMPI of the IMS subscription for the subscriber
In particular, as illustrated in FIG. 7 , the accessible storage in the HSS may include an external database 10 a acting as an HSS back-end shared by a plurality of HSS front-ends 1 a - 1 d , and a memory handler 11 for interfacing with the external database. Alternatively, as illustrated in FIG. 6 , the accessible storage in the HSS may be provided as an internal memory 10 .
This HSS also comprises a receiver 50 for receiving from the S-CSCF 2 an indication of the registration of said subscriber with the given IMPU 110 and the given IMPI 103 , and an identifier of said S-CSCF; a processing unit 20 for determining whether the given IMPU 110 and the given IMPI 103 are associated, and wherein this processing unit is arranged for determining whether the given IMPI 103 is a ‘primary’ IMPI or a ‘secondary’ IMPI, whether a ‘secondary’ IMPI 104 has been previously registered within an implicit registration set, and whether the given IMPU 110 is the shared IMPU associated with the implicit registration set 117 of ‘j’ IMPI's.
Moreover, this HSS also comprises a sender 40 for downloading towards the S-CSCF 2 the implicit registration set 117 of ‘j’ IMPI's, where the given IMPI 103 is a ‘primary’ IMPI and the given IMPU 110 is the shared IMPU associated with the implicit registration set 117 of ‘j’ IMPI's; or for rejecting the registration of the subscriber with the given IMPU and given IMPI towards the S-CSCF 2 , where the given IMPI 104 is a ‘secondary’ IMPI not previously registered by a ‘primary’ IMPI within an implicit registration set.
Furthermore, the sender 40 of this HSS may be arranged for downloading towards the S-CSCF, along with the implicit registration set 117 of ‘j’ IMPI's, a set of contact addresses IP.ad-3, IP.ad-4, IP.ad-5 and IP.ad-7 associated with the given IMPI 103 and usable to reach at least one IMPI selected amongst the set 151 of IMPI's in a number of fixed and mobile devices.
Correspondingly, the S-CSCF 2 illustrated in FIG. 9 comprises a sender 46 for submitting towards the HSS 1 or 1 a an indication of a registration of an IMS subscriber with the given IMPU 110 and the given IMPI 103 , and an identifier of the S-CSCF; a receiver 56 for receiving from the HSS 1 or 1 a the implicit registration set 117 of ‘j’ IMPI's associated with the given IMPU 110 ; a processing unit 25 for determining that the given IMPI 103 is a ‘primary’ IMPI of the IMS subscription; and an accessible storage 15 for storing a set of IMPI's 151 including the ‘primary’ IMPI 103 along with the IMPI's 104 - 15 in the implicit registration set 117 of ‘j’ IMPI's, and a set of IMPU's 152 including the given IMPU 110 explicitly registered.
Moreover, the receiver 56 of the S-CSCF may be arranged for receiving from the HSS 1 or 1 a , along with the implicit registration set 117 of ‘j’ IMPI's, a set of contact addresses IP.ad-3, IP.ad-4, IP.ad-5 and IP.ad-7 associated with the given IMPI 103 , and the accessible storage 15 may be arranged for storing the set of contact addresses in a set 153 of the data model shown in FIG. 8 .
Generally speaking, the contact addresses are usable to reach at least one IMPI selected amongst the given IMPI and the set 151 of IMPI's in a number of fixed and mobile devices. To this end, S-CSCF illustrated in FIG. 9 , may further comprise a second sender 47 arranged for using the contact addresses to reach at least one IMPI selected amongst the set 151 of IMPI's in a number of fixed and mobile devices 5 - 5 m . More precisely, the processing unit 25 of the S-CSCF may be arranged for instructing the second sender 47 to submit a message addressing the at least one IMPI towards a number of fixed and mobile devices 5 - 5 m identified by the contact addresses received from the HSS 1 or 1 a.
In particular, the S-CSCF 2 illustrated in FIG. 9 also includes a second receiver 57 for receiving during the step S- 125 the registration message originated from the UE 5 with the given IMPI 103 , the given IMPU 110 and the given contact address.
In particular, the S-CSCF 2 may be implemented so that the first and second receivers 56 and 57 , or the first and second senders 46 and 47 , are a same receiver 55 or sender 45 respectively, or even a unique input/output unit 35 .
Back to the first embodiment of the method illustrated in FIG. 5 , whereby the registration of an IMS subscriber with a given ‘secondary’ IMPI 104 and a given IMPU 110 is rejected if the ‘secondary’ IMPI 104 had not previously been registered by a ‘primary’ IMPI 101 - 103 , this method may further comprise additional steps to avoid a terminating call reaching the ‘secondary’ IMPI.
As illustrated in FIG. 10 , and upon receiving at the I-CSCF 3 an invitation to complete a terminating call, during a step S- 165 , for an IMS subscriber identified by a given second IMPU 114 , which is a non-shared IMPU associated with the ‘secondary’ IMPI 105 in the exemplary IMS subscription 100 shown in FIG. 2 , the I-CSCF sends a query during a step S- 170 towards the HSS 1 or 1 a , inquiring about the subscriber identified by the second given IMPU 114 . As receiving this query, the HSS determines during a step S- 175 that the second given IMPU 114 is a non-shared IMPU associated with a ‘secondary’ IMPI 105 not previously registered by a ‘primary’ IMPI 101 - 103 within an implicit registration set; and rejects during a step S- 180 such query about the subscriber with the second given IMPU 114 towards the I-CSCF 3 .
In order to carry out the method steps illustrated in FIG. 10 , an enhanced HSS 1 or 1 a is provided wherein the receiver 50 may be arranged for receiving the query from the I-CSCF 3 about the subscriber identified by the second given IMPU 114 ; and, responsive to this query, the processing unit 20 may be arranged for determining that the second given IMPU 114 is a non-shared IMPU associated with a ‘secondary’ IMPI 105 not previously registered by a ‘primary’ IMPI within an implicit registration set; and the sender 40 may be arranged for rejecting the query about the subscriber with the second given IMPU 114 towards the I-CSCF 3 .
Back to the second embodiment of the method illustrated in FIG. 5 , whereby the registration of an IMS subscriber with a given ‘primary’ IMPI 103 and a given IMPU 110 triggers the registration of an implicit registration set 117 of ‘j’ IMPI's 104 and 105 , this method may further comprise additional steps to terminate the registration of, at least, the ‘secondary’ IMPI's in the implicit registration set 117 of ‘j’ IMPI's.
As illustrated in FIG. 11 , and assuming the IMPI's in the IMS subscription 100 illustrated in FIG. 2 have been configured as ‘primary’ or ‘secondary’ IMPI's, the HSS 1 or 1 a may receive during a step S- 190 an indication of deregistering a subscriber with a given IMPI 103 and a given IMPU 110 from the S-CSCF 2 . Then, the HSS may determine during a step S- 195 that the given IMPI is a ‘primary’ IMPI and the given IMPU is the shared IMPU associated with the implicit registration set 117 of ‘j’ IMPI's; and the HSS may deregister during a step S- 195 all those ‘secondary’ IMPI's 104 - 105 included in the implicit registration set 117 of ‘j’ IMPI's with any IMPU they had previously been registered.
Particularly applicable for other embodiments not illustrated in any drawing, namely where the implicit registration set of ‘j’ IMPI's includes ‘primary’ and ‘secondary’ IMPI's, the HSS may deregister during the step S- 195 all those IMPI's included in the implicit registration set of ‘j’ IMPI's and not only those configured as ‘secondary’ IMPI's.
In order to carry out the method steps illustrated in FIG. 11 , an enhanced HSS 1 or 1 a is provided wherein the receiver 50 may be arranged for receiving from the S-CSCF 2 an indication of deregistering a subscriber with the given IMPI 103 and the given IMPU 110 ; and, responsive to this deregistration, the processing unit 20 may be arranged for determining that the given IMPI 103 is a ‘primary’ IMPI and the given IMPU 110 is the shared IMPU associated with the implicit registration set 117 of ‘j’ IMPI's; and wherein both the sender 40 in cooperation with the processing unit 20 may be arranged for deregistering towards the S-CSCF 2 all those ‘secondary’ IMPI's included in the implicit registration set of ‘j’ IMPI's with any IMPU they had previously been registered, or all those IMPI's included in the implicit registration set of ‘j’ IMPI's and not only those configured as ‘secondary’ IMPI's, choice which may be determined by a first configurable parameter set during the configuration step.
In another embodiment of the invention not illustrated in any drawing, there is provided a second configurable parameter set during the configuration step to determine whether just the exemplary RSI 117 associated with the shared IMPU 110 , which includes the fourth IMPI 104 and the fifth IMPI 105 , is the only one to be implicitly registered, or also those RSI's associated with other shared IMPU's in a same Implicit Registration Set of IMPU's are going to be implicitly registered as well. For example, as shown in the configuration element 134 of FIG. 4 , there is an Implicit Registration Set of IMPU's consisting of the third IMPU 109 and the fourth IMPU 110 ; then, depending on this second configurable parameter, just the RSI 117 associated with the given IMPU 110 , which includes the fourth IMPI 104 and the fifth IMPI 105 , is implicitly registered, or also the RSI 116 associated with the given IMPU 109 , which includes the first IMPI 101 , the second IMPI 102 , the fourth IMPI 104 and the fifth IMPI 105 , is implicitly registered as well.
On the one hand, as anticipated above, this method may further comprise a step of configuring at the HSS each ‘secondary’ IMPI of the IMS subscription as ‘barred’ for registration and, in particular, this step of configuring each ‘secondary’ IMPI as ‘barred’ for registration may include a step of barring for own registration the ‘secondary’ IMPI. This step is preferably made during the step S- 100 of configuring the IMS subscription for the subscriber, but it may be carried out at any time during operation. Where this barring is implemented, the determination carried out during the step S- 135 of this method, illustrated in FIG. 5 , that the given IMPI 103 is a ‘primary’ IMPI and the given IMPU 110 is the shared IMPU associated with the implicit registration set 117 of ‘j’ IMPI's further comprises a step not illustrated in any drawing of unbarring for own registration those ‘secondary’ IMPI's 104 - 105 included in the implicit registration set 117 of ‘j’ IMPI's, that is a reset of the registration barring ‘OWN’ in the configuration elements 124 and 125 , preferably carried out by the processing unit 20 of the HSS actuating on the accessible storage 10 or 10 a . More precisely, where the accessible storage is arranged for barring an own registration of the ‘secondary’ IMPI, the processing unit may be arranged for barring and unbarring such registration barring in the configuration 120 of the accessible storage.
On the other hand, and in order to avoid that a kid previously registered by the parents further registers other kid prevented by the parents from registration, the step of configuring each ‘secondary’ IMPI as ‘barred’ for registration may also include a step not illustrated in any drawing of barring any ‘secondary’ IMPI for registration of the implicit registration set of ‘j’ IMPI's associated with the given IMPU. To this end, the configuration elements 124 and 125 shown in FIG. 3 include a registration barring set to ‘RSI’. Moreover, not only a kid previously registered is prevented from registering other kids, but some other family member having a ‘primary’ IMPI assigned may be wanted to be prevented from registering any implicit registration set of ‘j’ IMPI's. To this end, this method may further comprise a step not illustrated in any drawing of configuring at the HSS a ‘primary’ IMPI 106 of the IMS subscription as ‘barred’ for registration of any implicit registration set of ‘j’ IMPI's associated with a shared IMPU. To this end, the configuration element 126 shown in FIG. 3 includes a registration barring set to ‘RSI’. These steps of barring any ‘primary’ or ‘secondary’ IMPI for registration of the implicit registration set of ‘j’ IMPI's may preferably be made during the above step S- 100 of configuring the IMS subscription for the subscriber, but they may be carried out at any time during operation. In principle, this barring for registration of any implicit registration set of ‘j’ IMPI's, dislike the barring for own registration, should preferably not be reset after the implicit registration, but the processing unit 20 and accessible storage 10 - 10 a of the HSS may also be arranged to this end.
Moreover, in order to support an effective control over call establishment procedures, the method may further comprise a step of configuring at the HSS each non-shared IMPU associated with each ‘secondary’ IMPI of the IMS subscription as ‘barred’ for call establishment. To this end, and in accordance with the exemplary IMS subscription illustrated in FIG. 2 , the exemplary configuration 130 of FIG. 4 shows the configuration elements 136 and 138 respectively provided for configuring the sixth IMPU 106 and the eighth IMPU 108 , which are non-shared IMPU's respectively associated with the ‘secondary’ IMPI 104 and with the ‘secondary’ IMPI 106 , wherein these configuration elements 136 and 138 indicate the sixth IMPU 106 and the eighth IMPU 108 as barred for call establishment.
This step of configuring each non-shared IMPU associated with each ‘secondary’ IMPI of the IMS subscription as ‘barred’ for call establishment may preferably be made during the above step S- 100 of configuring the IMS subscription for the subscriber, but it may be carried out at any time during operation.
Where this barring is implemented to control the call establishment procedures, the determination carried out during the step S- 175 of the method shown in FIG. 10 , that the second given IMPU 114 is a non-shared IMPU associated with a ‘secondary’ IMPI 105 not previously registered by a ‘primary’ IMPI 101 - 103 within an implicit registration set, may be carried out by encountering that the IMPU 114 is ‘barred’ for call establishment in the configuration element 138 . Correspondingly, the determination carried out during the step S- 135 of the method illustrated in FIG. 5 , that the given IMPI 103 is a ‘primary’ IMPI and the given IMPU 110 is the shared IMPU associated with the implicit registration set 117 of ‘j’ IMPI's, further comprises a step not illustrated in any drawing of unbarring for call establishment the non-shared IMPU's 112 and 114 associated with each ‘secondary’ IMPI 104 - 105 included in the implicit registration set 117 of ‘j’ IMPI's. That is, a reset of the barring for call establishment in the configuration elements 136 and 138 , preferably carried out by the processing unit 20 of the HSS actuating on the accessible storage 10 or 10 a . More precisely, where the accessible storage is arranged for barring the non-shared IMPU's associated with each ‘secondary’ IMPI, the processing unit may be arranged for barring and unbarring such barring in the configuration 130 of the accessible storage.
Furthermore, where the barring for call establishment of each non-shared IMPU associated with each ‘secondary’ IMPI, where the barring for own registration of each ‘secondary’ IMPI, or where both are implemented, the deregistration of ‘secondary’ IMPI's, which is carried out as a result of the determination made during the step S- 195 of the method illustrated in FIG. 11 , includes a step of barring for call establishment in the configuration 130 each non-shared IMPU associated with each ‘secondary’ IMPI, and a step of barring for own registration each ‘secondary’ IMPI in the configuration 120 .
The invention may also be practised by a computer program, loadable into an internal memory of a computer with input and output units as well as with a processing unit. This computer program comprises to this end executable code adapted to carry out the above method steps when running in the computer. In particular, the executable code may be recorded in a carrier readable medium.
The invention is described above in connection with various embodiments that are intended to be illustrative and non-restrictive. It is expected that those of ordinary skill in this art may modify these embodiments. The scope of the invention is defined by the claims in conjunction with the description and drawings, and all modifications that fall within the scope of the claims are intended to be included therein.
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The present invention faces the issue of exercising a parental control over children's activities in the IMS network, in terms of registering into the IMS network as well as in terms of call establishment, and provides for a new IMS subscription model supporting a hierarchy of IMPI's, so-called ‘primary’ IMPI's and so-called ‘secondary’ IMPI's, whereby only the primary IMPI's are allowed to register themselves, whereas the secondary IMPI's can only register themselves after having been previously registered by a primary IMPI. To this end, the present invention provides for a new method and an enhanced HSS to allow the implicit registration of one or more ‘secondary’ IMPI's upon the explicit registration of an IMS subscriber with a given IMPI/IMPU pair, wherein the given IMPI is a ‘primary’ IMPI and the given IMPU is associated with a registration set of IMPI's which includes said one or more ‘secondary’ IMPI's.
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[0001] This application is a divisional of U.S. application Ser. No. 11/052,683 filed Feb. 7, 2005, and claims the benefit thereof.
FIELD OF THE INVENTION
[0002] This invention relates to portable tanks, in particular, tanks transportable by trailer.
BACKGROUND OF THE INVENTION
[0003] A clarifier/thickener tank of a clarifier/thickener system serves two purposes. First, the clarifying aspect of the tank produces liquid clarified of suspended solids. Secondly, the thickener aspect of the tank concentrates the clarified suspended solids to an increased solids percentage.
[0004] Most conventional clarifier/thickener tanks have a cylindrical shape. A rectangular shape is sometimes used but is less common because of inefficiencies that can be introduced during clarification from this geometry. The cylindrical form is the most common configuration and efficient in terms of clarifier ability. The performance of the thickener aspect is independent of shape but dependent on the overall depth of the tank which provides weight from the fluid itself and the overlying thickened sludge to dewater or thicken the slurry. A clarifier/thickener tank typically has a funnel shaped bottom with steep sides to assist in removal of the solid slurry. For a conventional clarifier/thickener tank equipped with a sludge removal device such as a rake system, the slope of the bottom is about 1.5 inches for every twelve inches of run. The preferred diameter of a cylindrical clarifier/thickener tank can vary depending on the water flow rate, the density of the slurry, the slurry setting characteristics and other factors.
[0005] It is desirable to have a portable clarifier/thickener system so that the system may be transported to locations where the temporary use of the system is desired without the effort and expense of constructing and dismantling a fixed installation at each location the system is utilized. These construction and dismantling activities involve considerable expense from the labor, transportation and crane rental required to complete the installation. These costs become even more significant if the locale of operation is in a remote area or access to the site is intermittent.
[0006] The diameter of tanks which can be transported is limited by transportation laws which limit the width of a load which can be transported by road. As transported loads increase beyond a width of 10 to 12 feet, increasingly expensive and restrictive permits require purchase. For example, as load widths increase beyond 14 feet it is common for the permits to require the use of escort vehicles as well as limitations on the routes and times that the load can be transported. (See, for example, Nova Scotia Department of Transportation & Public Works, Highway Operations, Policies and Procedures Manual, Procedure Number PR5033, Mar. 5, 2006.) As a result, the transport limitations place a limit on the clarifying rate of such a system since the clarifying rate of a clarifier/thickener tank is dependent on the square foot surface area of the interior of the tank. To overcome this limitation, multiple smaller tanks can be placed in series. However, this creates complexity in the system from duplication of piping, valves, sludge pumps, feed splitters, etc. Also, the capacity to accumulate and thicken solids depends on the volume of the tank.
SUMMARY OF THE INVENTION
[0007] A portable tank is disclosed which allows for rapid and inexpensive mobilization and demobilization of a clarifier/thickener at multiple locations while maintaining a desirable clarification.
[0008] According to one broad aspect, the invention provides a tank assembly comprising a plurality of tank sections each capable of being connected to at least one other tank section, wherein each tank section has a dimension that enables the section to be accommodated at or within a predetermined width limit for transportation by public road, and wherein a dimension of the tank directly across the sections when the tank is assembled exceeds said predetermined width limit.
[0009] In some embodiments, the tank assembly comprises a bottom and a side wall extending upwardly from said bottom and wherein at least two sections each comprise a portion of said bottom and a portion of said side wall.
[0010] In some embodiments, said predetermined width limit is defined as the maximum width for transportation without a permit in the jurisdiction in which said tank is to be transported.
[0011] In some embodiments, said dimension of the tank directed across the sections is 11 feet or more.
[0012] In some embodiments, each section has opposed edges in which one of said edges is for connection to another tank section and a dimension between said edges is greater than half said predetermined width limit.
[0013] In some embodiments, the tank assembly further comprises mounting means for mounting a fluid treatment device therein.
[0014] In some embodiments, said tank comprises mounting means for mounting a rotary device therein.
[0015] In some embodiments, said rotary device includes a rotor having a diameter which exceeds said predetermined width limit.
[0016] In some embodiments, said tank when assembled is substantially cylindrical.
[0017] In some embodiments, the plurality of tank sections comprise two substantially uniform semi-cylindrical halves.
[0018] In some embodiments, the opposed edges define an open face in a transportation position.
[0019] In some embodiments, the at least two tank sections are pivotally attached along the divide.
[0020] In some embodiments, at least two tank sections are pivotally attached.
[0021] In some embodiments, the tank assembly further comprises at least a portion of at least one of a clarifier and a thickener mounted to said tank assembly.
[0022] In some embodiments the tank sections are adapted to together hold liquid when the tank is assembled.
[0023] In some embodiments, the tank assembly further comprises a frame and wheels supporting the tank sections.
[0024] In some embodiments, the tank assembly further comprises a plurality of retractable downward supports for supporting the assembled tank.
[0025] According to one broad aspect the invention provides a tank assembly comprising a plurality of tank sections each capable of being connected to at least one other tank section and a fluid treatment apparatus capable of being mounted within the tank assembly when the tank assembly is assembled.
[0026] In some embodiments, the fluid treatment apparatus comprises at least one of a clarifier and a thickener.
[0027] In some embodiments, said tank assembly has an upper portion and a lower portion and the divide between at least two tank sections is directed from said upper portion to said lower portion of said tank.
[0028] In some embodiments, the at least two tank sections are pivotally attached along the divide.
[0029] In some embodiments, the tank assembly further comprises a first support connected to the first tank section at a position spaced from the pivotal axis, and extending upwardly therefrom and coupled to a second support for supporting at least part of the weight of at least one of the tank sections.
[0030] According to one broad aspect, the invention provides a method of transporting a tank assembly comprising providing at least two tank sections wherein each tank section has a dimension that enables the section to be accommodated at or within a predetermined width limit for transportation by public road and wherein a dimension of the tank assembly directed across the sections when the tank assembly is assembled exceeds said predetermined width limit and orienting each tank section for transportation with the dimension that enables the section to be accommodated at or within a predetermined width limit directed across the width of the road.
[0031] According to one broad aspect, the invention provides a method of assembling a first tank section and a second tank section pivotally connected to each other by a pivotal connection, comprising providing support for supporting the first tank section, such that the second tank section is free to move relative to said first tank section about said pivotal axis, and rotating the second tank section about the pivotal connection to form an assembled tank with the first tank section.
BRIEF DESCRIPTION OF THE DRAWINGS
[0032] Preferred embodiments of the invention will now be described with reference to the attached drawings in which:
[0033] FIG. 1 is left side view of a portable tank apparatus according to an embodiment of the invention;
[0034] FIG. 2 is a right side view of the embodiment of FIG. 1 ;
[0035] FIG. 3 is a top view of the embodiment of FIG. 1 ;
[0036] FIG. 4A is a perspective view of a pivoting hinge post assembly according to the embodiment of FIG. 1 ;
[0037] FIG. 4B is a perspective view of a stationary hinge post assembly according to the embodiment of FIG. 1 ;
[0038] FIG. 5 is a bottom perspective view of a pivot tank section according to the embodiment of FIG. 1 ;
[0039] FIG. 6 is a bottom perspective view of a stationary tank section according to the embodiment of FIG. 1 ;
[0040] FIG. 7 is a perspective view of the embodiment of FIG. 1 with the pivot tank section in a partially rotated position; and
[0041] FIG. 8 is a perspective view of the embodiment of FIG. 1 with the pivot tank section in a closed position.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0042] FIG. 1 shows a portable tank assembly 10 which includes a trailer deck 16 , a stationary tank section 14 and a pivot tank section 12 . Supporting trailer wheels 18 are provided on the trailer deck 16 and are located towards the rear of the trailer deck 16 . The stationary tank section 14 rests on supports (not shown) on the trailer deck 16 towards the front of the trailer deck 16 and the pivot tank section 12 rests on supports (not shown) on the trailer deck 16 towards the rear of the trailer deck 16 . The supports are constructed of hollow structural steel welded to the trailer deck 16 and support each of tank sections 12 and 14 at three points on the respective tank sections 12 and 14 . The supports for the stationary tank section 14 are permanently welded, while the supports for the pivot tank section 12 are bolted to allow the pivot tank section 12 to pivot as required.
[0043] The pivot tank section 12 and the stationary tank section 14 are semi-cylindrical tank halves with vertical side walls, a semi-conical shaped bottom, an open face and an open top.
[0044] FIG. 1 shows an interior view of the tank sections 12 and 14 . Vertical flanges 60 are provided on both tank sections 12 and 14 . The vertical flanges 60 extend up the two vertical edges of the open face of each of the tank sections 12 and 14 . The vertical flanges 60 extend outward from the vertical edges parallel to the open faces of the tank sections 12 and 14 and form opposed edges extending between an upper portion and a lower portion of the tank sections 12 and 14 . The flanges 60 have a plurality of closely spaced bolt holes defined therethrough. Similarly, bottom flanges 62 are provided which extend outward from the edge of the semi-conical shaped bottom of the open face of the tank sections 12 and 14 . The bottom flanges 62 extend parallel to the open faces of the tank sections 12 and 14 . The flanges 60 and 62 define a divide between the two tank sections 12 and 14 when assembled. A plurality of bolt holes are also defined through the bottom flanges 62 .
[0045] Both tank sections 12 and 14 include weir halfs 26 . The weir halfs 26 are continuous pieces of sheet metal with serrated upper edges. Each of the weir halfs 26 are welded to the tank sections 12 and 14 . The weir halfs 26 are positioned along an upper inner circumference of the wall of each of the tank sections 12 and 14 . Each of the weir halfs 26 is angled inward from the respective wall of tank sections 12 and 14 at an approximately 45 degree angle. The weir halfs 26 are welded to the walls of tank sections 12 and 14 with a water-tight seal. The weir halfs 26 include weir flanges 92 located at the vertical edges of the weir halfs 26 . The weir flanges 92 extend inward parallel to the open faces of the tank sections 12 and 14 . The weir flanges 92 also have a plurality of bolt holes defined therethrough.
[0046] Three stationary jack legs 20 are fixed to the bottom surface of the stationary tank section 14 . The stationary jack legs 20 are spaced around the circumference of the stationary tank section 14 . The stationary jack legs 20 overhang the edge of the trailer deck 16 . The stationary jack legs 20 are shown in retracted position in FIG. 1 .
[0047] Three pivot jack legs 22 are affixed to a bottom surface of the pivot tank section 12 . The pivot jack legs 22 are spaced around the circumference of the pivot tank section 12 . The pivot jack legs 22 are depicted in FIG. 1 in a retracted and folded position. In the folded position, the pivot jack legs 22 may rest on the trailer deck 16 . The jack legs 20 and 22 are shown in more detail in FIGS. 5 and 6 . The jack legs 20 and 22 provide retractable support for the tank sections 12 and 14 .
[0048] The stationary tank section 14 includes a stationary cross member 38 . The stationary cross member 38 extends laterally across the stationary tank section 14 adjacent an upper end of the open face of the stationary tank section 14 . Similarly, the pivot tank section 12 includes a pivot cross member 40 . The pivot cross member 40 extends laterally across the pivot tank section 12 adjacent an upper end of the open face of the pivot tank section 12 . Six hand rails 24 are attached to the cross members 38 and 40 . The hand rails 24 are bolted to the inner longitudinal sides of the cross members 38 and 40 opposite to the open face of the tank sections 12 and 14 .
[0049] A drive assembly is supported by the cross member 38 . The drive assembly consists of an electric motor 44 , a gear reducer 46 and drive plate 48 at an upper end. The electric motor is connected to the gear reducer 46 which in turn is connected to the drive plate 48 . The drive assembly also includes a drive pipe 52 , a dispersion plate 54 , a tube 42 , an input pipe 50 and a rake assembly 166 . The drive plate 48 is connected to the drive pipe 52 which extends down through a center of the tube 42 . The dispersion plate 54 is connected to the tube 42 by four threaded rods (not shown). The rake assembly 166 is bolted to a lower end of the drive pipe 52 . The input pipe 50 is connected to an outside pipe connection 51 by a flexible connection (not shown). The input pipe 50 extends out from an upper side of the tube 42 . The input pipe 50 ends in a flange for easy connection to outside connection pipe connection 51 . The means by which the drive assembly is supported is described in greater detail with respect to FIG. 3 .
[0050] A bottom cone 56 is provided at a bottom point of the semi-conical shape bottom of the stationary tank section 14 . Two output pipes 58 extend out from angled sides of the bottom cone 56 . The output pipes 58 end with flanges for ready connection to associated piping and sludge pump (not shown).
[0051] The pivot tank section 12 is connected to the stationary tank section 14 by a loose hinge assembly. The hinge assembly includes hinge posts 30 and 32 and pairs of hinge plates 34 and 36 . The pivot hinge post 32 is vertically oriented and bolted to the pivot tank section 12 by the frontward vertical flange 60 of the pivot tank section 12 . The pivot hinge plates 34 are bolted to the pivot hinge post 32 . The stationary hinge post 30 is vertically oriented and bolted to the stationary tank section 14 by the rearward vertical flange 60 of the stationary tank section 14 . The stationary hinge plates 36 are bolted to the stationary hinge post 30 . Each of the pairs of hinge plates 34 and 36 are bolted to opposite ends of the hinge posts 30 and 32 . The hinge assembly is described in greater detail with reference to FIGS. 4A and 4B .
[0052] A mast assembly extends upward from the stationary hinge post 30 . The mast assembly includes a mast 28 , a cable 162 , a mast support 160 and a mast arm 164 . The mast 28 is a steel tube. The mast 28 has associated with it a mast upper top plate 170 , a mast lower top plate 172 , a plate angle support 174 , an upper mast pivot 176 and a lower mast pivot 178 .
[0053] The mast upper top plate 170 and the mast lower top plate 172 each have a protrusion with a hole defined therethrough. The mast upper top plate 170 and the mast lower top plate 172 are fastened at the top of the mast 28 with the mast lower top plate 172 spaced below the mast upper top plate 170 . The holes in their protrusions are vertically aligned. The plate angle support 174 is a triangle plate welded between the mast 28 and the bottom of the protrusion of the mast lower top plate 172 for support.
[0054] The upper mast pivot 176 are cylindrical with an attachment flange extending from one side. A pin extends through the hole in the protrusion in the upper top plate 170 through the center of the upper mast pivot 176 and through the hole in the protrusion in the lower top plate 172 .
[0055] The mast support 160 is a steel rod. The mast support 160 is angled between a rearward brace leg 82 (see FIG. 6 ) and an upper point of the mast 28 . The mast support 160 is removably bolted at each end.
[0056] The mast arm 164 is a steel rod. The mast arm 164 is horizontal and is connected at one end to an intermediate point of a brace 74 (see FIG. 3 ) and at the other end to the lower mast pivot 178 . The mast cable 162 connects the upper mast pivot 176 to the end of the mast arm 164 which connects to the brace 74 (see FIGS. 7 and 8 ).
[0057] The bottom end of the mast 28 is bolted to the top of a mast bearing support end flange 128 (see FIG. 4B ).
[0058] FIG. 2 shows a rear view of the tank sections 12 and 14 . The tank sections 12 and 14 include vertical stiffeners 72 . The vertical stiffeners 72 are comprised of elongated flat pieces of metal. The vertical stiffeners 72 are welded to an outer surface of the walls of the tank sections 12 and 14 such that they extend vertically. The tank sections 12 and 14 also includes similar horizontally oriented stiffeners (not shown) on the bottom.
[0059] The stationary tank section 14 includes a discharge box 68 which is located adjacent the top rear of the stationary tank section 14 . The discharge box 68 is hollow and open topped with a substantially triangular cross-section and a discharge pipe 70 extending from its bottom surface. The discharge pipe 70 ends in a flange for attachment to other piping of the assembly (not shown). The discharge box 68 communicates with the interior of the stationary tank section 14 through a hole in the wall of the stationary tank section 14 (not shown). The hole through the wall of stationary tank section 14 is defined above the weir half 26 of the stationary tank section 14 . The discharge box 68 is welded to the rear surface of the stationary tank section 14 in a fluid tight manner.
[0060] FIG. 3 shows the position of the tank sections 12 and 14 on the trailer deck 16 . In particular, the tanks sections 12 and 14 take up substantially the entire length of the trailer 16 and slightly overhang the edges of the trailer 16 . The weir halfs 26 extending around the circumference of the tanks sections 12 and 14 can be clearly seen in FIG. 3 . The substantially triangular cross-sectional shape of discharge box 68 can also be clearly seen in FIG. 3 .
[0061] FIG. 3 shows the support structure for the drive assembly. In particular, the pivot tank section 12 has drive supports 76 and angle braces 78 . The drive supports 76 extend laterally from the bottom surface of the cross member 40 symmetrically spaced around a midpoint of the cross member 40 . The drive supports 76 extend toward the open face of the pivot tank section 12 . The angle braces 78 extend at an approximate 45 degree angle between the cross member 40 and an outer end of the drive supports 76 . The drive supports 76 are spaced to fit under the drive plate 48 . The drive assembly is shown in its transportation position such that it is not centered on the center line of the tank. In this position, the drive assembly is supported by the drive supports 88 of stationary tank section 14 alone. In operation mode the drive plate 48 is unbolted from the drive supports 88 and shifted and bolted on both the drive supports 88 and the drive supports 76 present on both tank sections 12 and 14 and centered along the centerline of the assembled tank.
[0062] The cross member 40 also includes brace legs 84 . The brace legs 84 extend laterally from the open face side of the cross member 40 and terminate in flanges at the open face of the pivot tank section 12 . The brace 74 is provided in the pivot tank section 12 . The brace 74 extends horizontally between a centre point of the cross member 40 and the outer surface of the tank. The brace 74 is a beam which helps prevent deformation of the pivot tank section 12 during rotation.
[0063] The stationary tank section 14 also include drive supports 88 (see FIG. 6 ) and angle braces 86 which provide support for the drive assembly. The drive supports 88 extend outwardly from the cross member 38 under the drive plate 48 . The angle braces 86 extend at an approximately 45 degree angle between the cross member 38 and ends of the drive supports 88 .
[0064] The cross member 38 also includes brace legs 82 . The brace legs 82 are spaced along the cross brace 38 and extend outwardly therefrom. The brace legs 82 terminate in flanges at the open face of the stationary tank section 14 . The brace legs 82 are positioned to mate with leg braces 84 when the tank is in a closed position.
[0065] Also visible in FIG. 3 are cone bottom flanges 80 of the tank sections 12 and 14 which have a plurality of bolt holes defined therethrough. Cone bottom flanges are horizontal and connect the bottom cone 56 to the tank sections 12 and 14 when assembled.
[0066] FIGS. 4A and 4B show details of the hinge posts 30 and 32 and the hinge plates 34 and 36 . Turning to FIG. 4A , FIG. 4A shows the pivot hinge post 32 . The pivot hinge post 32 is an elongated hollow steel post with a square cross section. Also depicted are two hinge base plates 104 . Each of the hinge base plates 104 is a flat rectangular plate with six bolt holes defined around the perimeter. A first hinge base plate 104 is welded at an upper end of the pivot hinge post 32 and a second hinge base plate 104 is welded at the bottom end of the pivot hinge post 32 . Defined in the opposite face of the pivot hinge post 32 from the hinge base plates 104 is an upper rim opening 100 and a lower rim opening 102 . The upper rim opening 100 is located adjacent the top of the pivot hinge post 32 and accommodates a top side rim 98 ( FIG. 5 ) of the pivot tank section 12 when the pivot hinge post 32 is bolted to the pivot tank section 12 . Similarly, the lower rim opening 102 accommodates a bottom side rim 96 ( FIG. 5 ) of the pivot tank section 12 when the pivot hinge post 32 is bolted to the pivot tank section 12 .
[0067] Two rotating hinge support plates 110 extend outwardly from the pivot hinge plate 34 . The rotating hinge support plates 110 are perpendicular to the pivot hinge plate 34 . A rotating hinge 106 extends through and is connected to the outer end of each rotating hinge support plate 110 . A pivot hinge web plate 108 is provided which extends between the two rotating hinge support plates 110 . Also provided are two pivot hinge gussets 112 which connect from the rotating hinge support plate 110 to the pivot hinge plate 34 . The pivot hinge web plate 108 and the pivot hinge gussets 112 further support the hinge assembly. The entire hinge assembly structure may be welded together or may be cast as a single part. The pivot hinge plate 34 has six bolt holes defined therethrough which match to the bolt holes in the hinge base plate 104 to allow each pivot hinge plate 34 to be bolted to one of the hinge base plate 104 .
[0068] Turning to FIG. 4B , FIG. 4B shows the stationary hinge post 30 which is also an elongated steel hollow post having a square cross section. A series of bolt holes 190 are defined up a side face of the stationary hinge post 30 to enable bolting of the stationary hinge post 30 to the rearward vertical flange 60 of the stationary tank section 14 . A lower rim opening 124 is defined adjacent a lower end of one face of the stationary hinge post 30 . The lower rim opening 124 is shaped to accommodate the bottom side rim 196 (see FIG. 6 ) of the stationary tank section 14 . Similarly, adjacent an upper end of the stationary hinge post 30 , there is defined an upper rim opening 122 which is sized to accommodate the top side rim 198 (see FIG. 6 ) of the stationary tank section 14 such that the stationary hinge post 30 can be bolted flush against the exterior side of the stationary tank section 14 .
[0069] The stationary hinge assembly includes hinge base plates 120 and stationary hinge plates 36 . The hinge base plates 120 are located on an opposite face of the stationary hinge post 30 from the openings 122 and 124 . There are two hinge base plates 120 , one adjacent the lower end of the stationary hinge post 30 and the other adjacent the upper end of the stationary hinge post 30 . The flat steel hinge base plates 120 have four holes spaced along each of their vertical edges to accommodate attachment of the stationary hinge plates 36 .
[0070] The stationary hinge plates 36 have four holes defined on each of the vertical edges which align with the holes of the hinge base plates 120 to allow bolting together of the stationary hinge plate 36 and the hinge base plates 120 . Three stationary hinge support plates 118 extending laterally outwardly from the hinge base plates 36 . A stationary hinge 114 is located at an outer end of each of the stationary support plates 118 . The stationary hinges 114 are cylindrical and in vertical alignment but spaced apart to accommodate the rotating hinges 106 of the pivot hinge plate 34 when assembled. Two stationary hinge web plates 116 connect pairs of the stationary hinge support plates 118 . The hinge assembly can be cast as a single part or have component parts welded together.
[0071] The mast bearing support end flange 128 and a mast bearing support 126 are also provided. The mast bearing support end flange 128 is substantially a square flat plate with protrusion extending from one corner. There are bolt holes defined through the four corners of the square portion to allow bolting of the mast 28 to the mast bearing support end flange 128 . There is also a hole defined through the outer end of the protrusion. The mast bearing support 126 has the same shape as the protrusion of the mast bearing support end flange 128 . A mast bearing support end flange 128 is positioned atop the stationary hinge post 30 . The mast bearing support 126 is positioned directly in a vertical alignment below the mast bearing support end flange 128 and above the upper stationary hinge plate 36 . The mast bearing support 126 also has a hole defined through it at an extent which is in alignment with the hole defined through the end of the protrusion of the mast bearing support end flange 128 . The mast bearing support 126 and the protrusion of the mast bearing support end flange 128 extend outwardly laterally from a corner from the stationary hinge support 30 over the stationary hinge plates 36 . A cylindrical lower mast pivot 178 (see FIG. 1 ) is provided with an attachment flange extending from one side. The mast bearing support 126 and the mast bearing support end flange 128 support an end of the mast arm 164 (see FIG. 1 ) through the lower mast pivot 178 .
[0072] FIG. 5 shows bottom details of the pivot tank section 12 . In particular, the connection of the brace legs 84 , the drive supports 76 , and the angle braces 78 to the cross member 40 can be more clearly seen. The drive supports 76 and the angle braces 78 extend along a bottom of the cross member 40 and are fastened thereto by welding or bolting.
[0073] The pivot jack legs 22 can also be seen in more detail in FIG. 5 . In particular, the pivot jack legs 22 each comprise a pivot leg bottom 140 a pivot leg top 144 , a jack connection 142 , and a leg post 150 . The pivot leg bottoms 140 and the pivot leg tops 144 are connected by the jack connections 142 . A leg support plate 146 is provided at the top of each pivot leg top 144 . Each leg support plate 146 is a flat square plate which is perpendicular to the direction of the leg 22 and overhangs the sides of the pivot leg top 144 . Defined in each of the four corners of the leg support plates 146 are bolt holes.
[0074] FIG. 5 also shows leg base plates 148 which are flat square plates with bolt holes defined in the four corners which mirror the bolt holes of the leg support plates 146 . The leg base plates 148 are located at the lower end of the leg posts 150 which are permanently fixed to the bottom of the pivot tank section 12 . The leg base plates 148 and the leg support plates 146 are hinged along one edge (see FIG. 1 ). In FIG. 1 , the legs 22 are shown in a folded position. In FIG. 5 , the legs 22 are shown in their use position in which legs 22 are rotated about the hinge between the leg support plates 146 and the leg base plates 148 to be brought into the vertical position. The leg 22 is then retained in this position by bolting together the leg support plates 146 and the leg base plates 148 .
[0075] FIG. 6 shows the bottom details of the stationary tank section 14 . As with FIG. 5 , FIG. 6 shows how the drive supports 88 , the angle braces 86 and the brace legs 82 are connected to the cross brace 38 . In particular, the drive supports 88 and the angle braces 86 extend across a bottom surface of the cross member 38 and are bolted or welded thereto.
[0076] FIG. 6 also shows the stationary jack legs 20 . The stationary jack legs 20 are comprised of stationary leg tops 156 , stationary leg bottoms 154 and jack connectors 152 . The stationary leg tops 156 and the stationary leg bottoms 154 are square steel legs. The stationary leg top 156 and the stationary leg bottom 154 are connected by the jack connection 152 . The stationary leg tops 156 terminate at their upper ends with leg base plates 158 . Each leg base plate 158 has bolt holes defined through each of its four corners for attachment to the bottom of the stationary tank section 14 .
[0077] The portable tank assembly 10 is transported in the position depicted in FIGS. 1, 2 and 3 with the exception that the mast 28 is normally lowered for transportation. In particular, the mast support 160 , the mast 28 and the mast cable 162 are removed for transportation. The hand rails 24 , bottom cone 56 and one rake arm of the rake assembly 166 that extends beyond the footprint of the trailer deck 16 are removed. FIG. 7 shows the one arm that needs to be removed during transport.
[0078] The trailer deck 16 is connected to a transport truck and towed to the location where the portable assembly 10 is to be used. In this configuration, the width of the assembly tank sections 12 and 14 across the width of the road is within a predetermined width limit for transportation without a permit or for transportation using the desired permit level (i.e. acceptable cost and restrictions). Once at the location for use, the pivot tank section 12 is prepared to be rotated to align with the stationary tank section as shown in FIGS. 7 and 8 . The mast 28 is positioned vertically and bolted to the top of the mast bearing support end flange 128 . The mast cable 162 is attached from the upper mast pivot 176 at the top of the mast 28 to an outside corner of the mast arm 164 . The mast assembly provides support to the pivot tank section 12 during rotation. The bottom cone 56 is attached to the stationary tank section 14 and the rake arm that extends beyond the trailer footprint is attached ( FIG. 7 ). A gasket (not shown) is placed between the flanges 60 , 62 and 92 of the two tank sections 12 and 14 and between the bottom cone 56 and the flanges 80 of the two tank sections 12 and 14 . The pivot tank section 12 rotates about the hinges 106 and 114 , which in use, have a pin extending therethrough to connect the hinges 106 and 114 . The pivot tank 12 is rotated through the position shown in FIG. 7 to the position shown in FIG. 8 . At this point, bolts are inserted in all of the bolt holes in the flanges 60 , 62 , 92 and 80 to fasten the two tank halves together in a liquid tight manner to hold liquid. Flanges at the ends of the brace legs 82 and 84 are fastened. The stationary jack legs 22 are jacked down to provide support. The pivot jack legs 20 are also positioned to provide support by first unfolding the jack legs to the vertical position and bolting the leg supports 146 to the leg base plates 148 (see FIG. 5 ). The pivot leg bottoms 140 are then jacked down to provide support for the pivot tank section 12 . Next, the hand rails are installed and a fiberglass walkway (not shown) is positioned between the hand rails 24 and rests on the cross members 38 and 40 to provide access for an operator to walk to the drive assembly. The motor, gear reducer, tube and drive pipe and drive plate assembly is shifted to operation mode.
[0079] Connections are then made to the various pipes to allow operation of a clarifier/thickener system utilizing the portable tank assembly 10 . In particular, a pipe is connected to input pipe 50 to pump the fluid to be treated into the assembled portable tank assembly 10 . In operation, the dispersion plate 54 acts to evenly spread the incoming slurry across the bottom of the assembled tank. The slurry enters in through the input pipe 50 flows down through the tube 42 and is evenly spread through the circumference of the tank by the dispersion plate 54 . The threaded rods allow the adjustment of the gap between the dispersion plate 54 and the tube 42 to allow for different flow rates. The connection of the drive pipe 52 to the rake assembly 166 connects the rake assembly 166 to the gear reducer 46 and motor 44 . The rake moves at a rate around 3 rpm at the rake tips and functions to “pull” the thickened sludge to the center of the tank at the point of the bottom cone so that it can be continuously pumped from the tank. The drive unit is actuated to drive the drive assembly. The rake assembly 166 rakes in a circular motion around the bottom of the tank for sludge treatment. Slurry is drained out of the bottom of the tank through bottom output pipes 58 . Clarified water spills over the weir 26 and exits the tank through the discharge box 68 . The operation of the clarifier/thickener system is conducted in a manner known in the art.
[0080] In the operation configuration, the width of the assembly tank sections 12 and 14 across the width of the road exceeds the predetermined width limit.
[0081] Although a specific embodiment of the invention has been explained, it will be evident to those skilled in the art that modifications can be made within the scope of the invention. For example, forms of legs other than jack legs and folding legs can be used. The legs could alternatively be transported separately and installed at the worksite. Hydraulic legs may also be used.
[0082] With respect to the hinge, any sufficiently durable pivot means known in the art could be used. With respect to pivoting the tank section 12 into position, means other than the mast assembly shown could be used to support the pivot tank section 12 . For example, pivot section 12 could be supported manually from the bottom.
[0083] Other drive systems with or without rake systems could be used for the clarifier/thickener system. Additionally, this tank can be used in other applications, including other fluid treatment applications, and apparatuses outside of the field of clarifier/thickener systems. Other rotary devices may also be used. The tank may be used for a clarifier or thickener system alone, rather than for both.
[0084] The portable tank assembly is preferably all steel construction but other materials of acceptable strength and durability can be substituted. Welding and bolting of the steel section has been described. Other attachment means can, of course, be alternatively use.
[0085] Although the invention is disclosed as having two equal semi-cylindrical sections, it will be understood other tank shapes and unequal division of the tank into two or more sections is contemplated by the invention.
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A tank assembly comprises a plurality of tank sections. Each tank section is capable of being connected to at least one other tank section. Each tank section is dimensioned to enable the section to be accommodated at or within a predetermined width limit for transportation by public road. A dimension of the tank directed across the sections when the tank is assembled exceeds the predetermined width limit.
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FIELD OF INVENTION
This invention relates to light fixtures, and in particular to devices, apparatus, assemblies, fixtures, systems and methods of a sliding hanger bracket for a light shade, such as a glass bowl, to lower away from a ceiling fan or light base, and tilt allowing the light shade to be cleaned and to change light sources, such as the light bulbs, without having to disassemble the light fixture.
BACKGROUND AND PRIOR ART
Light fixtures with light shades, such as those having a glass type bowl have been used for ceiling mounted lights and for ceiling fans for many years. See for example, U.S. Pat. Des. No. 404,167 to Dolan; U.S. Pat. No. 4,342,073 to Ranten; and U.S. Pat. No. D543,302 to Ertze. These popular types of ceiling fan light kits and flush mounted or semi-flush mounted light fixtures require disassembly of the shade/bowl portion of the light in order to clean the inside of the shade/bowl and/or to change out the lights sources (bulbs) when needed. However, cleaning the inside of the shade/bowl and changing out the light source has many problems.
The light shade/bowl is usually fixed to the fixture by at least one or more rotatable fasteners, such as nuts. The difficulty of trying to disassemble the overhead shade/globe is difficult and can be time consuming. The light shade/bowl is also usually a fragile piece of the light fixture and is often made of glass or thin plastic. Dropping the light shade/bowl and breaking it can often occur when the shade/bowl is being disassembled. Also, the person can be can also be injured from the falling shade/bowl and/or by other injuries such as falling off a ladder, and the like.
Thus, the need exists for solutions to the above problems with the prior art.
SUMMARY OF THE INVENTION
A primary objective of the present invention is to provide devices, apparatus, fixtures, systems and methods of using a sliding hanger bracket that allows a light shade to lower away from a light fixture on a ceiling fan or ceiling base, and tilt the shade to be cleaned and to change out light sources (bulbs) without having to disassemble the light fixture.
A secondary objective of the present invention is to provide devices, apparatus, fixtures, systems and methods of providing light shades on ceiling fixtures and ceiling fans to be tilted for cleaning out the shades and for changing light sources, where the light fixtures appear undistinguishable from traditional ceiling light fixtures or lights on ceiling fans.
A unique benefit in the invention is that the sliding bracket can rigidly hold the lamp shape in place securely until service is needed for the light assembly—cleaning or changing bulbs. The novel sliding bracket can then be lowered to allow the user to service the light kit. The user merely needs to simply push up and move the shade to one side and the light kit assembly will lower to the cleaning position. In this position, it is possible to tilt the light fixture from side to side to allow greater access for servicing the bulbs and inside of the light shade.
The tilt and clean assembly can include a dual bracket assembly where one bracket is fixed, has downward parallel arms and is slotted and the other bracket slides from locked position to cleaning position by using pins that are secured through the slots in the fixed bracket. When in the locked position, the light assembly is undistinguishable from other light kits.
An overhead light fixture according to the invention can include an upper bracket having a top end and a bottom end, the top end being attached to a ceiling mounted member, a bottom bracket having a top end and a bottom end, the top end of the lower bracket being slidable from a retracted lock position located above the bottom end of the upper bracket to a lowered position, a pivotable portion for allowing the lower bracket to tilt relative to the upper bracket, when the bottom bracket is in the lowered position, a removable light source attached to one of the upper bracket and the bottom bracket, and a light shade attached to the bottom end of the bottom bracket, wherein the light shade is tiltable when the bottom bracket is in the lowered position so that the light source and inside of the light shade are serviceable.
The ceiling mounted member can include a ceiling mounted member for attaching the light fixture to a ceiling. The ceiling mounted member can include a an attachment member for attaching the light fixture to a ceiling fan. The light shade can have a bowl shape or another shape.
The upper bracket can include an elongated leg member having an elongated slot, and a sliding member attached to the top end of the lower bracket so that the bottom bracket can slide up and down by the sliding member sliding within the elongated slot. The sliding member can also the pivotable member. The sliding member can be a pin. Alternatively, the sliding member can be a screw.
The upper bracket can include a second elongated leg member having a second elongated slot, the second elongated member being parallel to the first elongated leg member, and a second sliding member attached to the top end of the lower bracket so that the bottom bracket can slide up and down by the second sliding member sliding within the second elongated slot.
The vertical slot can include a hook shaped slot at the top of the first elongated slot for locking the bottom bracket in the retracted lock position.
A method of servicing a light source and inside of a light shade on overhead light fixture without having to disassemble the light fixture, can include the steps of attaching a top bracket to a ceiling mount member, attaching a bottom bracket to a light shade, slidably attaching the top bracket and the bottom bracket to each other, sliding the bottom bracket from an up position to a down position, tilting the light shade and the bottom bracket when the bottom bracket is in the down position, and servicing the light source and inside of the light shade when the light shade is tilted without disassembling the overhead light fixture.
The method can include the step of providing a ceiling mounted light as the overhead light fixture. The method can include the step of attaching the ceiling mount member to a ceiling fan.
The method can include the steps of providing the top bracket with an elongated vertical leg member having a longitudinal slot, attaching a pin to the bottom bracket, and sliding the bottom bracket up and down to the top bracket by the pin sliding in the longitudinal slot.
The method can include the steps of providing the top bracket with a second elongated vertical leg member having a second longitudinal slot, the second elongated vertical leg member being parallel to the first elongated vertical member, attaching a second pin to the bottom bracket, and sliding the bottom bracket up and down to the top bracket by the second pin sliding in the second longitudinal slot.
The method can include the step of locking the bottom bracket in the up position. The locking step can include the steps of providing the first longitudinal slot with a hook slot at an upper end and positioning the first pin in the hook slot.
The method can include the step of pushing up on the bottom bracket to release the bottom bracket from the locked up position.
An overhead light fixture assembly for allowing light shades and lights sources to be serviceable without having to disassemble the fixture assembly, can include a top rigid member attached to a ceiling mount member, a bottom rigid member moveably attached to the top rigid member, a light shade attached to the bottom rigid member, and a removable light source attached to the fixture assembly between the ceiling mount member and the light shade, wherein the bottom rigid member with light shade is moveable from an upper position to a lower position, and the light shade is tiltable in the lower position to allow the light source and interior of the light shade to be serviced.
The assembly can include a lock position for locking the bottom rigid member to the top rigid member with the bottom rigid member is in the upper position.
Further objects and advantages of this invention will be apparent from the following detailed description of the presently preferred embodiments which are illustrated schematically in the accompanying drawings.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 is a perspective view of the exterior of the novel ceiling mount light assembly.
FIG. 2 is a perspective view of the light assembly of FIG. 1 with bottom bracket dropped and tilted back for bulb and cleaning access.
FIG. 3 is a perspective view of the exterior of the novel mount light assembly mounted to a ceiling fan.
FIG. 4 is a perspective view of the light assembly of FIG. 3 with bottom bracket dropped and tilted back for bulb and cleaning access.
FIG. 5 is a front view of the light assembly of FIGS. 1-2 locked up without bulbs and with shade in dash line.
FIG. 6 is a front view of the light assembly of FIG. 5 with bottom bracket dropped.
FIG. 7 is a front view of the light assembly of FIG. 6 with bottom bracket tilted away from viewer.
FIG. 8 is a side view of light assembly of FIG. 5 with brackets locked up without bulbs and with shade in dash line.
FIG. 9 is a side view of the light assembly of FIG. 6 with bottom bracket dropped.
FIG. 10 is a side view of the light assembly of FIG. 7 with bottom bracket tilted to the left.
FIG. 11 is a back view of the light assembly of FIG. 8 with brackets locked up without bulbs and with shade in dash line.
FIG. 12 is a back view of the light assembly of FIG. 9 with bottom bracket dropped.
FIG. 13 is a back view of the light assembly of FIG. 10 with shade tilted toward the viewer.
FIG. 14 is a perspective view of light assembly of 11 with brackets locked up without bulbs and with shade in dash line.
FIG. 15 is a perspective view of light assembly of FIG. 12 with bottom bracket pushed up.
FIG. 16 is a perspective view of the light assembly or FIG. 15 showing the bottom bracket half way dropped.
FIG. 17 is a perspective view of the light assembly of FIG. 16 showing the bottom bracket fully dropped.
FIG. 18 is a perspective view of the light assembly 17 showing the bottom bracket fully dropped and tilted away from the viewer for bulb and cleaning access.
FIG. 19 is an exploded view of the ceiling mount light assembly of the preceding figures.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Before explaining the disclosed embodiments of the present invention in detail it is to be understood that the invention is not limited in its applications to the details of the particular arrangements shown since the invention is capable of other embodiments. Also, the terminology used herein is for the purpose of description and not of limitation.
A description of components will now be described.
10 Tilt & Clean fixture assembly. 20 Top/upper bracket. 23. Through-hole 24. Horizontal member 26. vertical leg 28. vertical leg 30 Bottom/lower bracket. 32. vertical leg 34. vertical leg 36. horizontal member 37. through-hole 40 Light socket bracket. 42. Horizontal member 43. Through-hole 50 Light bulb. 60 Light shade. 70 Mount flange. 80 Mount flange to top bracket mounting shaft. 87. nut 90 Upper finial. 100 Lower finial. 110 Light switch. 120 Bottom bracket pivot screw(s) or pin(s) 130 Slot in upper bracket. Item 140 Bottom bracket lock bar. 150 Upper bracket lock hook. 160 Ceiling mount light assembly. 170 Fan mount light assembly. 180 Ceiling fan. 190 Shade mount flange. 200 Shade & finial mounting shaft. 210 Finial mounting nut. 220 Resting slot at the top of each top bracket slot.
FIG. 1 is a perspective view of the exterior of the novel ceiling mount light assembly 160 . FIG. 2 is a perspective view of the light assembly 160 of FIG. 1 with bottom bracket 30 dropped and tilted back for bulb 50 and cleaning access.
Referring to FIGS. 1-2 , the ceiling mount light assembly 160 can include a mount flange 70 which can attached to a ceiling. Mount flange 70 can support a light shade/bowl 60 with a decorative upper portion (upper finial) 90 and decorative lower portion (lower finial) 100 , with a tilt and clean fixture assembly 10 between the mount flange 70 and light shade/bowl 60 .
FIG. 3 is a perspective view of the exterior of the novel mount light assembly 170 mounted to a ceiling fan 180 . FIG. 4 is a perspective view of the light assembly 170 of FIG. 3 with bottom bracket 30 dropped and tilted back for bulb 50 and cleaning access.
Referring to FIGS. 3-4 , the ceiling fan mount assembly 170 can include a mount flange 70 which is attached to the motor portion of a ceiling fan 180 . Similar to the previous embodiment, mount flange 70 can support a light shade/bowl 60 with a decorative upper portion (upper finial) 90 and decorative lower portion (lower finial) 100 , with a tilt and clean fixture assembly 10 between the mount flange 70 and light shade/bowl 60 .
Referring to FIGS. 2 and 4 , the tilt and clean fixture assembly 10 can include a bottom bracket 30 is pivotally attached to a top bracket 20 , which mounts a light socket bracket 40 thereon which holds the bulbs 50 in place. The top bracket 20 has two parallel legs each having elongated vertical slots 130 which allows for a bottom bracket pivot screw 120 to up and down in these slots 130 allowing for the bottom bracket 30 slide up and down. A bottom bracket bar 140 and light switch 110 will be described later.
FIG. 5 is a front view of the light assembly 160 of FIGS. 1-2 locked up without bulbs 50 and with shade 60 in dashed lines.
FIG. 6 is a front view of the light assembly 160 of FIG. 5 with bottom bracket 30 dropped.
FIG. 7 is a front view of the light assembly 160 of FIG. 6 with bottom bracket 30 tilted away from viewer.
FIG. 8 is a side view of light assembly 160 of FIG. 5 with brackets 20 , 30 locked up without bulbs 50 and with shade 60 in dashed lines.
FIG. 9 is a side view of the light assembly 160 of FIG. 6 with bottom bracket 30 dropped.
FIG. 10 is a side view of the light assembly 160 of FIG. 7 with bottom bracket 30 tilted to the left.
FIG. 11 is a back view of the light assembly 160 of FIG. 8 with brackets 20 , locked up without bulbs 50 and with shade 60 in dashed lines.
FIG. 12 is a back view of the light assembly 160 of FIG. 9 with bottom bracket 30 dropped.
FIG. 13 is a back view of the light assembly 160 of FIG. 10 with shade 60 tilted toward the viewer.
FIG. 14 is a perspective view of light assembly of 11 with brackets 20 , 30 locked up without bulbs 50 and with shade 60 in dashed lines.
FIG. 15 is a perspective view of light assembly 160 of FIG. 12 with bottom bracket 30 pushed up such that pivot screws ( 120 ) have been lifted out of resting slots ( 220 ) and lock bars ( 140 ) have been lifted out of lock hooks ( 150 ). This lines the pivot pins up with the upper bracket slots ( 130 ) so that the bottom bracket can be lowered.
FIG. 16 is a perspective view of the light assembly 160 of FIG. 15 showing the bottom bracket 30 half way dropped. The pivot screws 120 can be seen following the upper bracket slots.
FIG. 17 is a perspective view of the light assembly 160 of FIG. 16 showing the bottom bracket 30 fully dropped.
FIG. 18 is a perspective view of the light assembly 160 showing the bottom bracket 30 fully dropped and tilted away from the viewer for bulb 50 and cleaning access.
FIG. 19 is an exploded view of the ceiling mount light assembly 160 of the preceding figures.
Referring to FIGS. 1-4 and 19 , the mount flange 70 can be attached to a ceiling or to a ceiling fan 180 . Underneath the mount flange 70 can be a downwardly extending shaft 80 for passing through a through-hole 23 in a horizontal member 24 of the top bracket 20 , and through a through-hole 43 in an upper horizontal member 42 of the light socket bracket 40 . The lower surface of the shaft can have threaded exterior surface so that a nut 87 can hold the light socket bracket 20 and top bracket 20 mounted in place to the mount flange 70 .
Bottom bracket pivot screws 120 can be screwed into openings in upper ends of vertical legs 32 , 34 of bottom bracket 30 , so that the tip ends of the screws 120 can loosely pass into the slots 130 on parallel legs 26 , 28 of top bracket 20 . When the tilt and clean fixture assembly 10 is in the up position bottom bracket lock bar 140 rests in the bracket lock hooks 150 securing the bottom bracket 30 in the up position.
Another mounting shaft 200 can have exterior threaded surfaces so that a top end of the shaft 200 passes through an opening in a shade mount flange 190 and through a through-hole 37 in horizontal member 36 of the bottom bracket 30 . The finial mounting nuts 210 can be fastened to threaded exterior surface of the upper end of the shaft 200 and sandwich to both sides of the through-hole opening 37 in horizontal member 36 of bottom bracket 30 . The bottom end of the shaft 200 passes through a through-hole opening in an upper final decorative portion, so that a lower finial portion, such as a decorative nut can be fastened thereon mounting the shade 60 to the bottom bracket 30 .
The tilt and clean fixture assembly 10 can have a locked up position, a pushed up release position, a partially dropped position, and fully dropped extended position and a tilt position.
The locked up position of the tilt fixture assembly 10 is shown in FIGS. 5 , 8 , 11 , and 14 . Referring to FIGS. 5 , 8 , 11 , 14 and 19 , tilt fixture assembly 10 , outer ends of bottom bracket pivot screw(s) 120 are in the resting slots 220 which is at the top of the vertical slots 130 of each of the vertical legs 26 , 28 of the top bracket 20 . The outer ends of the bottom bracket pivot screws 120 lock into these slots 220 when the bottom bracket 30 is in the up position. Here, the bottom bracket bar 140 rests in the upper bracket lock hooks 150 securing the bottom bracket 30 in the up position. In this locked up position, the exterior of the ceiling mount light assembly 160 and ceiling fan mount assembly 170 appear undistinguishable from traditional ceiling light fixtures and or from lights on ceiling fans.
The pushed up position is shown in FIG. 15 . To release the tilt fixture assembly 10 from the locked up position, a user can push up on the bottom of the shade 60 , preferably around the finial portions 90 , 100 , so that outer ends of pivot screws 120 move up in slots 220 to the top of vertical slots 130 . FIG. 15 is a perspective view of light assembly 160 of FIG. 12 with bottom bracket 30 pushed up such that pivot screws 120 have been lifted out of resting slots 220 and lock bars 140 have been lifted out of lock hooks 150 . This lines the pivot pins (ends of screws 120 ) up with the upper bracket slots 130 of the top bracket 20 so that the bottom bracket 30 can be lowered.
The partially half dropped position is shown in FIG. 16 . Here, the outer ends of pivot screws 120 are able to ride in slots 130 of the vertical legs 26 , 28 as the bottom bracket 30 slides downward relative to the top bracket 20 until the bottom bracket 30 reaches a fully dropped position. The fully dropped extended position is shown in FIGS. 6 , 9 , 12 , 17 .
Next, the user can push sideways against the bottom portions of shade 60 , preferably about finial portions 90 , 100 so that the shade 60 and bottom bracket 30 become tilted which allows access to the bulbs 50 , bulb socket bracket 40 and the inside of shade 60 . The tilted position is shown in FIGS. 7 , 10 , 13 and 18 .
In the tilted position, the bulbs 50 can be changed out and/or the inside surface of the shade 60 can be cleaned.
After bulbs 50 are replaced or changed out and/or the inside surface of the shade 60 is cleaned, the above steps can be reversed until the bottom bracket 30 is back in a locked up position with top bracket 20 .
Although the light sockets are shown attached to the top/upper bracket, the light socket(s) can be attached to the bottom/lower bracket.
While the brackets have been shown with generally rectangular shapes, the brackets can have other shapes, such as single elongated members.
While the upper/top bracket is shown with two vertical legs, this bracket can have a single elongated leg with a single elongated slot, or more than two elongated legs, and the like.
Although the upper bracket is shown with longitudinal slots and the bottom bracket with pins or screws, the bottom bracket can have the longitudinal slot(s) and the top bracket can have pin(s) or screws.
Although the shade is shown as a bowl, the shade can have other shapes, such as but not limited to globe shaped, rectangular shaped, and other geometrical shapes and the like.
Although the sliding brackets are shown having slots and pins, the brackets, the brackets can slide relative to one another by having telescoping parts where one part telescopes relative to another part.
While the invention has been described, disclosed, illustrated and shown in various terms of certain embodiments or modifications which it has presumed in practice, the scope of the invention is not intended to be, nor should it be deemed to be, limited thereby and such other modifications or embodiments as may be suggested by the teachings herein are particularly reserved especially as they fall within the breadth and scope of the claims here appended.
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Devices, apparatus, fixtures, systems and methods of using a sliding hanger bracket for overhead lights that allows the light shade, such as a glass bowl, to lower away from a ceiling fan or light base, and tilt allowing the light shade to be cleaned and change light sources, such as the light bulbs, without having to disassemble the light fixture. The hanger bracket can have an up position locked in place where the outside of the overhead light appears undistinguishable from traditional ceiling light fixtures or lights on ceiling fans.
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BACKGROUND OF THE INVENTION
The present invention relates to a flowmeter designed to find areas containing currents in a hole bored in rock.
In searching rocks via measurements in deep bore holes, a serious problem is the slowness of the measurements. Measuring only the vertical current at a given depth in a hole provides practically no information about chinks at different depths in the rock or the magnitude and direction of currents flowing in them. On the other hand, making accurate measurements e.g. by sections of a few hundred meters over the whole length of the hole to obtain the flow rates and directions for the section is a very slow process in long holes going to depths as large as thousands of meters.
As the bore hole may contain long stretches of solid rock without any fissures or currents, the object of the invention is to produce a new type of flowmeter which makes it possible to search even deep holes and locate the areas containing currents for more elaborate further investigation.
As for the features characteristic of the invention, reference is made to the claims.
SUMMARY OF THE INVENTION
The flowmeter of the invention comprises suitable flexible and elastic parting elements by means of which the section to be measured is separated from the hole substantially pressure-tightly. In other words, the parting elements are made of an elastic material that is pressed against the surfaces of the hole under measurement, such that they are tightly pressed against the hole without any inflatable or expandable structures activated by means of a pressure medium. Moreover, the flowmeter is provided with an open flow duct forming a free flow connection past the section under measurement delimited by the parting elements, so that currents occurring in other parts of the hole will not produce any pressure differences against the parting elements and these will, with a relatively low pressure, sufficiently seal off the hole section to be searched. In addition, the flowmeter comprises a measuring duct leading from the section under measurement to a point outside it and provided with measuring instruments by means of which the total flow of currents flowing into or out of the section can be measured.
The flexible and elastic parting elements used are preferably plate-shaped or ring-shaped rubber or plastic discs with a free external diameter somewhat larger than the diameter of the hole to be searched. Moreover, in a hole measured from a direct radial direction, the rubber or plastic discs preferably have a shape turned or curved somewhat upwards, permitting easy descent of the flowmeter down the hole by the agency of its own weight. At the measuring depth, the flowmeter is pulled back up through a small distance, causing the discs to buckle into a different position. In this condition, the internal tension of the parting element itself presses it against the hole surface, increasing its tightness.
The rubber discs of the invention acting as parting elements cannot withstand a very large pressure. On the other hand, in this type of measurement the pressure level in the section under measurement is the same as in the rest of the hole, so there is no need for a high pressure-tightness. However, to ensure tightness, both parting elements are made up of several, e.g. three successive rubber discs. The prototype of the flowmeter of the invention was implemented using three rubber discs, which can withstand the pressure of a 11/2-meter water column and therefore provide a sufficient tightness in all relevant measurement circumstances.
Especially when relatively large and sloping holes are being searched, the flowmeter's own weight may press the rubber discs to one side, causing the sealing to leak on the other side. In such applications it is preferable to use separate disc-shaped, plug-shaped or other similar rigid centering elements which, having a diameter nearly equal to that of the hole, prevent significant radial motion of the flowmeter in the hole.
The measuring equipment preferably includes a suitable impulse source and sensors for measuring the direction and velocity of the impulse transmitted by the impulse source.
The length of the bore hole section measured by the flowmeter of the invention is preferably freely adjustable. This can be achieved e.g. by using suitable extension pieces, of which a desired number can be mounted between the parting elements. In this way, the length of the hole section measured at a time may vary e.g. from one meter to over ten meters. Therefore, the hole can be first searched in very long sections, whereupon the sections containing currents can be checked in shorter sections. Hole portions that require slower and more precise flow measurements using more accurate equipment can thus be located with an accuracy of e.g. one meter.
It is also possible to implement the flowmeter using a telescopic structure in the meter body between the parting elements to allow adjustment of its length.
The flowmeter of the invention has significant advantages over prior-art technology. The flowmeter allows very fast measurement of holes several kilometers in length, making it possible to locate hole portions containing currents, which are then examined more closely using other equipment. Thus, as compared to prior art, the time required for measuring and examining a single hole is reduced from months to a few days.
DETAILED DESCRIPTION OF THE INVENTION
In the following, the invention is described by referring to the attached drawing, which presents a diagram representing a flowmeter as provided by the invention.
The flowmeter of the invention as presented in the drawing comprises an open pipe 7 with three ring-shaped, elastic parting elements 1 at each end, forming between them a measurement section 3 in the hole 2. The pipe 7 forms an open flow duct 4 past the measurement section 3 delimited by the parting elements 1 in the hole.
The parting elements 1 are elastic and flexible rubber flanges which, slightly deviating from the direction of the radius of the hole, extend obliquely upwards. Their size is so chosen that their elasticity will cause them to press against the round surface of the hole, in other words, their free external diameter is somewhat larger than that of the hole.
The pipe 7 between the parting elements 1 is provided with two apertures 8 which, however, do not communicate with the open flow channel 4, but form the starting point of a measuring duct 5 which runs inside the pipe 7 to measuring equipment 6 and, through this equipment, opens into the hole portion above the flowmeter.
The measuring equipment 6 comprises an impulse source 10 placed in the measuring channel, and, placed on either side of it, sensors 11 allowing the impulse sent by the impulse source, i.e. the velocity and direction of motion of the impulse, to be measured.
Moreover, the flowmeter is provided with a hoisting and control cable 9 by means of which the flowmeter can be raised and lowered in the hole under measurement e.g. using a suitable winch and through which the measurement information obtained from the measuring equipment 6 is transferred to suitable processing apparatus provided above ground.
The flowmeter is used as follows. The flowmeter, suspended by the hoisting and control cable 9, is lowered into the hole to be measured to a desired measuring depth. At this depth, the flowmeter is pulled up through a short distance (a few centimeters), causing the plate-shaped parting elements to be pressed tightly against the hole surface. In this way, a section 3 to be measured has been separated from the hole with sufficient sealing. To ensure that the parting elements will not be affected by currents and pressure differences outside the measurement section 3, pipe 7 provides a free flow path (arrows A) for external currents past the measurement section 3.
If the rock 12 within the area covered by the measurement section 3 contains any fissures 13 with currents (arrow B) in them, these currents can cause a flow through the apertures 8 into the measuring duct 5 and through it (arrow C) further outside the flowmeter.
The flow rates in the measuring duct 5 may show large variations, which is why flow measurement is performed by two methods. First, flow measurement is started by an impulse method, in which the water is heated momentarily by means of a heating thermistor 10 and the movement of the heat impulse produced by it in the water is monitored by means of sensors 11 placed on either side of the heating thermistor at a distance from it. As the cross-sectional area of the measuring duct 5 is known, both the magnitude and direction of the flow are obtained by this method. This method can be used to measure currents with flow rates varying from a few milliliters to three thousand milliliters per hour.
Above the upper limit stated above, the divergence of the measurement results increases, and the flow is determined by using a cooling method. In the cooling method, the heating thermistor 10 is heated, whereupon its cooling down is monitored, because the cooling takes place the faster the higher is the flow rate. By using the cooling method, it has been possible to extend the measuring range to 60000 ml/h and beyond.
After the measurements on a given section have been finished, the flowmeter can be easily moved, raised or lowered to the next place, and measurements can thus be continued one section at a time over the whole length of the bore hole.
In addition, the apparatus preferably comprises a pump for keeping the water level in the hole under measurement at a constant height. This can be implemented using a long surge pipe whose lower end is blocked while the upper end is open. With this solution, the pumping of the water is effected from inside the surge pipe as the water in the hole flows into the surge pipe placed on a constant height. The water level inside the pipe varies but remains at constant height in the hole, i.e. at the level of the upper end of the pipe.
The apparatus may further comprise a pump for pumping water into the hole while the hoisting and control cable is being pulled up. This prevents the water level from falling as a result of the cable being raised. In this way, the pumps can be used to keep the pressure conditions as constant as possible throughout the measuring operation.
The particulars of the use of the flowmeter and the processing of the data are in themselves known in the art, so they will not be explained in detail in this context. They can be summarized at a general level by saying that the measuring programs proper are contained in a measuring computer which sends control commands to a processor in the flowmeter and receives measurement results from the processor. The measurement results are subjected to conversions as required and they are presented on a display screen and saved in files. Moreover, the measuring computer reads the pressure data (air pressure and ground water level), controls the hose pump, reads the pulses of a cable counter and stops the winch on the basis of the cable counter pulses. The measuring programs of the processor are stored in the flowmeter's program storage. These programs are used to take care of measurement timing, selection of measuring channels, control of analog/digital conversion and sending the measurement results to above-ground equipment.
The invention has been described above in detail by the aid of the attached drawing, but different embodiments of the invention are possible within the scope of the inventive idea defined by the claims.
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Flowmeter for locating zones containing currents in a bore hole made in a rock. The flowmeter comprises parting elements (1) for separating a measurement section (3) in the hole from the rest of the hole in a substantially pressure-tight manner; an open flow duct (4) forming a free flow link between the hole portions on opposite sides of the flowmeter past the measurement section; and a measuring duct (5) leading from the section under measurement to a point outside it, together with measuring equipment (6), for measuring the magnitude and direction of flow between the measurement section and the hole portion outside it.
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FIELD OF THE INVENTION
[0001] The present invention generally relates to socks for athletic wear and more particularly to an athletic sock to accommodate a protective device for the user to guard against injury or protect from aggravation of preexisting injuries.
BACKGROUND OF THE INVENTION
[0002] With the growing numbers of adults and children participating in athletic contests such as soccer, basketball, baseball and other sports, it has become increasingly significant that injuries be prevented and/or at least minimized as possible. Soccer players, for example, are frequently struck along the shin areas of their legs during play which can result in cuts, bruises or even broken bones. To prevent such injuries, shin guards have been in use many years formed from rigid materials such as plastic or metal which are attached by the use of straps and other means to hold the guards in place on the players' legs during the rigors of the game.
[0003] One conventional approach is to utilize two pairs of socks such that one pair of socks is placed directly on the user's leg under the pads and the other pair over the pads. This approach has proven, however, to be quite unsatisfactory. Specifically, this technique necessitates the wearing of soccer shoes which are oversized in order to accommodate the added thickness due to the wearing of a second athletic sock over the foot area. Also, flexibility of the ankle which is required for playing soccer is substantially reduced.
[0004] U.S. Pat. No. 4,669,126 is directed to a sock used for playing soccer which accommodates a shin guard. U.S. Pat. No. 5,157,791 is directed to a sock having a exterior compartments for containing articles and a cuff which folds over for locking purposes. U.S. Pat. No. 5,581,817 illustrates a sock having an extended leg portion which is folded over a shin guard. Each of these prior art approaches have deficiencies, however, that the present invention overcomes. For example, U.S. Pat. No. 4,699,126 utilizes two layers of material overlying the user's leg. This approach adds weight to the user's leg as well as increasing the level of constriction felt by the user. Similarly, U.S. Pat. No. 5,581,817 utilizes one layer of material which is doubled over causing the same negative results referred to above with respect to the '126 patent.
[0005] There is a need for an athletic sock that accommodates a protective device that does not constrict the user's leg nor impede movement at the ankle.
SUMMARY OF THE INVENTION
[0006] To solve the aforementioned disadvantages of conventional bonding tools, the present invention relates to sock for use with an athletic protector, such as a shin guard. The athletic sock comprises a leg section formed from a first substantially elastic material and a pocket comprising a second substantially elastic material coupled to an inside front portion of the leg section.
[0007] According to another aspect of the present invention, an inside upper portion of the pocket is free from attachment to the inside portion of the sock such that the athletic protector may be disposed within the pocket from the upper portion of the pocket.
[0008] According to a further aspect of the present invention, the pocket further comprises means for maintaining the athletic protector within the pocket.
[0009] According to still another aspect of the present invention, the pocket is comprised of a single sheet of material.
[0010] According to a yet a further aspect of the present invention, the pocket is formed from a tubular material positioned substantially flat against only a portion of the inner portion of the leg section.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The invention is best understood from the following detailed description when read in connection with the accompanying drawing. It is emphasized that, according to common practice, the various features of the drawing are not to scale. On the contrary, the dimensions of the various features are arbitrarily expanded or reduced for clarity. Included in the drawing are the following Figures:
[0012] FIG. 1 is a side view of a first exemplary embodiment of the present invention;
[0013] FIG. 2 is a view of the embodiment of FIG. 1 with the sock turned inside out;
[0014] FIG. 3 is a top perspective view of the embodiment of FIG. 1 ; and
[0015] FIG. 4 is a sectional side view of the embodiment of FIG. 1 .
DETAILED DESCRIPTION OF THE INVENTION
[0016] Referring now to FIG. 1 , a first exemplary embodiment of the present invention is illustrated. As shown in FIG. 1 , athletic sock 100 has a leg section 102 , ankle section 104 foot section 110 and cuff section 108 . In one exemplary embodiment, athletic sock 100 may also include a heel portion (not shown) disposed between foot section 110 and ankle section 104 . Athletic sock 100 may be formed from a variety of conventional materials, such as cotton for example, with or without elastic components. Material 106 is coupled to the inside of front portion 112 of leg section 102 to form a pocket 114 at the inside of front portion 112 . Material 106 may be a cotton based material or a resilient material such as Lycra® for example. Material 106 may be a single sheet of material or may be a section of tubular material folded against the inside of front portion 112 . In either case, the edges of material 106 are sewn or otherwise attached to front portion 112 based on the size of the guard to be inserted into pocket 114 . As referred to herein, front portion 112 may comprise a portion of the side sections of leg portion 102 .
[0017] Referring now to FIG. 2 , sock 100 is shown turned inside-out to better illustrate the forming of pocket 114 . As shown in FIG. 2 , material 106 is attached to the inside front section of leg section 102 along all sides of material 106 except at the top portion. In this way a shin guard 120 (shown in FIG. 4 ) may be easily inserted into pocket 114 from the top of the sock. As also shown in FIG. 2 , pocket 114 is preferably positioned above ankle portion 104 to minimize interference with the user's movement during play. Pocket 114 is also preferably positioned below cuff portion 108 .
[0018] Pocket 114 may also include a closure 115 to maintain the shin guard in position during play. It is contemplated that closure 115 may be an elasticized portion of material 106 or may be a combination of hook and loop material, for example.
[0019] FIG. 3 is a top perspective view of athletic sock 100 further illustrating the formation of pocket 114 at the front inside portion of sock 100 .
[0020] FIG. 4 illustrates a sectional side view of sock 100 . As shown in FIG. 4 , pocket 114 is formed either by section 112 and a single layer of material 106 . As discussed above, if material 106 is a tubular material, it may be folded against the inside of front portion 112 and attached thereto to form pocket 114 between opposing walls of material 106 . Shin guard 120 is easily inserted into sock 100 either prior to or after sock 100 is placed on the user's leg. During breaks in play the user may also easily remove shin guard 120 from the inside pocket 114 , by simply reaching into the top to sock 100 , and reinsert shin guard 120 when play resumes. It is also notable that shin guard does not directly contact the user's leg thus minimizing the prevalence of perspiration that typically occurs when a shin guard is place directly against the skin. This has the added benefit of reducing sweat on the shin guard thereby increasing the level of hygiene in that socks are readily laundered, while shin guards are not.
[0021] While preferred embodiments of the invention have been shown and described herein, it will be understood that such embodiments are provided by way of example only. Numerous variations, changes and substitutions will occur to those skilled in the art without departing from the spirit of the invention. Accordingly, it is intended that the appended claims cover all such variations as fall within the spirit and scope of the invention.
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A sock for use with an athletic protector comprises a leg section formed from a first substantially elastic material and a pocket comprising a second substantially elastic material coupled to an inside front portion of the leg section.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is based on and claims priority to U.S. Provisional Application No. 60/743,952, filed Mar. 30, 2006, the entire contents of which is fully incorporated hereby by reference.
BACKGROUND OF THE INVENTION
[0002] Training has become a significant industry throughout the world. For any type of learned skill, there are live seminars, audio and video presentations, and computer programs available to assist a person in developing those skills.
[0003] Many of the training techniques used, while marginally effective, can tend to be boring and can lose the focus of the trainee. With the advent of audio/visual technology, training tools such as Microsoft® PowerPoint® have been developed in an attempt to keep the interest of the trainee. PowerPoint® offers the trainer the ability to transition slides and use multiple colors, photographs, sounds, videos and the like during part of the training presentation. While tools such as this can successfully achieve the goal of keeping the interest of the trainee, as anyone who has sat through a training seminar or training program of any type can attest, there is significant room for improving the methods by which training is presented.
SUMMARY OF THE INVENTION
[0004] The present invention utilizes specific techniques, based upon empirical study, to significantly increase the ability of a trainee to remain focused on the training materials and subject matter and actually learn and retain the training subject matter. More specifically, the present invention utilizes audio and/or visual (e.g., a personal computer) elements, with a strict set of rules which must be followed regarding sentence length, narrators, and underlying music within the dialog to create a specific rhythmic “feel” to the training. As a result of using such techniques, the Applicant has found significantly improved results over prior art training methods.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] FIGS. 1A-1F illustrate a flowchart describing steps performed in creating an audio-based logical training program in accordance with the present invention;
[0006] FIGS. 2A-2G illustrate a flowchart describing steps performed in creating a PC-based logical training program in accordance with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0007] The present invention, referred to herein as “logical training”, is a proven training method that allows a trainee the opportunity to learn “by doing” without significant reading or writing. It is a formula based method with custom written dialogue, custom scored music, testing and measuring results. A benefit of logical training is that it combines auditory, visual, tactile and kinesthetic learning styles into one program. It is used to teach trainees how to perform specific functions, such as how to operate equipment, sell merchandise, and use computer software. The method is a self-paced teaching style allowing trainees to train on their own, at their own pace using hands-on applications, with little reading and no writing. When necessary, programs can be bi-lingual. This method of training is most useful in the business community where the cost of training is high, time is limited and there is insufficient availability of trainers. Logical training can help businesses train their employees in a variety of ways inexpensively, efficiently and quickly.
[0008] In preferred embodiments, logical training programs can be delivered in two platforms: Audio based and PC based. In both platforms, audio is the main source of delivering the information to the trainee. A major component of logical training is making the training compartmentalized, fun, easy-to-use and enjoyable, resulting in a very high retention rate. A specific style and method, defined in more detail below, is used in every logical training program. This is achieved with carefully designed scripts and the use of custom created music. The script is recorded with multiple announcers, which makes the program easier to listen to. This is because the ear is constantly adjusting to the different sounds of the announcer voices, an element that has been found to decrease the likelihood that the trainee will be distracted.
[0009] The custom underscoring music is composed purposely to contain no melodic passages, but with strong focus on rhythmic and harmonic structures. The combination of this specific rhythmic/harmonic structure and specific parameters regarding the narrative being delivered over the rhythmic/harmonic structure, significantly increases the retention of information by the trainees. In accordance with the present invention the announcers speak at a specific pace, which is quick enough to keep the listener attentive but slow enough so that the information can be absorbed. The music tempo is selected to match the pace of the dialogue.
[0010] During the script writing process, the script is divided into multiple segments. Each segment contains: information to be delivered, review sections, and questions asked that must be answered by the trainee. Each segment length is kept under 5 minutes. By using review sections followed by questions in the scripts, learning breaks are created allowing scripts to be thirty minutes in length without the trainee becoming bored, pre-occupied or losing interest. In addition to the short exercises that trainees will perform while hearing music underscore, throughout each program there are also several “Stop and Start” sections where the trainee will hear instructions to stop the program, perform a specific exercise, then start the program when they are ready to continue. The exercises given in a “Stop and Start” section are considerably longer than the short exercises that contain music underscoring. These longer exercises are often completed in different lengths of time depending on the abilities of the trainee. The logical training method of the present invention allows for this by keeping these exercises self-paced.
[0011] Trainees preferably listen to the audio through headsets. This makes it easier for the trainees to comprehend the program without distraction. Audio delivered logical training programs preferably place the trainee in front of whatever they need to learn, in all cases wearing a headset or headphones. For example, if the trainee is to learn how to operate a piece of equipment, the trainee is situated with the equipment, headphones on, and is taught how to operate it. If the trainee is to learn software, they sit at the computer while wearing the headset. If the trainee is learning how to sell merchandise, they are located in the area in the store where the merchandise is contained, in front of the physical merchandise, and the training materials are delivered via the headset.
[0012] Programs delivered on PC can use a specially-designed, easy-to-use, custom interface with simple navigation. A most important element to a logical training program delivered via PC is the construction of the program itself. The program is broken into segments that match the audio components. Trainees will watch visuals on screen while listening to the recorded dialogue with specialized musical underscoring as described generally above and more specifically below. The visuals use mostly pictures, quick diagrams, and key words and minimize or, ideally, completely avoid, the need to read lengthy passages. PC delivered programs are designed to have the trainee begin training at a PC terminal. At a particular part of the program where hands-on opportunities exist, the trainee is directed to take a portable medium on which the program is stored (preferably the same medium being used by the computer to retrieve the PC-delivered component of the training, e.g. a CD-ROM disc on which the computer program is stored) and use it with an audio device (e.g., a portable CD player) with a headset, and is directed to go to the station where the training will be continued. Once the hands-on applications are completed, the trainee is instructed to return to the PC terminal and to place the storage medium back into the computer for the training to be completed.
[0013] This process can also be accomplished when the program is delivered via the web and there is no CD or other portable medium available on which the computer software is stored. In this situation, an accompanying portable audio device such as a CD Player, MP3 player, IPod etc, is provided to the trainee, with the appropriate audio information, to be used at the times when the PC training program instructs the trainee to engage in a hands-on task. Once the task is completed, the trainee can simply turn the accompanying portable audio player off and continue the PC training. PC logical training programs can also be provided on hand-held multimedia devices that have audio/video capability. When this occurs, the trainee uses one piece of equipment for the entire training. (When applicable, logical training PC programs can be integrated with existing Learning Management Systems which allows others such as management to easily obtain test scores and results.)
[0014] A complete software program for downloading both audio as well as PC programs, either hand-held or CD-ROM based, has been developed by the applicant. With the use of dedicated IP address, users of the logical training method of the present invention can simply log on to an external website where they can easily download the most current version of their training programs. The portable devices can be loaded through a USB connector on their PC terminal. For larger corporations, the IT or MIS department is granted permission to connect to a dedicated IP address manually or via dedicated computer scripting on a regular or semi-regular basis. The IT or MIS department downloads the updated or new program(s) into their server, and then sends it through their intranet to the various locations for the end user to download into the portable device. Proprietary software can be provided allowing an icon to appear on the PC terminal that connects the user directly with the programs to be downloaded. Each program is clearly identified for easy downloading selection. In addition, the software automatically checks for updates to any program(s) already loaded onto the handheld device that have been updated since the unit was last connected to the terminal. The custom software is cross platform and can be easily modified for the end user's specific needs.
[0015] Following are examples illustrating specific criteria to be used in accordance with the present invention. It is understood that while use of all of the following criteria simultaneously will result in the most beneficial training, individual aspects of the present invention utilized separately may also result in substantial benefits of the prior art.
Formula:
Script:
[0016] The script must apply step-by-step instruction as follows:
[0017] 1) Develop fall outline of program
[0018] 2) Following the outline, begin with an introduction that briefly explains the program, the objectives, what will be learned and how the trainee will be tested. This section should be no longer than 60 seconds.
[0019] 3) Develop script modules as follows:
a. Information—introduce a section of new information and provide an overview with explanation. This section is not to be longer than five minutes b. Review—review the information and state the task that will be performed. This section is to be no longer than two minutes. c. Task to be performed—give instructions to the task and have it performed. The instructions provided section is not to exceed one minute. The task has no specific time limit because the program exercises are self-paced. However, the length of the exercise should be kept to a minimum so that program continuity is maintained. Any task to be performed that will take longer than three to five minutes should be divided into two tasks whenever possible. d. Review of task—review the task to make sure it was completed correctly. This section is not to be longer than two minutes. e. Questions—Ask trainee two questions to be answered at the end of each segment, give approximately twenty seconds for the trainee to answer the question. On the “Audio Only” version, trainee uses an “Answer Page” which is a pre-printed paper with the number of each question on the page. The questions themselves are not printed and are only ‘heard’ through the logical training program. Next to each question number are the letters A, B and C. The trainee is instructed to circle the correct letter for each question asked. On a PC delivered program, questions are asked at the terminal, and with the mouse the trainee selects the correct answer.
[0025] 4) Make sure the script is written for at least two announcers speaking alternately. Each announcer is limited to no more than (2) sentences or 10 seconds of speaking at a time, whichever is less. The purpose is to keep the listener focused.
[0026] 5) Script must be written in “normal everyday speaking” language and allow for the announcers to easily speak within a tempo range of 110-152 beats per minute. Normal everyday speaking language is defined as talking rather than reading. For example, in most cases use contractions such as “can't” instead of “cannot,” etc. Also, modern day phrases should be incorporated such as “Check out”, “Way to Go,” “That's Awesome,” etc., to keep the program more upbeat and positive.
Music:
Rules for Music “Soundbed” Composition:
[0027] 1) Tempo must be no slower than 110 beats per minute and no faster than 152 beats per minute.
[0028] 2) There are three primary drum rhythm patterns all in 4/4 time. The kick drum can use these patterns as follows:
a. b. c.
[0032] With each pattern the snare drum maintains strong down beats on the second and fourth beat of each measure as follows:
a.
[0034] The high-hat can be all eighth notes for the slower tempos and all quarter notes for the faster tempos as follows:
a. b.
[0037] The high-hat may also be altered to accommodate a triplet feel with the kick drum utilizing a dotted quarter/eight not triplet feel, the snare still maintaining a heavy 2 and 4 and the high-hat playing eight note triplets as follows:
[0000] 3 3 3 3 c.
Note: When creating Light Jazz (Swing style music) a dotted feel is acceptable for the high-hat as follows:
d.
[0039] 3) Music should be 70% major key compositions and only 30% minor key composition
[0040] 4) The duration of a music “soundbed” should be no more than 90 seconds.
[0041] 5) “Soundbeds” cannot have “key” modulations
[0042] 6) All music composed must be in groups of 8, 16 or 32 bar phrases
[0043] 7) All music composed must follow these music forms:
[0000]
a.
A
b.
ABA
c.
AABA
[0044] 8) The end of each phrase must return to the tonic chord or the dominant chord only when the phrase will be repeated, as in an AABA form.
[0045] 9) There is to be no melody and no melodic passages. (Melody of any type will distract the listener).
[0046] 10) Music “soundbeds” must have energy, strong rhythm, not be too slow (less than 110 beats per minute), and they should be musically simple, meaning limited use of flatted or diminished chords, multiple clashing motifs, and not generally dissonant (unpleasant) to the ear.
[0047] 11) All music beds must have a definite ending which is usually a resolved tonic chord on either beats one, three or four of the last measure. There cannot be any fade-outs, or long ending chords with decay.
[0048] 12) All music written is to have a “happy” feel with a sense of being “pleasant” and “lighthearted.”
Acceptable Music Styles:
[0049] There are four basic styles of music “soundbeds” that are acceptable:
[0050] 1) Rock'n Roll Beds
[0051] 2) Light Jazz Beds
[0052] 3) Groove Beds
[0053] 4) Light/Adult Contemporary
[0000] Rules as follows:
Rock'N Roll Beds
[0054] a. “Soundbed” composition must maintain strong use of “major” chords.
[0055] b. Electric guitars should use “power” chords (heavy sounding chords with a distortion guitar sound).
[0056] c. Electric guitars may also use “muted” notes (Clean guitar sound playing one or two notes with the strings muted by the right hand).
[0057] d. All other music composition rules above apply.
Light Jazz Beds:
[0058] a. Use of minor seventh and minor ninth chords is acceptable, but must not be too dissonant (unpleasant to the ear).
[0059] b. Bass must follow straight quarter note walking.
[0060] c. Piano is to be simple, with right hand chords sustained using half and whole notes mixed with light rhythm but nothing complex. Piano not to use any jazz riffs, fast moving passages or heavy rhythms, as they can easily draw attention away from the speaker. Left hand should be kept simple playing only root on inversion of chord or doubling the bass.
[0061] Chords are to be a mixture of light jazz (7th's and 9th's both major and minor) and non-jazz chords. For example:
Fmaj7-Gm9-Fmaj7-Gm7-BbMaj7-Am7-BbMaj7-C
[0063] A chord progression using a pattern like this is for an AABA form where the A is repeated is acceptable.
[0064] d. Strong swing “dotted note” rhythm with energy is required.
[0065] e. Tempos to stay within 110-132 beats per minute.
[0066] f. All other music composition rules above apply.
Groove Beds:
[0067] a. “Soundbed” to have strong rhythmic groove with a definite pulse. Bass rhythmic pattern to be in sync with kick drum.
[0068] b. Use of light synthesizer “sound pads” is acceptable.
[0069] c. No dissonant sounds or anything unpleasant to the ear.
[0070] d. Use of light ostinato parts, such as muted guitar notes, synthesizer single note phrases or short multiple note phrases are acceptable provided they are not too prominent or distracting.
[0071] e. All other music composition rules above apply.
Light/Adult Contemporary:
[0072] a. “Soundbeds” are written in only major keys.
[0073] b. Tempos between 132-152 beats per minute.
[0074] c. Use of simple pattern chord phrases that use mostly major chords with some minor chords added. For example here is an acceptable 16 bar chord progressions:
A-F#m-D-A-D-A-Bm-E-A-F#m-D-A-D-A-E-A
[0076] d. All other music composition rules above apply.
Recording/Mixing
[0077] a. When recording announcers, there is to be a high level of enthusiasm in their recorded voice. There must be strong inflection and emphasis on “key” words and phrases either when giving instruction or if it is something specific that is to be retained by the trainee.
[0078] b. Announcers must have “pleasant” voices to listen to, which means speakers must not be too raspy, have a strange accent, lisp, etc.
[0079] c. Recorded passages must match the pace of the acceptable tempo. Make sure the feel of the dialogue is within the 110-152 beats per minute parameter.
[0080] d. While recording, double check for word redundancy in the script, and if present, look for alternate words. (Word redundancy will distract the listener.)
[0081] e. Record multiple takes of each section. After recording, select takes that are the most clear, easy to understand and enthusiastic.
[0082] f. When editing and mixing dialogue, keep the levels of both announcers, including high and low volume peaks, the same.
[0083] g. Compose/select music beds that best match the natural pace of the dialogue. (Follow “Rules for Music “Soundbed” Composition).
[0084] h. Mark “key” sections on the script where the music “soundbed” should change to maintain the attention of the listener. The key periods when this should occur are as follows: When a new topic is introduced; and/or when a sub-topic or a section within a segment gives the trainee information in the form of a list, such as rules or steps of a task.
[0085] i. Assemble the edited dialogue segments with the music “soundbeds” carefully placed to match the natural rhythm of the dialogue.
[0086] j. Recorded dialogue is to be placed in the center of the music, as if it were the melody keeping the music level strong for greater listener impact.
[0087] k. Listen carefully to playback to make sure the music is loud enough to be heard clearly, but not too loud as to interfere with or distract from spoken dialogue. If the music feels like it is fighting with the dialogue in any part of the script, change the “soundbed”(s) to something more appropriate.
[0088] l. Confirm there are no recorded sections with one announcer speaking longer than 10 seconds when giving instructions.
[0089] m. Ensure that there is no more than 90 consecutive seconds of the same “soundbed” used for instructional underscoring.
[0090] n. “Soundbeds” volume must be set between −16 db's and −28 db's of digital zero (0).
[0091] o. “Soundbed” music to be changed at every change in subject matter
[0092] p. Programs to be mastered at −3 db's @ 44.1 k, 16 or 24 bit word lengths.
Building a Logical Training Program (Audio Only)
Step 1:
[0093] FIGS. 1A-1F illustrate a flowchart describing steps performed in creating an audio-based logical training program in accordance with the present invention. The steps of the preferred embodiment are as follows:
[0094] Analyze the learning objectives and goals of the program to be created (step 101 ):
Study the needs and information the trainee must obtain (step 102 ). List opportunities for hands-on training applications (step 103 ). Formulate script segments (step 104 ). Approximate script segment length to make sure there is enough and/or not too much information in order to keep the segment length between three and five minutes (step 105 ).
Step II
[0099] Build a full outline of the script/program (step 106 )
List all segments, components and hands-on opportunities (step 107 ). Test outline against learning objectives (step 108 ). Confirm that outline matches all goals to be achieved (step 109 ).
Step III
[0103] Script formulation (step 110 )
Approximate segment lengths to be between three and five minutes (step 111 ). Approximate exercise lengths—time out the length of time to perform task(s) (step 112 ). Assess practicability of segments and exercises against goals to be achieved (step 113 ). List questions to be asked during the program (step 114 ).
Step IV
[0108] Write script (step 115 )
Carefully create first draft of script for multiple announcers (step 116 ). First part of script to be an introduction that briefly explains the program, the objectives, what will be learned and how the trainee will be tested (step 117 ). Write each module (step 118 ):
Introduce a section with new information and provide an overview with an explanation (follow time guides listed above) (step 119 ). After explaining the information, write a review of the information and then state the task that will be performed (follow time guides listed above) (step 120 ). Write careful instructions of the task explaining each step (follow time guides listed above) (step 121 ). Write the instructions to stop the program, perform the task and then continue the program when ready (follow time guides listed above) (step 122 ). Write a review of the task to make sure it was completed correctly (follow time guides listed above) (step 123 ). Write in the appropriate questions relating to the information provided and task that was performed (follow time guides listed above) (step 124 ). Begin writing the next segment and continue the same process until all the segments are written (follow time guides listed above) (step 125 ). Write an ending to the script that confirms the program is completed. If there is a second program to be listened to, write that in the closing section (follow time guides listed above) (step 126 ).
Read through the entire script carefully (step 127 ). Confirm that it flows properly between speakers for continuity and length. For example, no single announcer is speaking more than 10 seconds or two consecutive sentences (step 128 ). Look for words in which pronunciation will be important (step 129 ). Mark words where pronunciation will need to be provided or confirmed (step 130 ). Proof draft against all goals to be achieved (step 131 ). Confirm that written sections provide content and review sections provide sufficient information before hands-on applications (step 132 ). Confirm that hands-on instruction is clear by reading it out loud to an assistant. Ask assistant follow up questions to make sure they comprehend what was needed (step 133 ). Confirm that written and review portions of the script provide sufficient information before questions are asked (step 134 ). Time all segments individually and for length of full script (use a stopwatch) (step 135 ). Confirm that entire script is written in “normal everyday speaking” language (follow explanation listed above) (step 136 ). Confirm that the script can be easily spoken by the announcers within a tempo range of 110-152 beats per minute (step 137 ).
Step V
[0131] Test script (step 138 )
Test written portions with equipment, merchandise, software, etc., and make sure all provided information is accurate. Go through the script and perform all the tasks to make sure that all the instructions and information is correct (step 139 ). Test all hands-on exercises and make sure that examples and instructions provided are accurate and that all exercises can be completed properly (step 140 ). Confirm that all information regarding the questions has been thoroughly provided and that all questions can be answered correctly (step 141 ). Test script against outline to make sure all topics have been thoroughly covered (step 142 ). Test script against all goals to be achieved (step 143 ).
Step VI
[0137] Record and Produce audio (step 144 ) Make sure reading delivery has the necessary pace, inflection and vocal interaction (step 145 ).
Make sure that a high level of enthusiasm is delivered and maintained throughout the recording process (step 146 ). Announcers' voices must be “pleasant” meaning pleasing to listen to (follow guidelines listed above) (step 147 ). Record several takes to achieve the highest quality of delivery (step 148 ). Play back multiple takes and ensure the vocal tempo is paced within the 110-152 beats per minute (step 149 ). While recording the script, make sure there is no word redundancy in the script. If so, stop the session and change any redundant word or words with alternates before continuing (step 150 ). Once the script has been recorded, review all the recorded materials and select the specific takes that are the most clear and enthusiastic (step 151 ). Digitally edit the best-recorded takes together ensuring a consistent and natural flow (step 152 ). When editing and mixing dialogue together, keep the volume levels of both announcers including their “high” and “low” volume peaks the same (step 153 ). Mark the lengths of each segment by timing them with a stopwatch or computer timer (step 154 ). Indicate beginning and ending sections of custom music needed (step 155 ). Mark key spots during each segment where the music needs to change (step 156 ).
Step VII
[0149] Compose custom music for segments (step 157 )
Listen to a portion of the dialogue and match tempo speed to be between 110 and 152 beats per minute (step 158 ). Measure length of music bed to be written (step 159 ). Select best drum rhythm patterns for the section from one of the three primary patterns (step 160 )
Follow all music “soundbed” rules listed above (step 161 )
When “soundbed” is written and recorded, mix the instrument parts together down to two stereo tracks (step 162 ). Listen for any musical parts, instrument parts, sounds or frequencies that might clash with the dialogue or distract the listener. If found, either eliminate, re-do or alter these sections as necessary. If it cannot be fixed in any way, discard the “soundbed” and create a new one (step 163 ). Continue the process until all the necessary “soundbeds” have been written, recorded, mixed and mastered for program use (step 164 ).
Step VIII
[0157] Placing music into program (step 165 )
Place recorded custom music under dialogue segments (step 166 ). Match recording levels between announcers and music, keeping music loud enough to drive the pace of the program but soft enough for the dialogue to be easily heard and understood. This is done by starting the music level at zero and gradually increasing it until the proper level is reached. “Soundbeds” must be between −16db's and −28 db's of digital zero (0) (step 167 ). Make sure the dialogue is clearly understood while hearing the pulse of the music “soundbeds” (step 168 ). Recorded dialogue is to be placed in the “center” of the music “soundbed(s)” as if it were the melody keeping the music level strong for greater listener impact (step 169 ). Listen carefully to the playback of the section. If the music feels like it is “fighting” with the dialogue in any part of the section, change the “soundbed” with a new one (step 170 ). Listen to the “flow” of the dialogue with music “soundbed”. Confirm there are no speaking sections with an announcer speaking more than 10 seconds when giving instruction (step 171 ). Continue the process of adding the “soundbeds” and mixing them with the dialogue; repeat as needed until desired mix is achieved (step 172 ). Make sure that the music “soundbed” is changed where the script introduces a new piece of information or an informational section that is marked with greater emphasis for the listener (step 173 ). Once all “soundbeds” are inserted, listen back and confirm that there are no music “soundbeds” that are longer than 90 consecutive seconds when used for instruction underscoring (step 174 ). Make sure that the flow of one “soundbed” to another makes ‘musical’ sense so that the “soundbed” transition is not overpowering, distracting from the dialogue. (Listen for unpleasant rhythmic/tempo changes or key/harmonic changes) (step 175 ). If a “soundbed” change feels unpleasant, replace one of the “soundbeds” with another one that transitions without distracting from the dialogue while listening (step 176 ). During the final mixing process, “soundbeds’ are to be between −16 db's and −28 db's of digital 0 (step 177 ). Place three seconds of silence between “Stop and Start” sections (step 178 ). Digitally master the full program at −3 db's @ 44.1K, 16 or 24 bit word lengths (step 179 ) Prepare to burn master audio disc (step 180 ). Burn master audio disc (step 181 ).
Step IX
Test completed program (step 182 )
[0000]
Test the program with an individual to make sure that all the information is presented accurately and at the correct pace (step 183 ).
Make sure that the individual can follow all the exercise instructions (step 184 ).
Grade score after questions are answered (step 185 ).
If necessary, make adjustments/corrections to the program by either re-recording corrected dialogue and/or allowing less or more time for short exercises (If changes are to be made, repeat necessary steps from above) (step 186 ).
Confirm that all goals have been achieved (step 187 ).
Step X
[0179] Implement program (step 188 )
Pre-test all trainees before providing training to see what they already know (step 189 ). Give logical training program to all trainees (step 190 ).
Step XI
[0182] Analyze results (step 191 )
Grade all answers to questions (step 192 ). Review pre-test scores against completed answers given for the training questions (step 193 ). Test trainees on their new knowledge (step 194 ). Confirm all goals were achieved (step 195 ).
Building a Logical Training Program (PC Based)
Step I:
[0187] FIGS. 2A-2G illustrate a flowchart describing steps performed in creating a PC-based logical training program in accordance with the present invention. The steps of a preferred embodiment are as follows:
[0188] Analyze the learning objectives and goals of the program to be created (step 201 ):
Determine whether the program will be delivered via CD-ROM, Web, or handheld device (step 202 ). Study the needs and information the trainee must obtain (step 203 ). List opportunities for hands-on training applications (step 204 ). Formulate script segments (step 205 ). Approximate script segments length to make sure there is enough and/or not too much information in order to keep the segment length between three and five minutes (step 206 ).
Step II
[0194] Build a full outline of the script/program (step 207 )
List all segments, components and hands-on opportunities (step 208 ). Match visuals with information in segments (step 209 ). Test outline against learning objectives (step 210 ). Confirm that outline matches all goals to be achieved (step 211 ).
Step III
[0199] Script formulation (step 212 )
Approximate segment lengths to be between three and five minutes (step 213 ). Approximate exercise lengths—time out the length of time to perform task(s) (step 214 ). Assess practicability of segments and exercises against goals to be achieved (step 215 ). List questions to be asked during the program (step 216 ).
Step IV
[0204] Write script (step 217 )
Carefully create first draft of script for multiple announcers (step 218 ). First part of script to be an introduction that briefly explains the program, the objectives, what will be learned and how the trainee will be tested (step 219 ). Write each module (step 220 ):
Introduce a section with new information and provide an overview with an explanation (follow time guides listed above) (step 221 ). After explaining the information, write a review of the information and then state the task that will be performed (follow time guides listed above) (step 222 ). Write careful instructions of the task explaining each step (follow time guides listed above) (step 223 ). Write the instructions to stop the program, perform the task and then continue the program when ready (follow time guides listed above) (step 224 ). Write a review of the task to make sure it was completed correctly (follow time guides listed above) (step 225 ). Write the appropriate questions relating to the information provided and task that was performed (follow time guides listed above) (step 226 ). Begin writing the next segment and continue the same process until all the segments are written (continue following time guides listed above) (step 227 ). Write an ending to the script that confirms the program is completed. If there is a second program to be listened to, write that in the closing section (follow time guides listed above) (step 228 ).
Read through the entire script carefully (step 229 ). Confirm that it flows properly between speakers for continuity and length. For example, no single announcer is speaking more than 10 seconds or two consecutive sentences (step 230 ). Look for words in which pronunciation will be important (step 231 ). For example, when scripts are written there are often words that are used that are directly related to the specific training being conducted. Teaching a store associate about cookware might require the use of the brand name “Calphalon®”. Word such as these are identified prior to the recording session to make certain they are pronounced correctly and consistently by all of the announcers. Geographic sensitivity may also be an issue in pronunciation, for example, someone from Boston may not pronounce the word “Market” the way it is pronounced in New Jersey. So if a training program is being produced that will be used only in Massachusetts only, it may be desirable to have the announcers use the “Boston” pronunciation of certain words. Mark words where pronunciation will need to be provided or confirmed (step 232 ). Build a storyboard (step 233 ). Match visuals with the written dialogue on the storyboard (step 234 ). Proof draft against all goals to be achieved (step 235 ). Confirm that written/visual and review portions provide sufficient information before hands-on applications (step 236 ). Confirm that hands-on instruction is clear by reading it out loud to an assistant. Ask the assistant follow up questions to make sure they comprehended what was needed (step 237 ). Confirm that written/visual and review portions of the storyboard/script provide sufficient information before questions are asked (step 238 ). Time all segments individually and for length of full script (use a stopwatch) (step 239 ). Confirm that hands-on portion flows properly with PC segments (step 240 ). For example, using the cookware example, assume that the trainee saw a segment on the PC that explained the metals used in a frying pan and discussed the different gauge levels of the metals. During the hands-on training, it would be desirable when the trainee is holding the frying pan to remind them to examine the texture of the metal, feel the weight and see if they can figure what type of metal was used and what the gauge was. Confirm that the entire script, both PC portion and audio only portion, is written in “normal everyday speaking” language (follow explanation listed above) (step 241 ). Confirm that the entire script, both PC portion and audio only portion can be easily spoken by the announcers within a tempo range of 110-152 beats per minute (step 242 ).
Step V
[0230] Test script (step 243 )
Test written portions with equipment, merchandise, software, etc., and make sure all provided information is accurate. Go through the script and perform all the tasks to make sure that all the instructions and information is correct (step 244 ). Test all hands-on exercises and make sure that examples and instructions provided are accurate and that all exercises can be completed properly (step 245 ). Confirm that all information regarding the questions has been thoroughly provided and that all questions can be answered correctly (step 246 ). Test script against outline to make sure all topics have been thoroughly covered (step 247 ). Test script against all goals to be achieved (step 248 ).
Step VI
[0236] Design computer interface (step 249 )
Build an easy to use interface that is interactive with simple navigation (step 250 ). Design interface to allow for required number of segments from script (step 251 ). Create an easy to use Questions and Answers section (step 252 ). Design an opening instructional section explaining how to easily navigate through the program (step 253 ). Review visuals and plan out how to use them throughout the program (step 254 ).
Step VII
[0242] Record and Produce audio (step 255 )
Make sure reading delivery has the necessary pace, inflection and vocal interaction (step 256 ). Make sure that a high level of enthusiasm is delivered and maintained throughout the recording process (step 257 ). Announcer's voices must be “pleasant” meaning pleasing to listen to (follow time guides listed above) (step 258 ). Record several takes to achieve the highest quality of delivery (step 259 ). Play back multiple takes and ensure the vocal tempo is paced within the 110-152 beats per minute (step 260 ). Record several takes to achieve the highest quality of delivery (step 261 ). The delivery of the information is very important. Therefore when recording the script, it is done in sections and the announcers record each section several times making sure that there are multiple takes. When the session is over, the recorded sections are listened to and the ones that are the best are selected, that is, those offering the best delivery, enthusiasm, clarity, etc. While recording the script, make sure there is no word redundancy in the script. If so, stop the session and change any redundant word or words with alternates before continuing (step 262 ). Once the script has been recorded, review all the recorded materials and select the specific takes that are the most clear and enthusiastic (step 263 ) Digitally edit the best recorded takes together ensuring a consistent and natural flow (step 264 ) When editing and mixing dialogue together, keep the volume levels of both announcers including their “high” and “low” volume peaks the same (step 265 ) Mark the lengths of each segment by timing them with a stopwatch or computer timer (step 266 ) Indicate beginning and ending sections of custom music needed (step 267 ) Mark key spots during each segment where the music needs to change (step 268 ) Divide PC segments from hands-on segments (step 269 ) Digitally mix hands-on audio and music segments together (step 270 )
Step VIII
[0257] Compose custom music for segments (step 271 )
Listen to a portion of the dialogue and match tempo speed which needs to be between 110 and 152 beats per minute (step 272 ) Measure length of music bed to be written (step 273 ) Select best drum rhythm patterns for the section from one of the three primary patterns described above (step 274 ) Follow all music “soundbed” rules listed above (step 275 ) When “soundbed” is written and recorded, mix the instrument parts together (step 276 ) Listen for any musical parts, instrument parts, sounds or frequencies that might clash with the dialogue or distract the listener. If found, either eliminate, re-do or alter these sections as necessary. If it cannot be fixed in any way, discard the “soundbed” and create a new one (step 277 ) Continue the process until all the necessary “soundbeds” have been written, recorded, mixed and mastered for program use (step 278 )
Step IX
[0265] Placing music into program (step 279 )
Place recorded custom music under dialogue segments (step 280 ) Match recording levels between announcers and music, keeping music loud enough to drive the pace of the program but soft enough for the dialogue to be easily heard and understood. This is done by starting the music level at zero and gradually increasing it until the proper level is reached. “Soundbeds” must be between −16 db's and −28 db's (step 281 ) Make sure the dialogue is clearly understood while hearing the pulse of the music “soundbeds” (step 282 ). After everything is recorded and mixed together (meaning the dialogue and soundbeds), it is desirable to be sure that the levels of both the music and dialogue are optimal. Should the music be too loud, it will drown out the narration. By listening carefully and adjusting the faders (volume controls) of both the narration and music an optimal balance between both can be achieved. The music needs to be loud enough to provide the energy necessary to keep the trainee engaged in the program but the music needs to be low enough to not pull away the listening attention of the trainee from the narration to the music. Recorded dialogue is to be placed in the “center” of the music “soundbed(s)” as if it were the melody keeping the music level strong for greater listener impact (step 283 ) Listen carefully to the playback of the section. If the music feels like it is “fighting” with the dialogue in any part of the section, change the “soundbed” with a new one (step 284 ). Listen to the “flow” of the dialogue with music “soundbed”. Confirm there are no speaking sections with an announcer speaking more than 10 seconds when giving instruction (step 285 ). Continue the process of adding the “soundbeds” and mixing them with the dialogue (step 286 ) Make sure that the music “soundbed” is changed to a different one where the script introduces either a new piece of information or an informational section that is marked with greater emphasis for the listener (step 287 ) Once all “soundbeds” are inserted, listen back to the script sections and confirm that there are no music “soundbeds” that are longer than 90 consecutive seconds when used for instruction underscoring (step 288 ) Make sure that the flow of one “soundbed” to another makes “musical” sense so that the music soundbed “transition” is not over powering, distracting the ear away from the dialogue. (Listen for unpleasant rhythmic/tempo changes or key/harmonic changes) (step 289 ) If a “soundbed” change feels unpleasant, replace one of the “soundbeds” with another one that works better which is one that transitions without distracting dialogue while listening (step 290 ) Keep the audio dialogue segments separate in chunks with matched “soundbeds” (step 291 )
Step X
[0278] Build PC Program (step 292 )
Load audio segments and music “soundbeds” into the software program being used to build the PC program (step 293 ). Build visual sections that coincide with and reinforce the audio information (step 294 ). Keep visual sections simple with pictures, graphs and limited amounts of words (step 295 ). Use key words or short word “phrases” only for major points and avoid any long sections of words that need to be read (step 296 ). Use lots of movement with the visuals to keep the viewer interested (step 297 ). Test all functions of each segment (step 298 ). Confirm that all visuals and audio work well together (step 299 ). Balance out levels of music and dialogue (step 300 ).
Step XI
[0287] Mastering the disc (step 301 )
Prepare PC for disc burning (step 302 ) Prepare hands-on audio section for CD burning (step 303 ) Burn master disc (step 304 ) If the program is web based, provide to client's IT or MIS for downloading onto their intranet (step 305 ). If the audio hands-on component is downloaded via MP3, load MP3 players and test (step 306 ). If PC program is provided through handheld computer, prepare the file for downloading into device, download and test (step 307 ).
Step XII
[0294] Test completed program (step 308 )
Test the program with an individual to make sure that all the information is presented accurately and at the correct pace (step 309 ). Make sure that the individual can follow all the exercise instructions (step 310 ). Grade score after questions are answered (step 311 ). If necessary, make adjustments/corrections to the program by either re-recording corrected dialogue, or correcting visuals or problems with the PC navigation (If changes are to be made, repeat necessary steps from above) (step 312 ). Confirm that all goals have been achieved (step 313 ).
Step XIII
[0300] Implement program (step 314 )
Pre-test all trainees before providing training to see what they already know (step 315 ). Give logical training program to all trainees (step 316 ).
Step XIV
[0303] Analyze results (step 317 )
Grade all answers to questions (step 318 ). Review pre-test scores against completed answers given for the training questions (step 319 ). Test trainees on their new knowledge (step 320 ). Confirm all goals were achieved (step 321 ).
[0308] What follows is an example of using the logical training method of the present invention to teach product knowledge in a retail store. For this example, cookware is the product category for which training is going to be given to a trainee, using the headset method described above.
[0309] The trainee will stand in the cookware department of the store wearing the headset and begin listening to a logical training program. First the trainee will hear instructions on how to use the program. The narrators will give instructions on how to use the device they are using to listen to the program. Once completed, the narrators will begin to give the trainee an overview of the products and key points of the cookware department. For example the narrators could explain to the trainee what is in the cookware department, discussing the elements that make up pots and pans.
[0310] Next, the trainee will hear specific instructions to pick up a particular item and study it while the narrators point out key characteristics such as the handle, metal gauge or other important elements the trainee will need to know. The program will continue with several specific requests from the narrators for the trainee to perform various functions and exercises to better understand what they are learning. Throughout the program there will be review sections and quiz questions to be answered by the trainee.
[0311] Finally, when all the information about the products has been explained to the trainee, the narrators will then teach the trainee how to use that information with a customer. The narrators will reinforce the “customer service” steps of greeting the customer and asking questions and will provide the trainee with the types of questions they should ask and prepare them for the types of questions most customers are likely to ask them. A complete “How to sell Cookware” example is provided by the narrators for the trainee to understand how the information they have learned is used and continues until the trainee hears about “add-on” selling and closing the sale which for most retailers includes “thanking the customer by name.”
[0312] Once the trainee has completed the entire program he or she returns the device to their manager along with their answers to the quiz questions. When questions are on the program as in this example of a Cookware Product Knowledge Program, the retailer would typically be provided with an “Answer Sheet” for the trainee to circle the correct answer to the question. The “Answer Sheet” could be numbered 1-10 with each number having letters A, B, & C. While listening to the program, the narrators ask the trainee questions that have to be answered. The trainee circles the correct letter for each question. The questions are never on the “Answer Sheet.”
[0313] While there has been described herein the principles of the invention, it is to be understood by those skilled in the art that this description is made only by way of example and not as a limitation to the scope of the invention. Accordingly, it is intended by the appended claims, to cover all modifications of the invention which fall within the true spirit and scope of the invention.
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A method is disclosed that utilizes specific techniques, based upon empirical study, to significantly increase the ability of a trainee to remain focused on the training materials and subject matter and actually learn and retain the training subject matter. More specifically, the present invention utilizes audio and/or visual (e.g., a personal computer) elements, with a strict set of rules which must be followed regarding sentence length, narrators, and underlying music within the dialog to create a specific rhythmic “feel” to the training. As a result of using such techniques, significantly improved results over prior art training methods can be obtained.
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RELATED APPLICATIONS
[0001] This application claims priority to Provisional Pat. App. No. U.S. 61/309,006, filed 1 Mar. 2010. Other related applications include U.S. Ser. No. 13/026,317, concurrently filed as PCT/US11/24700 on 14 Feb. 2011; provisional U.S. 61/147,733 filed 27 Jan. 2009; and provisional U.S. 61/304,405 filed 13 Feb. 2010. All related applications are incorporated by reference.
FEDERALLY SPONSORED RESEARCH AND DEVELOPMENT
[0002] None
APPENDICES
[0003] None
BACKGROUND
[0004] Related fields include short-range wireless communication, small watercraft traditionally propelled by manual implements (paddles, oars, poles, and the like), and particularly wireless control of a function of the watercraft by an operator using or holding such an implement.
[0005] Where navigable water is accessible, small manually-propelled watercraft tend to be useful and popular, either by themselves or as accessories to larger craft (tenders, lifeboats, dinghies, and the like). They are much less expensive to build and maintain than larger craft, and can travel in shallow waters and narrow passages where larger craft cannot. Their uses include fishing and other aquatic harvesting such as pearl-diving and mollusk-gathering; ferrying passengers; carrying messages and market goods (in “floating markets” the watercraft itself becomes the market stall); repairing or maintaining docks, buoys, and larger ships; and, increasingly in many locations, recreation and tourism.
[0006] Motors, navigation and communication equipment, and other useful devices developed for dry land and larger vessels were once impractical for small watercraft because the devices or their fuel supplies were too large, heavy, awkward, or hazardous. Advances in device miniaturization and efficient lightweight power supplies have now mitigated those disadvantages in many cases. For example, a stand-up-paddle (SUP) derivative of a simple surfboard can be equipped with a lightweight electric motor to assist propulsion as and when the operator desires, a global-positioning system (GPS) can fit in the pocket of a pack or jacket, and an LED spotlight for rescue, salvage, or wildlife observation is lightweight, energy-efficient, and produces relatively little unwanted heat. Many modern navigation and measurement devices can provide audible signals, including fairly complex synthesized speech, so the operator can make use of a device without looking at it.
[0007] Besides onboard devices, some nearby, associated, but offboard systems would benefit from being operable remotely, but at fairly close range, by operators of small watercraft. For example, “mother” ships and small docks could save energy by leaving only the minimum necessary beacon lights burning through the night if arriving small-watercraft operators could remotely and temporarily turn on extra lights while coming in to tie up.
[0008] A practical obstacle remains, though: To control these devices, an operator using a manual implement such as an oar, paddle, or pole to propel or steer a watercraft must first “ship oars” or otherwise secure the implement before turning attention to the target device. This can require some care if there are other people, fragile goods, or potentially entangling nets and poles on board, or if the water is choppy. Under some conditions, such as strong currents, shallow shoals, or tight spaces, pausing the use of the implement or diverting the operator's attention may be dangerous. For a very minimal structure such as an SUP board, there may not even be anywhere secure to ship the paddle.
[0009] Some wireless controllers or remotes are commercially available for certain marine outboard motors. These devices are typically designed to be hand-held, wrist-worn, or mounted on the watercraft hull or deck. To Applicant's knowledge as of this writing, no wireless device controller integrated into a manual propulsion implement, such as an oar, paddle, or pole, is available commercially.
[0010] Few patents address this specific field. U.S. Pat. No. 7,303,452 by Ertz et al. (“Kayak Paddle with Safety Light”), filed 4 Apr. 2005, describes paddle-mounted wireless control of LED safety lights. However, the lights are also mounted on the paddle, and the wireless control is taught simply as a possible alternative for cases where a wired connection from an LED-control circuit on the paddle to LED lights elsewhere on the paddle might be too difficult to route (e.g., through the interior of the paddle) or effectively waterproof. Nothing in Ertz teaches or suggests an on-paddle wireless controller to control devices external to the paddle.
[0011] Given the growing popularity of paddle sports such as kayaking and stand-up paddle surfing, as well as the enormous variety of traditional manually-propelled small watercraft (canoes, gondolas, pirogues, outriggers, dories, coracles, etc.), the persistent absence of such paddle-integrated wireless control devices in the market or in the patent literature indicates that this is a somewhat long-felt but unaddressed need.
[0012] A means of controlling an on-board target device (propulsion-assist motor, depth finder, global positioning system, two-way radio or satellite phone, etc.) with an actuator integrated with a manual-propulsion implement (e.g. paddle) and operable during normal use of the implement would therefore be useful to operators of small watercraft. The ability to use a target device without interrupting propulsion or steering can enhance the safety, efficiency, or pleasure of the journey. At a minimum, the ability to turn a battery-powered device on when needed and off when not needed would prolong the life of the battery; small watercraft are often used in non-urban areas where batteries and chargers may be scarce, and electric motors' power consumption is proportional to the cube of the velocity.
[0013] In addition, because many types of oars and paddles have asymmetrical blade profiles and blade angles, their use may require operators to switch hand positions, sometimes quite frequently; for instance, the hand on the grip and the hand on the shaft may need to trade places when moving the paddle from the port to the starboard side of the watercraft or vice versa. Therefore, operability with either hand is a desirable feature for a paddle- or pole-mounted actuator.
SUMMARY
[0014] A wireless transmitter controlled by a hand-operable actuator is mounted on or integrated into a manual marine-propulsion implement (“MMPI”) such as a paddle, oar, or pole. The actuator design and position on the implement allows an operator to control an electronically-responsive function of the watercraft while continuing to hold or use the MMPI. The wireless transmitter sends control signals to at least one wireless receiver aboard or near the watercraft. Each wireless receiver provides input to a controller for at least one function, such as (but not limited to) auxiliary motor propulsion, two-way radio, global positioning and navigation.
[0015] Alternate configurations of actuators and transmitters render the improvement compatible with different types of MMPI (non-limiting examples include oars, steering oars, sweeps, sculls, single- and double-bladed paddles, poles and stand-up paddles). Various ways of adding a transmitter and actuator to an MMPI adapt the improvement to diverse market conditions.
[0016] The transmitter's power supply is lightweight, long-lasting, and replaceable or rechargeable. The transmitter, actuator, power supply, receiver, controller, and any hard-wired connections are sheathed, coated, potted, or sealed as necessary to protect them from damage by exposure to fresh water and salt water as well as the typical mechanical shocks, abrasions, temperature cycling, and solar ultraviolet exposure expected during operation, transportation, and storage of the associated watercraft. Finally, it is a further object to provide various alternative means for mounting or otherwise integrating the paddle-integrated wireless controller with watercraft paddles and oars, in order to accommodate various different types of watercraft paddles and oars (for example, stand-up paddle surfing paddles, double-bladed surf-kayak paddles, rowboat oars, lifeboat oars, Venetian gondola sculling oars, etc.).
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] FIG. 1A illustrates one embodiment of a wireless transmitter and its actuator mounted on a single-bladed paddle having a handgrip on the end opposite the blade
[0018] FIG. 1B is a cutaway view of transmitter housing 106 , showing components inside.
[0019] FIG. 2 is a schematic block diagram of an alternate embodiment of the system electronics.
[0020] FIG. 3A illustrates a preferred embodiment for mounting an actuator and transmitter on an existing paddle.
[0021] FIG. 3B illustrates a simple embodiment of a shaft-mounting clip.
[0022] FIG. 4 illustrates a preferred embodiment for a paddle or pole with a forked or T-shaped grip.
[0023] FIGS. 5A , 5 B, and 5 C are examples of paddle shafts, oar handles, or pole sections with built-in multi-position selector switches as actuators.
[0024] FIG. 6 illustrates a removable shaft section that protects the electronics as in a built-in embodiment, yet is made to be interchangeable between different compatible MMPIs.
[0025] FIG. 7 illustrates an application example in stand-up paddle (SUP) surfing.
DETAILED DESCRIPTION
[0026] A simple preferred embodiment includes a wireless transmitter and a suitable power supply (for example, one or more compact lightweight batteries such as “coin” or “button” cells) encapsulated in a waterproof transmitter housing and connected to respond to a waterproof “on/off” actuator. Both case and actuator are mounted on the shaft of a paddle near the grip. The actuator is positioned a few centimeters from an operator's normal hand position while paddling; easy to reach while continuing to use the paddle, but unlikely to be hit or grasped unintentionally. A receiver corresponding with the transmitter controls a propulsion-assist system (e.g., an electric motor). The operator starts the propulsion-assist by pushing or squeezing the actuator with part of the hand grasping the paddle grip. Releasing the switch returns it to its default position and causes the propulsion system to deactivate; this is a safety precaution in case the operator drops the paddle or some other disruption occurs.
[0027] FIG. 1A illustrates one embodiment of a wireless transmitter and its actuator mounted on a single-bladed paddle having a handgrip on the end opposite the blade. Variants of this type of paddle are used on SUP surfboards and canoes, among others. Waterproof trigger unit 101 (made of waterproof ABS plastic or other suitable waterproof plastic, metal, or composite material) incorporating an actuator 102 , is securely mounted on paddle shaft 103 adjacent to paddle grip 104 .
[0028] In a typical paddling position, the knuckles of one of the operator's hands rest atop grip 104 with the fingers curling over and downward, while the other hand grasps shaft 103 . Here, actuator 102 is shown for clarity as a spring-loaded button mounted to be depressed and released along an axis parallel to shaft 103 , but other switch types such as Hall-effect sensors with magnets are also contemplated. Depending on the grip length, the operator's fingertips will either rest above or below actuator 102 while paddling. A small hand movement is necessary to bring the fingertip(s) into position to depress actuator 102 , so that it is unlikely to be done by accident; yet the movement is small enough that it need not interrupt the paddling rhythm. Another advantage of this design is that paddles are most often bumped from the blade-tip end or from the side during use, transport, or storage. Therefore, the illustrated position and orientation of actuator 102 reduces the risk of damage by typical bumping.
[0029] Transmitter housing 106 (made of waterproof ABS plastic or other suitable material), is also securely mounted on shaft 103 . Electrical leads 108 connect transmitter housing 106 to trigger unit 101 .
[0030] Trigger unit 101 and transmitter housing 106 are secured to shaft 103 by any suitable couplings 105 and 107 respectively. Trigger-unit coupling 105 may comprise, for example, an adjustable metal hose clamp, a metal or plastic spring clip, an elastic band, a flexible band with an adjustable buckle or latch, or an open-ended fabric band with patches of hook-and-loop fastening material (e.g. Velcro™) positioned to facilitate band length adjustment for secure attachment to shaft 103 . If trigger-unit coupling 105 can be temporarily loosened and slid along or rotated around shaft 103 , or can be removed and replaced, trigger unit 101 can be optimally positioned for different operators, or the same operator who switches hand positions. Transmitter-housing coupling 107 may also benefit from being made adjustable if, for example, it must face substantially toward a receiver even when operators switch hands or seats. Couplings 105 and 107 may be attached to trigger unit 101 and transmitter housing 106 by any suitable method, including adhesives, rivets, and threading through holes or loops on the backs or sides of trigger unit 101 and transmitter housing 106 . Inexpensive plastic tie-wraps or other commercially available cable-securing clamps or straps may serve as couplings 107 or 105 , either by design or as emergency repairs.
[0031] FIG. 1B shows components inside transmitter housing 106 . Compact electric power source 109 (illustrated here as a “coin cell” or “button cell,” though other power sources can also be used) delivers power to wireless transmitter 110 , which is in turn connected to antenna 111 (in this embodiment, a printed PCB antenna). Electrical leads 108 penetrate transmitter housing 106 at a sealed and waterproof penetration, operably connecting trigger unit 101 (see FIG. 1A ) to wireless transmitter 110 . As an example, electric power source 109 , wireless transmitter 110 , and antenna 111 may be similar to those in commercial automobile keyless-entry “fobs”. However, while some automobile fobs may delay transmission of a signal for as much as ½ second after a switch is activated, the reaction time of some of these MMPI-mounted controllers (e.g. for a propulsion-assist motor in a balance-critical watercraft used in rough waters) is preferably much shorter. In other embodiments, if shaft 103 is electrically conductive (for example, the aluminum shafts in economically priced kayak paddles), it may be electrically connected with wireless transmitter 110 such that shaft 103 itself functions as antenna 111 . Alternatively, a linear antenna may be deployed along the length of paddle shaft 103 , either attached to its outer surface or recessed in, or fished through, an exterior or interior channel.
[0032] FIG. 2 is a schematic block diagram of an alternate embodiment of the system electronics. In this embodiment, the trigger unit(s) may include multiple actuators, illustrated by non-limiting example here as an “on/off” switch 201 and a multi-position selector switch 261 . When an operator manipulates actuators 201 and 261 , the resulting signals go through electrical leads 208 to input block 223 of transmitter controller 224 . Transmitter controller 224 recognizes the incoming actuator signals and sends corresponding commands through output block 225 to control wireless transmitter 210 (which may be infrared as illustrated here, radio-frequency as in FIG. 1B , ultrasonic, or any other wireless technique compatible with the application). Power is supplied by power source 209 and the circuit is protected by ground connection 226 .
[0033] In some embodiments, transmitter controller 224 includes a microprocessor with an information-storage element. The microprocessor's retrieval and execution of instructions programmed into the storage element enables the controller to interpret combinations of actuator manipulations (e.g. double-click, click and hold, select a setting and click) and generate a corresponding variety of commands resulting in a corresponding variety of distinguishable signals from transmitter 210 .
[0034] Some applications benefit from a tactile feedback from actuators 201 and 261 , such as a click or a persistent shape change, when the actuator is sufficiently engaged to change the signal of the wireless transmitter. With tactile feedback, the operator need not look down at the actuator or hear an audible alert such as a beep. This advantage is highly desirable in noisy and highly dynamic environments, such as rapids or surf.
[0035] Preferably, the transmitter does not interfere with other signal traffic, including similar wireless controllers for nearby watercraft. Limiting the transmitter's range, keying its frequency to its own receiver, and complying with local frequency-allocation standards (e.g., approved remote-control protocols for vehicle and building doors) all help to achieve this.
[0036] The signal from transmitter 210 is received by corresponding wireless receiver 230 on a target device. There may be more than one target device and associated receiver. Receiver 230 sends its signals through input block 243 of target-device controller 244 . Target-device controller 244 translates the incoming receiver signal(s) into commands sent out through output block 245 to control the target device.
[0037] Target-device controller 244 may also have an associated microprocessor and storage element with stored instructions. For example, suppose the target device is a propulsion-assist motor and the watercraft is sensitive to balance. A very sudden cutoff of the motor may destabilize the craft or its operator. Therefore, the target-device microprocessor may retrieve an execute a “gradual stop” routine that ramps down the motor power gradually. This can be critically important for safety and control especially in surf or whitewater.
[0038] FIG. 3A illustrates a preferred embodiment for mounting an actuator and transmitter on an existing paddle. In some environments, such as river rapids, paddles often break. This embodiment enables an intact actuator/transmitter to be easily transferred from a damaged paddle to an undamaged one. Here, ruggedized waterproof transmitter housing 301 contains the trigger unit as well as the transmitter, its power source, and any antenna, speaker, or optics needed for broadcast of the transmitter signal. Actuator 302 is mounted directly on housing 301 , eliminating the need for external, potentially vulnerable electrical leads 108 (see FIGS. 1A , 1 B). In this example, transmitter housing 301 is integrated with or attached to shaft-mounting clip 305 , which can be attached to or released from paddle shaft 303 . Shaft-mounting clip 305 is installed on shaft 103 to position actuator 302 optimally for operation by one or more of user's fingers gripping paddle grip 104 .
[0039] FIG. 3B illustrates a simple embodiment of shaft-mounting clip 305 : a partial cylinder of “springy” plastic, metal, or composite. Opening 351 can be temporarily stretched wider to admit shaft 303 ; then the stiffness and tension of the material return opening 351 as close to its original narrow width as the bulk of shaft 303 allows, so that shaft-mounting clip 305 tightly grips shaft 303 . Optionally, the inside surface 352 of clip 305 may be lined or coated with a non-slip material to anchor the transmitter assembly in place. Alternatively, the flexible-band-based couplings described in conjunction with the embodiment of FIG. 1 may be used here as well.
[0040] In some situations, watercraft and their MMPIs are regularly transported overland without much protection (e.g. thrown in a wagon or truck bed). The configuration of FIGS. 3A , 3 B with the removable clip or strap is one solution; the actuator/transmitter assemblies can be taken off the MMPI shafts, transported in a separate container such as a tackle box or backpack, and then popped back on at the beach or boat-launch. Another alternative is the “built-in” approach. MMPIs used in water that is reasonably smooth (such as a lake, harbor, or deep river) can last a long time but electronics attached to the outsides of them can be vulnerable. For these applications, all components of the trigger unit and transmitter except the actuator(s) are sealed and, if necessary, cushioned in cavities fabricated inside the MMPI grip or shaft. The cavities may be sealed by, among other options, screw-on or snap-on cover(s) incorporating perimeter O-rings or other elastomeric gaskets. The MMPI with built-in electronics can be a single piece, or the modified grip or shaft section can be detached from the remainder of the shaft and the blade, if any, and attached to the shaft and blade of a different MMPI. Alternative paddle grip may be integrally manufactured with the watercraft paddle shaft, or alternative paddle grip may incorporate a threaded protrusion for threading into a threaded insert in an open end of paddle shaft.
[0041] FIG. 4 illustrates a preferred embodiment for a paddle or pole with a forked or T-shaped grip. An actuator 402 is positioned on end of each arm of grip 404 . The two actuators are redundant to each other. No matter which hand is on grip 404 or which way the paddle blade (not shown) is oriented, one or the other actuator 402 is easily reached by the operator without interrupting the maneuvering of the watercraft. Also, this figure illustrates “purpose-built” embodiments where all the electrical hardware from the actuator to the transmitter is routed inside grip 404 or shaft 405 for maximum protection from mechanical damage. In another embodiment, curved triggers similar to pistol triggers with or without trigger guards are installed on the arms of the grip as actuators, in such orientations that the triggers can be operated with either hand grasping the paddle grip. Hence, if the user switches the paddle from port to starboard or vice versa without rotating the paddle blade, and switches “shaft hand” and “grip hand” accordingly, actuators as described above are still convenient to reach and easy to use.
[0042] FIGS. 5A , 5 B, and 5 C are examples of paddle shafts, oar handles, or pole sections with built-in multi-position selector switches as actuators. These multi-position actuators may be used besides, or instead of, on/off switches, depending on the nature of the target device. For example, the positions may correspond to variations in speed of a motor, brightness of a spotlight, or volume of a speaker. These controls may be located on or near an oar handle, near a paddle grip, in the middle of the shaft of a double-ended paddle such as a kayak paddle, or between the center and top end of a pole.
[0043] In FIG. 5A , rotatable selector 561 incorporates a selection indicator 562 which may be aligned with any of markers 563 by hand-rotating rotatable selector 561 around the shaft of the MMPI. Rotatable selector 561 is preferably a ring or cylindrical shell of plastic, hard rubber, or other electrically insulating, moisture-insensitive material. Internal electrical contacts (not visible) complete one of several distinct electrical circuits depending on which set marker 563 is aligned with selection indicator 562 . Depending on which circuit is completed, the built-in wireless transmitter (not shown in this view) sends a different command to the corresponding wireless receiver (also not shown in this view). Internal mechanical detents (not shown) may correspond with markers 563 , making an audible or touch-sensible “click” as indicator 563 becomes aligned with a marker. This can obviate the need for the operator to look at selector 561 while operating it.
[0044] FIG. 5B illustrates a selector comprising a built-in array 564 of buttons 565 . Each button can manipulate internal electrical contacts to complete a circuit as with the rotatable selector of FIG. 5A . When multiple receivers or variables need to be controlled, button array 564 can be advantageously coupled with a microprocessor-controlled transmitter so that double-taps and multiple buttons pressed simultaneously can be recognized and result in different transmitter signals.
[0045] FIG. 5C illustrates a built-in slider control for applications where continuous or quasi-continuous control of a target-device variable is desired. The position of slider 567 in slot 566 varies a resistance, capacitance, or inductance in a circuit within the trigger unit (not visible in this view). The transmitter signal depends on the trigger-unit output. Alternatively, a similar design could be used for control in discrete steps by distributing markers or detents along the length of slot 566 .
[0046] FIG. 6 illustrates a removable shaft section that protects the electronics as in a built-in embodiment, yet is made to be interchangeable between different compatible MMPIs. Actuator(s) (illustrated here as rotatable outer cylinder 610 ) are accessible from the outside of, and other trigger-unit and transmitter electronics are sealed inside of, housing 601 . Housing 601 is slightly larger in maximum diameter than shaft 603 for convenient location by touch. A removable seal 609 allows access to the power source (e.g., battery) for recharging or, if needed, replacement. Another approach to recharging the transmitter's power source is to position small, lightweight solar cells on parts of the MMPI likely to receive sunlight, such as the shaft surface or the blade surfaces. The strength of the removable shaft section is provided by central axle tube 606 , designed to be similar in strength and rigidity to the rest of MMPI shaft 603 . The ends of axle tube 606 mate in any suitable way (threads, bayonet-type latch, snap-in features, set screws, or the like) with recesses 607 , 608 in shaft 603 and grip 604 . For some MMPIs, such as kayak paddles, long poles, or two-handed sweeps, another shaft 603 would take the place of grip 604 ; for sculls and single-handed oars, the interchangeable section may itself be the end of the handle.
[0047] When an operator rotates outer cylinder 610 to various positions, the characteristics of a trigger-unit circuit (for example, contact between conductive areas on the inside of cylinder 610 and the outside of axle tube 606 ) change, resulting in corresponding changes in the transmitter signal. When not desiring to engage whatever function the receiver controls, the operator user may grip an adjacent part of shaft 603 rather than outer cylinder 610 . On a single-bladed, two-handed paddle, as on canoes and SUP surfboards, a rotatable actuator like outer cylinder 610 may be more conveniently operated with the “shaft hand” than the “grip hand,” and in those cases may be installed further down shaft 603 than immediately adjacent to end grip 604 .
[0048] With this type of actuator, the transmitter controller may be set up so that rotating outer cylinder 610 continuously in one direction causes the transmitter to send signals interpreted by a receiver controlling a propulsion motor to first activate, then continuously increase the power delivered to the motor. Conversely, rotating outer cylinder 610 continuously in the opposite direction causes the transmitter to signal the receiver to command the controller to first decrease power level, and then finally deactivate the motor. Additionally, outer cylinder 610 may be spring-loaded so that it returns to the “off” position unless actively prevented from doing so. If the operator must continuously apply torque to outer cylinder 610 to maintain motorized propulsion, the motor will safely shut down if, for example, the operator accidentally drops the paddle.
[0049] Alternatively, outer cylinder 610 may have a series of internal detents to create “click-stop” positions for specific functions, such as “off”, low, medium, high, and reverse speed settings for a propulsion system. With this type of design, the operator may maintain propulsion at constant power, similar to an automobile's “cruise control” function, without continuing to rotate outer cylinder 610 .
[0050] FIG. 7 illustrates an application example in stand-up paddle (SUP) surfing on a board with a propulsion motor controlled via a wireless receiver (such as the battery-powered electric jet-pump propelled surfboard previously disclosed by Applicant in international application #PCT/US11/24700). Paddle-integrated wireless controller 701 , with a transmitter signal 710 keyed to a receiver on propulsion unit 751 , is built into or mounted on paddle 700 . In the water, operator 777 stands on board 750 and holds paddle 700 with one hand on grip 704 and the other on shaft 703 , just as in normal paddling of an unmotorized SUP board. When a propulsion assist is desired (for instance, to escape an eddy or adverse current, evade an obstacle, or catch an incoming wave), operator 777 engages an actuator for controller 701 , producing a “motor on” transmitter signal 715 that activates propulsion unit 751 . If operator 777 ceases to need a propulsion assist, as after attaining desired dynamic equilibrium on a moving wave face, propulsion unit 751 may be deactivated using the actuator for controller 701 . A motorized SUP surfboard may also be used in “flat” water such as lakes, ponds, rivers, and even swimming pools, where operators may learn and practice basic skills or simply enjoy the ride. A wireless controller for the motor that does not interfere with paddling or steering enhances learning progress and enjoyment.
[0051] Only the claims appended here (along with those of parent, child, or divisional patents, if any) define the limits of the protected intellectual-property rights. The written description above and the accompanying drawings provide illustrative examples of how an authorized person may practice the invention without undue experimentation, including the best mode known to the inventors at the time of filing. The claims may encompass other embodiments, variations, and equivalents that are implicit in, or may be extrapolated from, the foregoing description; all of these must be considered to be protected under the applicable law.
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Wireless transmitters are integrated with manual marine-propulsion implements associated with small watercraft (paddles, oars, poles, and the like). The transmitters are controlled by hand-operated actuators. The actuators are designed to be manipulated without looking and positioned within convenient reach of an operator's normal hand position on the implement. A corresponding wireless receiver on a target device enables the transmitter signal to control the device. Thus, an operator of a small watercraft can control a useful target device without first shipping or otherwise securing the manual implement, and may simultaneously continue to manually propel or steer the watercraft with the implement. Application examples include a propulsion-assist motor on a stand-up paddled (SUP) surfboard.
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TECHNICAL FIELD OF THE INVENTION
[0001] This invention relates to the field of thermal storage using phase change material (PCM). In particular, it refers to a thermal energy storage system suitable for being charged and discharged with a heat-transfer fluid in a thermal exchange process (evaporation/condensation) and which stores heat in the form of latent heat of fusion of a phase change material.
[0002] The thermal storage system proposed can be used in solar thermal plants for steam generation and in production processes in which the storage of heat may be an interesting differentiating factor from an economic point of view.
BACKGROUND OF THE INVENTION
[0003] Phase change materials can be an interesting, efficient and high energy density alternative for storing heat and particularly for applications at constant temperature. There are countless phase change materials and exchange system related thereto, which are aimed at, among others:
Improving the thermal conductivity of the phase change material given that the phase change materials most commonly used have a low thermal conductivity (approximately 0.5 W/mK). Obtaining the maximum energy density possible. Managing the volume expansion of the phase change material. The materials normally used expand on melting and contract during crystallisation/solidification. Optimising the thermal transfer or exchange between the storage material and the transfer method . . . .
[0008] At the moment, the exchange systems based on phase change materials for generating saturated steam or for evaporating/condensing heat-transfer fluids, are designed to always be charged from the upper part of the system. In other words, the heat-transfer fluid passing through the phase change material chamber is always carried out from the upper part of the machine and it circulates to the lower part. The main reason for this is that it enables the correct management of the volume expansion of the phase change material, leaving free space in the upper part of the machine for the expansion of this phase change material.
[0009] As shown in the heat exchanger system in FIG. 1 of the prior art, at the beginning of the charging process, the phase change material is solidified, occupying an area in the tank up to the level indicated by a thick dashed line. When the charging begins from the upper part (the steam or heat-transfer fluid enters from the upper part), the phase change material begins to melt and expand, occupying the free space situated above the dashed line. If the system were to be charged from the lower part with the solutions that are currently available in the prior art, excess pressure would be generated in the exchange phase which could damage the chamber, as the lower part does not have any room for expansion. Therefore, the solutions proposed up until now require charging to always be carried out in a descending vertical direction.
[0010] As a result of this, at the time of charging, the steam or heat-transfer fluid must always enter from the upper part, condensing along the tubes and exiting as condensed steam through the lower part, without the possibility of natural recirculation, thus limiting the speed/flow of the fluid within the tubes to a level that enables the condensation and also the thermal transfer speed of the steam or heat-transfer fluid to the phase change material. Furthermore, in order to obtain a totally condensed liquid at the exit, a condensing tank would be needed at the lower part of the system.
[0011] There are a number of different patents in the prior art that refer to heat exchange systems between a thermal storage phase change material and a heat transfer fluid. Patent US20070175609 describes a thermal exchange system between a phase change material and a fluid thanks to the use of graphite sheets within the phase change material with the aim of increasing heat conductivity. The invention however, does not provide details about how the charging and discharging operations are carried out.
[0012] U.S. Pat. No. 4,993,481A describes a thermal energy storage system using a porous ceramic moulding containing a phase change material and in turn crossed by a series of channels where the heat-transfer fluid circulates. In this case the invention is designed for heat-transfer or work fluids such as gases or liquids without phase change (without evaporation/condensation) therefore it does not allow for a natural recirculation given the density difference of the fluid.
[0013] U.S. Ser. No. 00/522,0954 describes a heat exchanger/accumulator based on phase change materials with the particular feature that its cylindrical design allows the thermal expansion of the phase change material during charging. The system does not offer any thermal conductivity improvements for the phase change material or any transfer speed improvements on the work fluid side.
[0014] Patent CN201093907Y offers a heat exchanger system between a phase change material and a heat-transfer fluid, characterised in that it is made up of a series of finned tubes arranged in parallel and a system that allows this fluid to circulate in the desired direction, whether charging or discharging the system; however, with this system, as the load is in a vertical ascending direction, the same problem would occur in relation to the expansion of the phase change material mentioned above and therefore this patent would not solve this dilemma.
[0015] The document “Development of High Temperature Phase-Change-Material Storages”—Doerte Laing, Thomas Bauer, Nils Breidenbach, Bernd Hachmann, Maike Johnson—Institute of Technical Thermodynamics, German Aerospace Center (DLR)—describes a thermal energy storage system using a phase change material and a heat exchanger system based on vertical finned tubes capable of exchanging heat with saturated steam. This document also describes the way of charging the system with a single step process but always in a descending direction (starting charging at the upper part and ending at the lower part), which means that if we want to obtain saturated water at the exit of the system, we would need a condensate tank at the lower end to enable saturated water to be obtained with the aim of being pumped back to the rest of the cycle. The system can only be charged in this way (downwards) given the aforementioned volumetric expansion problem with the phase change material, thus allowing the material to expand without creating over-pressurisation areas.
[0016] Patent WO2010146197 refers to a composite phase change material made up of a carbon or graphite foam and hydroxide salt. The material as a whole may increase the thermal conductivity of the salt thanks to the carbon and graphite conductive matrix and also enable the local management of the volume expansion of the salt.
[0017] In view of what is available in the prior art, this invention aims to improve the following aspects:
Use a phase change material that enables the use of a system that can be charged and discharged from the bottom thereof (in vertical ascending direction), thus allowing the natural recirculation of the heat-transfer fluid in the condensation/evaporation process and achieving a better thermal transfer between this work fluid and the phase change material. This will also enable the flow that passes through the thermal exchange tubes to be increased, which means the fluid circulation speed increases and, in turn, the Reynolds numbers increase and also the effectiveness of the thermal exchange between the heat-transfer fluid and the phase change material. It also means the recirculation pump does not have to be used or the condensate tank at the lower end of the machine, which is currently required during the charging processes of the systems that exist in the prior art. To obtain a phase change material that is capable of managing its own volume expansion or if not, using a phase change material exchanger configuration that enables the local management of the volume expansion of the phase change material. To obtain a system capable of being discharged in three different ways: I) with a single passage of steam (the steam circulates through the exchanger tubes once only), ii) with forced recirculation thanks to a recirculation pump and iii) with natural recirculation (thanks to the different steam densities in circulation). Both the discharging and charging of the system with a single passage (the fluid only passes through the exchange tubes once) are significantly less effective than discharging and charging via natural recirculation and which takes place from the lower part of the system (a process in which there is an internal recirculation of the heat-transfer fluid with the aim of increasing the flow that goes through the exchange tubes).
INVENTION DESCRIPTION
[0021] The invention consists of a thermal storage system and the process for carrying out the exchange of heat between the storage material contained in said system and the heat-transfer fluid (system charging/discharging process).
[0022] The storage system consists of a heat exchanger via which the heat-transfer fluid circulates and a storage material, with this material being a phase change material that has a minimum thermal expansion of less than 5% and is capable of managing its own volume expansion by itself.
[0023] During the system charging process, it is the heat-transfer fluid in gas form that provides the storage material with heat, which melts at the same time as the heat-transfer fluid condenses. During the discharging process it is the storage material that provides the heat-transfer fluid with heat which turns from liquid form to gas form while the storage material solidifies.
[0024] The phase change storage material consists of a rigid matrix that includes a phase change material and is contained in a casing or external tank.
[0025] The heat exchanger comprises a set of vertical straight tubes that penetrate the storage material via which the thermal exchange takes place between the heat-transfer fluid that circulates through them and the storage material. These tubes are separated from one another, allowing the fusion or crystallisation of all the storage material that exists between them.
[0026] At the lower end, the vertical tubes connect with at least one lower chamber via lower sub-chambers. The lower sub-chambers include a series of injectors that enable the heat-transfer fluid to be inserted in gas form into the lower part of the heat exchanger when charging the system.
[0027] At the upper end, the preferably vertical tubes connect with at least one upper chamber by means of upper sub-chambers. The upper chamber is, in turn, connected to a drum located outside of the casing and at a level that is higher than the upper chamber. One or more recirculation downpipes extend from the drum, which are also located outside of the casing and which connect the aforementioned drum with the lower chamber. Heat-transfer fluid in liquid form circulates through these downpipes from the drum and enters the vertical tubes that penetrate through the storage material through the lower chamber and sub-chambers.
[0028] The drum also has an exit for heat-transfer fluid in gas form and an entry or exit point for heat-transfer fluid in liquid form whether this if for discharging or charging respectively.
[0029] For charging the system, the heat-transfer fluid in liquid form that descends the downpipes mixes with the heat-transfer fluid in gas form that is injected into the system through the lower sub-chambers. This fluid in gas form inserted through the lower part of the system and mixed with the fluid in liquid form that comes from the downpipes, enables, through the density differences with the fluid in liquid phase contained in the downpipes, a natural recirculation of fluid, taking advantage of this fact to increase the through-flow along the vertical tubes of the heat exchanger and thus increase the thermal transfer of the heat-transfer fluid. The water level remains constant in the drum thanks to the extraction of heat-transfer fluid in liquid form.
[0030] The heat-transfer fluid in liquid form and in gas form is mixed in order to enable the transfer of heat by the fluid to the storage material, given that thermal transfer is always more effective by mixing liquid-gas than just gas.
[0031] In solar thermal plants, system charging is carried out during the day, that is, while steam is being generated in the plant through solar radiation. Discharging would take place at night when there is no solar radiation, thus using the heat stored in the storage phase change material to produce steam.
[0032] Below is a description of the process for charging the thermal storage system described above, comprising a phase change material
[0033] 1) Insertion of the heat-transfer fluid in gas phase into the system's lower sub-chambers through the injectors, where it mixes the recirculated heat-transfer fluid in liquid form from the drum and which descends via the downpipes, passing through the lower chamber or chambers.
[0034] 2) Ascending circulation of the mixture of fluid in liquid form and gas form by natural circulation via the vertical heat exchanger tubes thanks to the density difference between the fluid in liquid form and gas form and the liquid fluid contained in the downpipes.
[0035] 3) Transfer of heat from the heat-transfer fluid in gas form contained in the mixture that ascends via the vertical thermal exchange tubes to the phase change material housed in the casing, thus generating the condensation of said fluid.
[0036] 4) Energy gained from the heat-transfer fluid in gas form by the heat-transfer fluid, which melts.
[0037] 5) Circulation of condensed fluid collected in the upper sub-chambers and chambers up to the drum.
[0038] 6) Extraction of heat-transfer fluid in liquid form from the drum, maintaining the constant charging conditions and a constant level in the drum.
[0039] Thanks to the aforementioned storage system and the charging method thereof via the lower part, the natural recirculation of the heat-transfer fluid is possible because of the density difference between the heat-transfer fluid in evaporation/condensation in the thermal exchange vertical tubes and the heat-transfer fluid in liquid form in the downpipes. As mentioned above, this natural recirculation means the pass-through increases in the recirculation circuit and therefore the thermal transfer increases (increased Reynolds numbers and thermal transfer coefficient).
[0040] Also, thanks to this natural recirculation, the system does not need a recirculation pump.
[0041] Below is a description of the thermal storage system discharging process (normally discharged during periods without sunlight, either at night or in transitory periods):
[0042] 1) Drum supply with heat-transfer fluid in liquid form to maintain constant discharging conditions.
[0043] 2) The heat-transfer fluid in liquid form which is in the drum at a low temperature (lower than the melting temperature of the phase change material), descends down the downpipes by gravity, passing through the lower chambers and sub-chambers until it enters through the lower part of the thermal exchange vertical tubes.
[0044] 3) Once the heat-transfer fluid is in the thermal vertical exchange tubes, the heat-transfer fluid absorbs the latent heat of crystallisation of the phase change material thanks to the thermal exchange via the vertical tubes, with the phase change of said fluid beginning and changing to gas phase at the same time as the storage material begins to crystallise.
[0045] 4) As the heat-transfer fluid starts to change to gas phase it circulates up the vertical tubes thanks to the different pressures with the fluid in liquid phase which circulates along the downpipes, which favours natural circulation.
[0046] 5) The heat-transfer fluid in gas form which is collected by the upper part of the vertical tubes travels along the upper sub-chambers and along the upper chamber, to the drum, from where it is extracted via a steam extraction pipe.
[0047] Therefore, this invention's system enables charging and discharging operations to be performed via the lower part thereof, which enables the natural recirculation of heat-transfer fluid in both cases, thus increasing the transfer of heat between the heat-transfer fluid and the phase change material. This feature means a recirculation pump is not required (required for forced recirculation) and neither is the condensate tank, which would be necessary in the lower part of the machine in order to obtain saturated water in charging systems in the prior art. This invention uses the drum located in the upper part of the system instead of the condensate tank.
DESCRIPTION OF THE FIGURES
[0048] FIG. 1 : Heat exchanger of the prior art
[0049] FIG. 2 : Complete outline of this invention's thermal storage system using phase change materials (PCM) (front and side view).
[0050] FIG. 3 . Outline of the PCM composite storage material made up of salts and a carbon, graphite or metal matrix.
[0051] FIG. 1 . Outline of 4 blocks (plan view) that contain the PCM composite storage material, showing the holes or orifices for enabling the vertical heat exchanger tubes to pass through.
[0052] The references that appear in the figures are as follows:
( 1 ) Drum ( 2 ) Steam extraction pipe ( 3 ) Heat exchanger tubes ( 4 ) Connection line between downpipe ( 8 ) and lower chamber ( 62 ) ( 5 ) Lower horizontal tubular plate ( 5 ′) Upper horizontal tubular plate ( 61 ) Upper chamber ( 62 ) Lower chamber ( 61 ′) Upper sub-chambers (connection between vertical tubes and upper chambers) ( 62 ′) Lower sub-chambers (connection between vertical tubes and lower chambers) ( 7 ) Connection pipe between the upper chamber ( 61 ) and the drum ( 1 ) ( 8 ) Downpipe ( 9 ) Steam injectors ( 10 ) Graphite, carbon or metal foam ( 11 ) Phase change salts ( 12 ) Phase change storage material rectangular matrix made up of graphite, carbon or metal foam infiltrated with phase change salts ( 13 ) Orifice for tubes to pass through ( 14 ) Thermal expansion joint or expansion compensator ( 15 ) Entry or exit pipe for heat-transfer fluid in liquid form
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0072] In order to provide a better understanding of the invention, below is a description, with the help of diagrams, of the preferred embodiment of this invention.
[0073] The thermal storage system of this invention comprises a composite storage material made up of a matrix ( 12 ) made of a rigid, graphite, carbon or metal foam ( 10 ) with high porosity and thermal conductivity, with said matrix being infiltrated with highly thermally energetic salts based on hydroxides ( 11 ) (see FIGS. 3 and 4 ). This storage material is located inside a casing or container tank.
[0074] As shown in FIG. 2 , the storage system also has a heat exchanger made up of heat exchanger tubes ( 3 ), preferably vertical, through which the heat-transfer fluid circulates and which pass through the storage material through tube pass-through orifices ( 13 , FIG. 4 ) so there is direct contact between this storage material and the vertical tubes ( 3 ).
[0075] The salt ( 11 ) infiltrated in the matrix ( 12 ) of the storage material melts when it receives heat and crystallises when the heat is extracted, coinciding with the condensation or evaporation of the heat-transfer fluid which passes through the heat exchanger tubes ( 3 ), a high thermal transfer is also obtained between the fluid and the phase change storage material thanks to the increased thermal conductivity provided by the carbon, graphite or metal foam ( 10 ) that this material is made up of.
[0076] Thanks to the use of this carbon, graphite or metal matrix ( 12 ), the storage material itself manages the volumetric expansion given that the phase change material (for example salt) expands and contracts in its fusion/crystallisation locally within the same empty spaces of the matrix ( 12 ) without filtering through, which enables the system charging process to be carried out through the lower part thereof and in an ascending vertical direction.
[0077] This compound storage material is housed in the system's casing in the form of squares that are preferably square, which enables the assembly, as the infiltrated blocks can be alternated with a non-infiltrated phase change material. A series of orifices ( 13 ) will be drilled into the blocks to enable the exchanger's vertical tubes ( 3 ) to pass through. These orifices ( 13 ) are preferably round for the preferably cylindrical tubes to pass through, given that they support high pressures and provide better thermal transfer than square channels and they are also easier to manufacture and purchase.
[0078] The heat exchanger tubes ( 3 ) (that produce the condensation or evaporation of the heat-transfer fluid) pass through two flat tubular plates ( 5 ′ and 5 ) located on the upper and lower part of the exchanger and protrude through the lower plate ( 5 ) of the storage material's container or casing. These tubes are welded and attached to the lower tubular plate ( 5 ), forming a watertight vessel to prevent storage material leakages, however they are not welded to the upper tubular plate ( 5 ′) thus enabling the thermal expansion thereof.
[0079] At the upper part, the heat exchanger tubes ( 3 ) are joined to a series of upper sub-chambers ( 61 ′) and these to an upper chamber ( 61 ), with the latter remaining free for vertical movement and thus being able to absorb the vertical expansion of the tubes thanks to the expansion joints ( 14 ), or via an expansion management bend or expansion compensators. The entire upper tubular plate ( 5 ′), upper sub-chambers ( 61 ′) and upper chamber ( 61 ) and joints or thermal expansion bends, remain in the storage material's chamber or casing.
[0080] The upper chamber ( 61 ) ends up, either separately or via the shared connection pipe ( 7 ), in a drum ( 1 ) located at the upper part of the chambers ( 61 ) and from where the heat-transfer fluid extraction pipe ( 2 ) comes out, preferably steam or dry saturated steam. The piping for inserting or extracting the heat-transfer fluid in liquid form ( 15 ) comes out of this same drum ( 1 ).
[0081] At the lower part, the heat exchanger tubes ( 3 ) are joined to a series of lower sub-chambers ( 62 ′) and these to a lower chamber ( 62 ) which, via one or more connection lines ( 4 ), connect with recirculation downpipes ( 8 ) (outside of the casing that contains the storage material) which enables the recirculation of the non-evaporated heat-transfer fluid, preferably water. These downpipes ( 8 ) come from the drum ( 1 ).
[0082] The lower sub-chambers ( 62 ′) include a series of steam injectors ( 9 ) to enable heat-transfer fluid to be inserted, preferably steam or saturated steam into the upper part of the heat exchanger tubes ( 3 ) in the case of charging. This steam inserted through the lower part of the system enables a natural recirculation of fluid to be created, through the density difference with the water contained in the downpipes ( 8 ), taking advantage of this circumstance to increase the through-flow and thus increase the thermal transfer on the steam side.
[0083] Optionally a recirculation pump system can be included on the line ( 4 ), to enable the discharge with forced recirculation and also the installation of a valve in the same place to enable the discharge in a single step.
[0084] Optionally, the system may include one or more valves in the downpipes ( 8 ) to enable the system to be charged and discharged without recirculation, only with the pressure of the system's incoming and outgoing steam respectively.
[0085] Below is a description of the system's charging process and the process for producing saturated steam (system discharge) by using the thermal storage energy via a phase change material consisting of a carbon, graphite or metal foam with infiltrated salts:
System Charging Process:
[0086] 1) The saturated steam enters the lower sub-chambers ( 62 ′) via the system's steam injectors ( 9 ) where it mixes with the recirculated water from the drum ( 1 ) via the downpipes ( 8 ) and passing through the lower chamber ( 62 ).
[0087] 2) Ascending circulation of the steam and water mixture through natural circulation via the heat exchanger tubes ( 3 ) thanks to the density difference with the water contained in the downpipe/s ( 8 ).
[0088] 3) Heat transfer between the saturated steam contained in the mixture, to the composite storage material made up of a carbon, graphite or metal foam ( 10 ) infiltrated with salt ( 11 ) housed in the casing and penetrated by the heat exchanger tubes ( 3 ).
[0089] 4) Energy gained from the steam produced by the salt ( 11 ) contained in the carbon, graphite or metal foam ( 10 ) which melts.
[0090] 5) Extraction of saturated water via the saturated water exit pipe ( 15 ) maintaining the constant level of the heat-transfer fluid in the drum ( 1 ).
[0091] This natural recirculation means the through-flow increases in the recirculation circuit and therefore the thermal transfer increases (increased Reynolds numbers and thermal transfer coefficient). Unlike forced recirculation, the system does not need a recirculation pump.
[0092] System discharge process:
[0093] 1) Drum supply with heat-transfer fluid in liquid form via the saturated water entry pipe ( 15 ) to maintain constant discharge conditions.
[0094] 2) Lowering through water gravity (liquid phase) at low temperature (below the melting temperature of the phase change material) from the drum ( 1 ) via the downpipe/s ( 8 ), passing through the chamber ( 62 ) and lower sub-chambers ( 62 ′) until it enters via the lower part of the heat exchanger tubes ( 3 ) that are in contact with the composite storage material consisting preferably of a carbon, graphite or metal foam ( 10 ) infiltrated with salt ( 11 ).
[0095] 3) Once the water is in the heat exchanger tubes ( 3 ) that are in contact with the storage material, the absorption by the water of the latent heat of crystallisation of the phase change material takes place thanks to the thermal exchange via the heat exchanger tubes ( 3 ), thus starting the phase change from water to steam at the same time as the storage material begins to solidify.
[0096] 4) As the water changes to gas phase (steam) it circulates up the heat exchanger tubes ( 3 ) thanks to the pressure difference with the water that circulates along the downpipes ( 8 ), which favours the natural circulation.
[0097] 5) The water steam generated is collected by the upper part of the heat exchanger tubes ( 3 ) and directed to the drum ( 1 ) where it is extracted via a steam extraction pipe. The water that has not evaporated collects in the drum waiting to once again circulate along the downpipes ( 8 ).
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Thermal storage system and its charging and discharging process using a heat-transfer fluid. The system includes a phase change storage material contained in a casing that is penetrated by heat exchanger tubes ( 3 ), preferably vertical ones, connected at their lower end with at least one lower chamber ( 62 ) via lower sub-chambers ( 62 ′) which include a series of injectors ( 9 ) for enabling the heat-transfer fluid to be inserted in gas form; at the upper end, these tubes ( 3 ) connect via upper sub-chambers ( 61 ′) with at least one upper chamber ( 61 ) which in turn is connected to a boiler ( 1 ) from which downpipes ( 8 ) extend via which heat-transfer fluid in liquid form circulates, located outside of the casing, connecting the aforementioned boiler ( 1 ) to the lower chamber ( 62 ), which enables the natural circulation of the heat-transfer fluid within the system.
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DESCRIPTION
This invention relates to a method for adjusting the shifting—or transmission ratio change—progressiveness in a transmission device, in particular in an automatic transmission device with multiple ratios.
This invention also relates to a transmission device implementing such a method.
From WO-A-9207206, there is already known an automatic transmission in which a clutch selectively connects two rotary members of a differential gearing such as an epicyclic train, according to whether one or the other of two antagonistic forces dominates. The first force, tending to disengage the clutch, is for example a tooth reaction, more particularly an axial thrust produced by helical gear teeth mounted in an axially movable manner. The second force, tending to engage the clutch, can be produced by springs and/or by tachometric centrifugal means. When the clutch is disengaged, it is necessary to prevent rotation of a third rotary member of the differential gearing, and this can be ensured by a free wheel preventing the third member from rotating in the reverse direction.
This type of transmission is very advantageous since its basic operation does not require an external power source, nor sensors, nor a control circuit. The transmission device itself does produce the forces which will control it and these forces are at the same time a measurement of the parameters necessary for the control.
For modern transmissions which have to provide a high level of comfort and optimisation of the operation, the previously mentioned forces are advantageously completed by additional forces, produced for example by hydraulic actuators. The additional forces can serve to modify at will the speed and torque conditions under which the transmission changes ratio, or can lock the transmission in a given ratio when that is desired (PCT/FR 94/00 176).
On the other hand, it has been observed, according to the invention, that the shifting process under the effect of forces such as a centrifugal force or a tooth reaction could exhibit certain defects.
WO-A-97/08 478 proposes solutions intended to remedy certain types of defects.
A particular defect to which the present invention is relevant, is the brutality which the action of an uncontrolled force generator, such as a spring or even more so a centrifugal force generator can have, particularly in the case of the above-mentioned transmissions, when the antagonistic force disappears and suddenly releases the force generator. For example, if the antagonistic force is proportional to the transmitted torque and the latter disappears because the driver releases the accelerator pedal, the uncontrolled force generator might suddenly actuate a clutch and cause a dangerous and uncomfortable shock.
The purpose of the present invention is to provide better control of a shifting process involving actuation of at least one selective coupling means.
According to the invention, the method for adjusting progressiveness of a change from an old transmission ratio to a new transmission ratio, in a transmission device comprising:
a device for selective coupling between two rotary members;
a force generator means for urging the selective coupling means towards a predetermined one of its slipping and gripping states, corresponding to the new ratio;
an actuating means capable of urging the selective coupling means towards the other of the said states, corresponding to the old ratio;
is characterised in that the method comprises, whilst the generator means is actuating the selective coupling means towards its state corresponding to the new ratio, a step of controlling the actuating means so that it produces a measured resistant force, slowing down the transition between the old ratio and the new ratio.
By means of the actuating means, the action of the force generator means is counter-balanced in a measured manner, systematically or only when necessary, in order to prevent the force generator means from provoking a too-sudden change in the selective coupling device.
The amount of the contrary force applied by the actuating means can either be a predetermined unique amount or an amount chosen from a series of predetermined amounts, the choice being made according to a selection criterion, for example the speed of rotation which determines the centrifugal effect if the force generator means is of the centrifugal type. Such a predetermined amount preferably consists of a progressively decreasing force, which therefore progressively allows the force generator means to urge the selective coupling means towards the new coupling state.
Preferably, a physical value is detected, this value being one which is influenced by the progressive change from the old transmission ratio to the new transmission ratio, and the actuating means is controlled as a function of the result of this detection.
In the case of a transmission in which the shiftings are carried out spontaneously, that is to say without the intervention of a processing unit and, for example, are carried out according to the direction and value of the resultant of various forces such as a centrifugal force and a tooth reaction force indicating the transmitted torque, the detection of the said physical value has the function of detecting that a change of ratio is in progress in the transmission. The counter-balancing action of the actuating means is initiated, at least in certain cases, according to this detection.
Furthermore, the detection of the physical value can be used to produce a servo-control of progressiveness. It is possible, for example, to calculate the time derivative of the transmission ratio and to adjust the counter-balancing action such that this derivative remains as close as possible to a reference value. It is possible to choose references other than the derivative. For example it is possible to fix a law of evolution of the ratio over time as a reference.
When the transmission offers a number of transmission ratios which is high in comparison with the number of gear trains used, there is in general at least one shifting process which requires activation of one coupling and the release of another coupling whilst perfectly synchronising these two operations. Any imperfection in this synchronisation renders the change of ratio uncomfortable for the occupants of the vehicle and introduces stresses and/or shocks, which cause wear, in the transmission.
The selective coupling means which initiates the shifting process can in such a case be the selective coupling means which is counter-balanced as just described and this selective coupling means can be the one whose actuation varies the input speed of the transmission device in the sense corresponding to the change of ratio to be effected. When the detected physical value reaches a certain predetermined level, the actuation of the other coupling means is initiated in its turn.
As physical value which is characteristic of the evolution of the ratio change process, it is indeed advantageous to choose the input speed, or the ratio between the input speed and the output speed of the transmission or, more generally, between two speeds the ratio between which is affected by the shifting process in question.
In such a case, a progressiveness control regulating the counter-balancing provided by the actuating means as a function of the evolution of the overall transmission ratio provided by the two transmission mechanisms will allow to compensate for all of the imperfections of the ratio change process in the two mechanisms. The overall result will therefore be very satisfactory despite the complexity of the shifting process which is involved.
Another advantage in choosing as a physical value one that indicates the state of the whole of the transmission device, and not just the state of a specified subassembly such as an epicyclic train in a transmission device which comprises several of them, and in particular in choosing as a physical value the ratio between the input speed and the output speed in the transmission, is that this value indicates, according to the range of values within which it is currently varying, which change of ratio is actually occurring. For example, in a device producing four transmission ratios with only two epicyclic mechanisms in series, there are three possible changes, i.e. from the first to the second ratio, from the third to the fourth ratio and from the third to the second ratio, which comprise the engagement of the same clutch. Because of the overall detection, it is possible to distinguish which of the changes is occurring and, if necessary, to modify the control criteria accordingly. Furthermore, the overall detection makes it possible to use a same detector assembly for all of the selective coupling means for which it is desired to apply the method according to the invention.
According to a second aspect of the invention, the transmission device for a vehicle, comprising:
at least one gear train;
a selective coupling means able, by changing from an old coupling state to a new coupling state, to cause the gear train to change from an old transmission ratio to a new transmission ratio;
a force generator means capable of causing the selective coupling means to change from the old coupling state to the new coupling state;
an actuating means capable of applying to the selective coupling means an action tending to force it towards the old coupling state;
control means for controlling the actuating means;
characterised in that the control means comprise progressiveness means for causing the actuating means to apply a measured amount of force slowing down the change of the selective coupling means from the old coupling state to the new coupling state under the action of the force generator means.
In the rest of this description, following convention, a transmission ratio will be called “slow” when it corresponds to a high input speed with respect to the output speed. In the opposite case, the ratio is called “fast”.
Other features and advantages of the invention will furthermore emerge from the following description relating to non-limitative examples.
IN THE ACCOMPANYING DRAWINGS:
FIG. 1 is a diagrammatic half-view in longitudinal cross-section of a transmission device with two ratios according to the invention, in the rest state;
FIGS. 2 and 3 are views similar to FIG. 1 but relating to operation as a reduction gear and as a direct drive respectively;
FIG. 4 is a time-based diagram showing a version of the method according to the invention;
FIG. 5 is as diagrammatic half-view of a transmission device with four ratios according to the invention; and
FIGS. 6 and 7 are time-based diagrams illustrating the operation of the embodiment shown in FIG. 5 .
The transmission device with two ratios shown in FIG. 1, intended in particular for a motor vehicle, comprises an input shaft 2 a and an output shaft 2 b aligned along the axis 12 of the device. The input shaft 2 a is connected to the output shaft of the engine 5 of a motor vehicle with the interposition of an input clutch 86 and possibly other means of transmission which are not shown. The output shaft 2 b is intended to drive, directly or indirectly, the drive wheels of a vehicle. Between the output shaft 2 b and the wheels of the vehicle there can, for example, be interposed another transmission device with two or more ratios and/or a manually controlled forward drive/reverse drive inverter and/or a differential for distributing the motion between the drive wheels of the vehicle.
The input 2 a and output 2 b shafts are axially immobilised with respect to a casing 4 of the transmission device, which is only partially shown.
The transmission device comprises a differential gearing formed by an epicyclic train 7 . The train 7 comprises a crown with internal teeth and a sun wheel 9 with external teeth, both meshing with planets 11 supported, at equal angular intervals about the axis 12 of the transmission device, by off-centred trunnions 14 of a planet holder 13 rigidly connected to the output shaft 2 b . The sun wheel 9 can rotate freely about the axis 12 of the transmission device with respect to the output shaft 2 b which it surrounds. However, a free-wheel device 16 prevents the sun wheel 9 from rotating in reverse, that is to say in the opposite direction to the normal direction of rotation of the input shaft 2 a with respect to the casing 4 of the transmission.
The crown wheel 8 is connected for common rotation with, but axially slidable with respect to the input shaft 2 a , by the intermediary of splines 17 .
A multi-disk clutch 18 selectively couples the crown wheel 8 with the planet holder 13 .
The stack of disks 19 and 22 of the clutch 18 can be axially clamped between a retaining plate 26 integral with the planet holder 13 and a movable plate 27 which belongs to a cage 20 , which is bound for common rotation with the planet holder 13 , but slidable with respect to the latter.
The cage 20 supports centrifugal flyweights 29 disposed in a ring around the clutch 18 . The flyweights are therefore bound for common rotation with the output shaft 2 b of the transmission device.
The rotation of the planet holder 13 tends to cause a body 31 of each flyweight 29 to pivot radially outwardly about its tangential pivoting axis 28 under the effect of centrifugal force, in order to cause the flyweights to move from a rest position defined by abutment of a stop 36 of the flyweights against the cage 20 (FIGS. 1 and 2) and a separated position which can be seen in FIG. 3 .
This results in a relative axial displacement between a nose 32 of each flyweight and the pivoting axis 28 of the flyweight. This displacement, which brings the nose 32 towards the movable plate 27 , can correspond to a compression of a Belleville spring 34 fitted between the nose 32 and the retaining plate 26 and/or a displacement of the movable plate 27 towards the stationary plate 26 in the sense of clamping the clutch 18 .
When the transmission device is in the rest state as shown in FIG. 1, the Belleville spring 34 transmits to the cage 20 , by the intermediary of the flyweights abutted in the rest position, a force which engages the clutch 18 such that the input 2 a of the transmission device is coupled in rotation with the output 2 b and the transmission device constitutes a direct drive capable of transmitting torque up to a certain maximum defined by the clamping force of the Belleville spring.
Furthermore, the teeth of the crown wheel 8 , of the planets 11 and of the sun wheel 9 are of the helical type. Thus, in each pair of gears meshing under load, axially opposed thrusts appear which are proportional to the transmitted circumferential force, and therefore to the torque on the input shaft 2 a and to the torque on the output shaft 2 b . The direction of helical inclination of the gear teeth is chosen such that the axial thrust Pac (FIG. 2) arising in the crown wheel 8 when it transmits a drive torque is applied in the direction in which the crown wheel 8 pushes the movable plate 27 , by the intermediary of a thrust bearing B 2 , in the direction separating the plates 26 and 27 , and therefore disengaging the clutch 18 . The force Pac also tends to bring the nose 32 of the flyweights 29 and the retaining plate 26 towards one another, and therefore to maintain the flyweights 29 in their position of rest and to compress the Belleville spring 34 . The planets 11 , which mesh not only with the crown wheel 8 but also with the sun wheel 9 undergo two opposite axial reactions PS 1 and PS 2 , which balance out, and the sun wheel 9 undergoes, taking account of its meshing with the planets 11 , an axial thrust Pap which is equal in intensity and opposite to the axial thrust Pap of the crown wheel 8 . The thrust Pap of the sun wheel 9 is transmitted to the casing 4 by the intermediary of a thrust bearing B 3 .
This is the situation shown in FIG. 2 . Assuming that this position is achieved, the basic operation of the transmission device will now be described. As long as the torque transmitted by the input shaft 2 a is such that the axial thrust Pac in the crown wheel 8 suffices to compress the Belleville spring 34 and to maintain the flyweights 29 in the rest position shown in FIG. 2, the separation between the retaining plate 26 and the movable plate 27 of the clutch is such that the disks 19 and 22 slip against each other without transmitting torque between them. In this case, the planet carrier 13 can rotate at a speed different from that of the input shaft 2 a , and it tends to be immobilised by the load which the output shaft 2 b must drive. The result of this is that the planets 11 tend to behave as motion reversers, that is to say to cause the sun wheel 9 to rotate in the opposite direction of rotation from the crown wheel 8 . But this is prevented by the free wheel 16 . The sun wheel 9 is therefore immobilised by the free wheel 16 and the planet carrier 13 rotates at a speed which is intermediate between the zero speed of the sun wheel 9 and the speed of the crown wheel 8 and of the input shaft 2 a . The module therefore operates as a reduction gear. If the speed of rotation increases and the torque remains unchanged, a time arrives at which the centrifugal force of the flyweights 29 produces on the movable plate 27 with respect to the retaining plate 26 an axial clamping force which is greater than the axial thrust Pac, and the movable plate 27 is pushed towards the plate 26 in order to achieve direct drive (FIG. 3 ).
The clutch 18 , as it is being engaged during the change to direct drive, increasingly transmits power directly from the crown wheel 8 , bound to the input shaft 2 a , to the planet carrier 13 , bound to the output shaft 2 b . Consequently, the teeth of the epicyclic train 7 work decreasingly, that is to say they transmit progressively decreasing force. The axial thrust Pac decreases and finally disappears. Thus, the axial thrust due to the centrifugal force can be applied fully in order to clamp the plates 26 and 27 against one another.
It can then happen that the speed of rotation of the output shaft 2 b reduces, and/or that the torque to be transmitted increases, to such a point that the flyweights 29 no longer provide in the clutch 18 a sufficient clamping force to transmit the torque. In this case, the clutch 18 begins to slip. The speed of the sun wheel 9 reduces until it becomes zero. The free wheel 16 immobilises the sun wheel and the tooth force Pac reappears in order to disengage the clutch, such that the transmission device then operates as a reduction gear. Thus, each time that a change of operation from a reduction gear to operation in direct drive or vice-versa occurs, the axial force Pac varies in the sense which stabilises the newly instituted transmission ratio. This is very advantageous on the one hand to prevent too-frequent changes of ratio about certain critical operating points and, on the other hand, in order that the situations in which the clutch 18 is slipping are only transient.
As shown in FIG. 1, complementary means are provided to selectively cause operation of the transmission device as a reduction gear in conditions other than those determined 12 by the axial forces of the Belleville spring 34 , the flyweights 29 and the teeth of the crown wheel 8 .
For this purpose, the transmission device comprises a brake 43 which allows to immobilise the sun wheel 9 with respect to the casing 4 independently from the free wheel 16 . In other words, the brake 43 is mounted operatively in parallel with the free wheel 16 between the sun wheel 9 and the casing 4 . The piston 44 of a hydraulic actuator 43 is mounted in a axially sliding manner for selectively applying and releasing the brake 43 . The brake 43 and the piston 44 have an annular shape having as their axis the axis 12 of the transmission device. The piston 44 is adjacent to a hydraulic chamber 46 which can be selectively fed with pressurised oil in order to drive the piston in the direction of applying the brake 43 .
Furthermore, the piston 44 is rigidly connected to a push rod 47 which can press against the cage 20 by means of an axial thrust bearing B 4 . The assembly is such that when the pressure existing inside the chamber 46 pushes the piston 44 into the position of applying the brake 43 , the cage 20 , before the brake 43 is applied, is pushed back sufficiently for the clutch 18 to be released.
Thus, when the piston 44 is in the position of applying the brake (FIG. 2 ), the sun wheel 9 is immobilised even if the planet holder 13 is tending to rotate faster than the crown wheel 8 , as is the case when operating in engine braking mode, and consequently the module operates as a reduction gear, as allowed by the release of the clutch 18 .
The assembly 43 , 44 , 46 , 47 which has just been described constitutes an actuating means which can be made available to the driver of the vehicle to force the module to change to operation as a reduction gear or to retain the operation as a reduction gear when the driver wishes to increase the engine braking effect, for example when going downhill, or when he wishes to increase the engine torque on the output shaft 2 b . When the torque is a driving torque, the brake 43 , if applied, carries out a redundant action with that of the free wheel 16 , but this is not harmful.
The feeding and draining of the chamber 46 are determined by the state of an electro-valve 69 . When it is in the rest state, the electro-valve 69 (FIGS. 1 and 3) connects the chamber 46 with a drain path 151 which is hydraulically resistant. When the electro-valve 69 is electrically energised (FIG. 2 ), it isolates the chamber 46 from the drain path 151 and connects it with the output of a pump 57 driven by the engine 5 . Irrespective of the state of the electro-valve 69 , the pump 57 can also serve to feed a lubrication circuit (not shown) of the transmission device.
The electro-valve 69 is controlled by control means 452 comprising a control unit 152 connected to a detector 153 of the speed V S of the output shaft 2 b , a detector 158 of the speed V E of the input shaft 2 a , a “manual/automatic” selector 154 made available to the driver, a detector of the position of the accelerator pedal 156 and a “normal/sport” selector 157 allowing the driver to choose between two different automatic behaviours of the transmission device.
The control unit 152 monitors the ratio between the input speed V E and the output speed V S . As long as the device is operating as a reduction gear (the situation shown in FIG. 2 ), this ratio is equal to about 1.4. If the input speed V E reduces with respect to the output speed V S , it is because the flyweights 29 have begun to engage the clutch 18 and consequently the transmission device has spontaneously initiated a change to direct drive operation. In this case, in order to ensure the progressiveness of this process and, more particularly, to ensure a certain duration of slipping of the disks 19 and 22 of the clutch, the control means 452 which have detected the reduction in V E with respect to V S control the feeding of the chamber 46 such that the piston 44 pushes the cage 20 in the direction tending to release the clutch 18 , in order to slow down the engagement process resulting in the situation shown in FIG. 3 . In practice, it is desired that the control means 452 cause as soon as possible the start of the action of the piston 44 . Taking account of the detection delay and of the inevitable response times, the action begins when the ratio V E /V S becomes lower than about 1.3.
In the example shown, the control means 452 comprise, in addition to the control unit 152 , a progressiveness stage 453 which also receives the signals V E and V S , continuously calculates the transmission ratio, detects the variation in the ratio V E /V S , resulting from the start of engagement of the clutch 18 and selectively produces on its output 454 a control signal producing a modulated energising of the electro-valve 69 such that the actuator 45 is fed as has just been described.
The method according to the invention will now be described more precisely with reference to FIG. 4 .
In this figure, the uppermost graph shows the evolution of the transmission ratio R=V E /V S , (vertical axis) with respect to time T (horizontal axis). The lowermost graph shows, along the same time scale T, the energisation level (the double line on the drawing) of the winding of the electro-valve 69 , and the pressure level PV (single line) in the chamber 46 .
According to a preferred feature used in this example, the intensity of the counter-balance effect provided by the actuator 45 is controlled by the progressiveness unit 453 by varying the width PW of electrical pulses applied to the electro-valve 69 . To do this, the signal on the output 454 is applied to a pulse generator 456 whose output 457 supplies the pulses to the electro-valve 69 . The width PW of the pulses varies from 0% (total absence of pulses) to 100%, corresponding to continuous working. The lower graph in FIG. 4 shows the evolution of the width of the pulses with respect to time, expressed in %. Small detail views show that a high percentage corresponds to a large pulse width and a low percentage corresponds to a small pulse width.
The pulse repetition frequency is constant and can for example be 50 Hz. The amplitude of the pulses outside of the cut-off periods is also constant, 12 volts for example.
In the example shown, the transmission ratio is initially equal to 1.4. Until the time T 1 the operation as a reduction gear is imposed by the actuator 45 since the width of the pulses applied to the electro-valve 69 is 100%. In this case it is a continuous signal applied by the control unit 152 . The actuator 45 is designed such that it is capable of overcoming the centrifugal force produced by the flyweights 29 even in the absence of tooth reaction force PAC for all speeds where this can be useful in practice. For example, if it is considered that the maximum speed V S for which it can in certain cases be necessary to impose operation as a reduction gear is 3,000 r.p.m., the force of the actuator 45 when the pulse width is continuously 100% is at least equal to the force produced by the centrifugal effect on the noses 32 of the flyweights when the cage 20 is rotating at 3,000 r.p.m.
Operation as a reduction gear continues for a certain time until the time T 2 at which the transmission ratio suddenly starts to decrease. The duration T 1 −T 2 can be very short if, as from the end of feeding the actuator 45 , the axial force produced by the flyweights 29 is greater than the reaction P AC . The duration T 1 −T 2 can be longer in the opposite case, and if it is necessary consequently to wait for the unbalance between the force produced by the flyweights 29 and the tooth reaction force P AC to begin to change direction. Whatever the case may be, the progressiveness unit 453 , which continuously calculates the ratio R=V E /V S detects slightly after the time T 2 that a change from operation as a reduction gear to operation as a direct drive has begun. The unit 453 thus causes, as from the time T 3 and up to the time T 5 a predetermined energising of the actuator 45 in order to slow down the process of change to direct drive, by counter-balancing in a measured manner the force produced by the flyweights 29 .
Since the actuator 45 is capable of maintaining the clutch 18 disengaged against the effect of the flyweights 29 even in the absence of any tooth reaction P AC , a durable energising of the actuator 45 at PW=100% would have the effect not of slowing down the change to direct drive, but in most case of preventing it totally and of causing a return to operation as a reduction gear.
In the example shown, the adjustment of the counter-balancing effect consists in applying to the electro-valve 69 , as shown at the bottom of FIG. 4, a pulse width which varies from 100% to 0% linearly between the time T 3 and the time T 5 . The time interval T 3 −T 5 is in agreement with the duration desired for good progressiveness of the ratio change.
More particularly, the effect of the pulses is to produce a rise in the pressure PV in the chamber 46 of the actuator 45 up to a level which is however distinctly below that produced by a pulse width durably fixed at 100% (see the graph at the bottom of FIG. 4 ). Under the effect of the pulses, the electro-valve 69 oscillates between the open state and the closed state. When it connects the chamber 46 with the pump 57 , a pressure wave is sent into the chamber 46 . When the electro-valve 69 connects the chamber 46 with the drain channel 151 , the hydraulically resistant nature of this channel prevents an immediate discharge of the chamber 46 . This results in a counter-balancing force on the piston 44 , this force being modulated substantially according to the profile of pulse widths PW over time T, but with a certain delay. Consequently, the resultant force applied to the clutch in the sense of engagement thereof increases from a very small value at the time T 2 to a value equal to the force produced by the flyweights when, a certain time after the end of the pulses at the time T 5 , the pressure in the chamber 46 is eliminated. Thus, the transmission ratio, instead of suddenly dropping along the dotted line 401 shown in FIG. 4, decreases progressively from the time T 4 (slightly after the time T 3 ), to the time T 6 , after the time T 5 of the end of the pulses. The profile of the decrease in ratio can vary greatly from one case to another, depending for example on whether the change of ratio is due to an increase, necessarily progressive, in the speed of rotation V S , or to a disappearance, which can be sudden, of the torque to be transmitted. Typically, as shown in FIG. 4, the decrease profile resembles the decrease profile of the pulse width PW.
Improved progressiveness can also be provided when the control means 452 , as a function of the signals they receive on their inputs, must control shifting from direct drive operation to reduction gear operation, by means of the actuator 45 .
To do this, instead of suddenly changing the width of the pulses PW to be applied to the electro-valve 69 from 0% to 100%, the electro-valve can be subjected to a progressive increase in the width PW of the pulses which are applied to it. It can however be advantageous to begin with a few pulses of large width in order to fill the chamber 46 rapidly and to rapidly take up the various plays and possible deformations of the system. After that, the pulses drop down to a smaller width and then increase again up to a durable level of 100%.
Finally, according to a variant shown in dotted line in the lowermost graph of FIG. 4, it is possible for the train of pulses applied to the electro-valve 69 in order to slow down the change to direct drive to start from a value of PW below 100%, the influence on the pressure in the chamber 46 being correspondingly reduced.
In the embodiment diagrammatically shown in FIG. 5, the transmission device comprises two planetary trains fitted in series, 107 , 207 . The planetary train 107 is similar to the one described with reference to FIGS. 1 to 3 : its crown wheel 108 is connected to the input shaft 2 a , its sun wheel 109 is connected to the casing 104 by the intermediary of a free wheel 116 , and its planet holder 114 , supporting planets 111 meshing with the crown wheel 108 and the sun wheel 109 , is connected to the output shaft 2 ab of the mechanism 107 , which is also the input shaft of the mechanism 207 . A clutch 118 makes it possible to couple selectively the crown wheel 108 with the planet holder 114 , in other words the input shaft 2 a with the intermediate shaft 2 ab in order to achieve direct drive in the planetary train 107 . When the clutch 118 is released, the planetary train 107 operates as a reduction gear, the sun wheel then being immobilised by the free wheel 116 . The reduction ratio provided by such a planetary train, that is to say a planetary train with an input on the crown wheel and an output on the planet holder, is commonly of the order of 1.4.
The second planetary train 207 is different in that its input shaft, constituted by the intermediate shaft 2 ab , is connected not to the crown wheel 208 , but to the sun wheel 209 , the crown wheel 208 being connected to the casing 104 by the intermediary of a free wheel 216 preventing the crown wheel 208 from rotating in the reverse direction. The output shaft 2 b is connected to the planet holder 214 supporting planets 211 each meshing with the crown wheel 208 and the sun wheel 209 . A clutch 218 allows to firmly connect the intermediate shaft 2 ab with the output shaft 2 b in order to achieve a direct drive in the second differential mechanism 207 .
When the clutch 218 is disengaged, the mechanism 207 operates as a reduction gear with the crown wheel 208 immobilised by the free wheel 216 . Taking account of the fact that the input is applied through the sun wheel 209 and the output is taken from the planet holder 214 , the reduction ratio is therefore typically equal to 3.
The clutches 118 and 218 are selectively engaged by a spring R 1 and respectively by the flyweights 229 driven in rotation by the planet holder 213 , and disengaged against the action of the spring R 1 and respectively of the flyweights 229 , by actuators A 1 and A 2 respectively, each controlled by an electro-valve V 1 and V 2 respectively, which are themselves controlled by the control unit 452 . Furthermore, in the case of the clutch 218 , a thrust bearing B 2 transmits the axial tooth force P AC from the crown wheel 208 to the cage 220 in the sense of disengaging the clutch 218 .
The unit 452 receives on its inputs the signals V E and V S supplied by the detectors 158 and 153 respectively as well as the signal from the detector 156 indicating the position of the vehicle's accelerator pedal, which corresponds to a load parameter C of the vehicle's engine, which can be expressed for example as a percentage of the maximum load.
The transmission device which has just been described is capable of providing four different ratios. The first ratio, or slowest ratio, is established when the two clutches 118 , 218 are disengaged and consequently the two planetary trains 107 , 207 are operating as reduction gears. The transmission therefore provides a reduction ratio equal to 1.4×3=4.2.
For operation in the second ratio, the clutch 118 is engaged and the clutch 218 is disengaged, such that the planetary train 107 operates as a direct drive and the planetary train 207 as a reduction gear, which gives a total reduction ratio of 3 in the transmission device.
For operation in the third ratio, the opposite case applies, the clutch 118 is disengaged and the clutch 218 is engaged, such that only the first planetary train 107 is operating as a reduction gear. This provides an overall reduction ratio equal to 1.4.
For operating in the fourth ratio, or the fastest ratio, the two trains 107 , 207 operate as direct drives, the overall ratio being equal to 1.
In the simple example which is illustrated, the changes of ratio in the first train are only controlled by the unit 452 according to the functional parameters V S (output speed) and C (load) but more sophisticated versions are conceivable, the first train for example then being similar to that of FIGS. 1 to 3 .
In this transmission device, the change from the second to the third ratio is difficult to control because the clutch 118 must be disengaged at the time the clutch 218 must be engaged. If the synchronisation between these two operations is imperfect, there is a risk of having, for a short time, either a simultaneous disengagement of the two clutches, that is to say a brief return to the first transmission ratio probably with a risk of excess speed of the engine, or a simultaneous engagement of the two clutches, that is to say a brief situation of direct drive in the whole of the transmission with a risk of inadequate speed of the engine. In both cases, the passengers suffer shocks and the mechanics suffer shocks and useless stresses. Furthermore, these functional irregularities, if they were allowed to occur, would react on the functional parameters sensed by the unit 452 , and this would disturb the shifting process even more.
It can be seen from FIG. 6 that the detection by the unit 452 of the overall ratio of the transmission device R=V E /V S allows the control unit to know what transmission ratio is being produced at any time and, consequently, upon variation of that ratio, what ratio change is in progress.
Consequently, when starting from the second transmission ratio, corresponding to R=3, the flyweights 229 of the second epicylic train 207 begin to engage the clutch 218 , the unit 452 detects that it is a change from the second ratio to the third ratio, a change for which it will be necessary to synchronise the action of the two clutches.
FIG. 7 illustrates the process which is used to avoid the above-mentioned disadvantages, and more generally to produce a virtually perfect transition between the second and the third transmission ratios.
In the example of FIG. 7 there is again found the time T 1 starting from which the control unit 452 authorises the engagement of the second clutch 218 , the time T 2 starting from which this engagement begins to happen, and the time T 3 starting from which the control unit 452 , in this example integrating the progressiveness unit, excites the actuator 245 in a measured manner to prevent a too-rapid engagement of this clutch. The train of pulses is also applied to the actuator 145 , which application advantageously initiates disengagement of the clutch 118 .
In this example, more perfected than the one shown in FIG. 4, the control unit 152 continuously calculates the ratio R and adapts the excitation (width of pulses) of the actuator 245 such that R varies according to a law defined with respect to time, which has been previously loaded into a memory of the unit 452 . In FIG. 7, this predetermined law is illustrated by a curve shown in dotted and dashed line 402 . Several types of servo-control are possible. For example it is possible at each instant to calculate the error between the value of R and a command value at that instant. It is also possible at each instant to calculate the time derivative of R and to correct the excitation of the actuator 245 to attempt to bring this derivative back to a predetermined command value.
At an instant T 7 , the unit 452 detects that R has passed through a threshold R S , for example R S =2. At that instant, the unit 452 commands continuous excitation, at PW=100%, of the actuator 145 in order to disengage the clutch 118 of the first train 107 . The hydraulic pressure in the actuator 145 is illustrated by the diagram at the bottom of FIG. 7 . Consequently, the train 107 progressively changes from operation in direct drive to operation as a reduction gear, as illustrated by the diagram 403 at the top of FIG. 7, its transmission ratio therefore changes from 1.0 to 1.4. Even if the coming into action of the actuator 145 is relatively sudden, this does not produce any shock on the input shaft 2 a or on the output shaft 2 b since the regulation provided by the actuator 245 affects the overall ratio of the transmission. Consequently, as illustrated by the curve 404 at the top of FIG. 7, if the coming into action of the actuator 145 is sudden, the regulation carried out by the actuator 245 will cause a corresponding sudden decrease of the transmission ratio in the train 207 , such that the overall ratio continues to follow the ideal profile 402 quite closely.
Returning to FIG. 6, when the unit 452 detects a change from the first to the second ratio or from the third to the fourth ratio, for each of which there is an engagement of the clutch 118 without modification of the state of the clutch 218 , the actuator 145 can be controlled as described with reference to FIGS. 1 to 4 or in a more sophisticated manner such that the transmission ratio or its time derivative follows a predetermined law or command. The pulses, also applied to the clutch 218 have no effect on the latter since the resulting pressure in the actuator 245 is insufficient.
In the right hand section of FIG. 6 there has also been illustrated the situations in which the transmission device causes a change to a slower ratio. In this case, the actuators can be controlled as described in WO-97/08 478, whose content is integrated in the present application by way of reference.
With regard to the change from the third to the second ratio (the right hand section of FIG. 6 ), the latter is initiated spontaneously by a slipping of the clutch 218 or on the intervention of the unit 452 provoking this slipping by an appropriate excitation of the actuator 245 . Starting from a time T 8 corresponding to the passing of a threshold which can be the threshold R S as illustrated or a slightly different threshold, the unit 452 begins draining the actuator 145 . In this case, the method according to the invention can also be used, by maintaining, by means of width-modulated pulses, a measured resistance in the actuator 145 against the action of the spring R 1 .
The invention is not of course limited to the examplary embodiments described and shown.
The use of the invention is not necessarily coupled with other control functions of a transmission.
The invention is compatible with transmissions other than those actuated by centrifugal force and/or tooth reaction forces.
In an embodiment where it is necessary to modify simultaneously the state of two clutches such as 118 and 218 in FIG. 5, the invention could be applied only to the clutch which is subjected to the action of the force generator, for example such as described with reference to FIGS. 1 to 4 , and the progressiveness of the change of state of the other clutch could be regulated in another way, by using, in particular, the disclosures of WO-A-96/23 144 and of WO-A-97/08 478.
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The invention concerns a method for adjusting the smooth engagement of a gear ratio shift wherein a planetary train ( 7 ) is engaged in direct gear by the action of centrifugal counter-weights ( 29 ) locking a clutch ( 18 ). The clutch release can be derived either from a hydraulic actuator ( 18 ) or from axial reactive forces of the ring helical toothing, reaction which is transmitted by an axial stop (B 2 ). In order to prevent the clutch ( 18 ) from being suddenly locked by the action of the counter-weights ( 29 ) in particular when the torque to be transmitted quickly disappears, a control unit ( 453 ) detects the instantaneous ratio (V E /V S ), and generates measured back pressure in the actuator ( 45 ) while the counter-weights ( 29 ) are locking the clutch ( 18 ). The invention is useful for adjusting the smooth engagement of gear ratio shifts.
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BACKGROUND
[0001] This invention pertains to banking via mobile communication devices. More particularly, this invention pertains to acquiring check images necessary for remote deposit via smart phones and other mobile communication devices.
[0002] Banks are encouraging customers to take advantage of depositing checks remotely via computer. Such a deposit requires a digital image of the check be captured via digital camera, smart phones, and such like. In particular, many banks have developed applications that can be downloaded to a user's (customer) smart phone for securely capturing an image of the check and then depositing the funds into the user's account.
[0003] However, capturing a clean image of a check is not always a simple process. Many individuals can have problems maintaining enough steadiness to take a clean picture. For example, the elderly, individuals with Alzheimer's disease, Parkinson's, and other conditions that cause shakes and tremors, may have difficulty holding a smart phone steady at least part of the time. Others may just have difficulty holding a camera or smart phone steady enough to capture a clear image.
BRIEF SUMMARY
[0004] According to one embodiment of the present invention, a deposit kit for use with mobile computing devices is provided. The deposit kit includes a container having (1) a top, a bottom, and a back, and further includes two sides each adjoining to the top, the bottom, and the back, (2) at least one series of fasteners along back and the two sides at a specified distance from the bottom, (3) a tray supported by the fasteners, and including (a) a base, (b) a stencil, and (c) an opening within the stencil corresponding to specified check measurements, (4) an opening in the top sufficiently sized to correspond to a camera lens of a mobile device, and wherein the top includes outline markings for placement of the mobile device, whereby the mobile device is utilized for securing at least one check image for use in a mobile deposit application.
[0005] In one embodiment the mobile deposit application corresponds to a specified banking institution.
[0006] In another embodiment, the deposit kit includes a plurality of stencils for use with the tray. The plurality of stencils include an opening for at least one of a standard size personal check, a standard size business check and an oversized check.
[0007] The plurality of stencils include openings measuring at least: 6 inches by 2⅞ inches, 8⅝ inches by 3½ inches, and 8¾ inches by 3 3/10 inches.
[0008] In one embodiment, the mobile device is a smart phone.
[0009] In one embodiment, the deposit kit includes interconnection between the top, the bottom, the back, and the two sides so that the deposit kit unfolds into a flat assembly.
[0010] In one embodiment, the deposit kit includes an open front for inserting the tray.
[0011] Other systems, methods, features and advantages of the present invention will be or become apparent to one with skill in the art upon examination of the following drawings and detailed description. It is intended that all such additional systems, methods, features and advantages be included within this description and be within the scope of the present disclosure.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] The above-mentioned features will become more clearly understood from the following detailed description read together with the drawings in which:
[0013] FIG. 1 is a perspective view of a mobile deposit kit;
[0014] FIG. 2 is a perspective view of an alternative mobile deposit kit;
[0015] FIG. 3-A is a top view of the mobile deposit kit of FIG. 1 ;
[0016] FIG. 3-B is a top view of an alternative mobile deposit kit of FIG. 1 ;
[0017] FIG. 4 is a tray for placement of checks within the mobile deposit kit;
[0018] FIG. 5 is a base for use with a stencil to form the tray of FIG. 4 ;
[0019] FIG. 6-A is a stencil for placement of checks within the tray of the mobile deposit kit;
[0020] FIG. 6-B is another embodiment of a stencil for placement of checks within the tray of the mobile deposit kit; and
[0021] FIG. 6-C is another embodiment of a stencil for placement of checks within the tray of the mobile deposit kit;
[0022] FIG. 7-A is a front view illustrating the use of the mobile deposit kit with a smart phone;
[0023] FIG. 7-B is a front view illustrating a smart phone in place for the use of the mobile deposit kit;
[0024] FIG. 8-A is a front view illustrating an alternative embodiment of a mobile deposit kit;
[0025] FIG. 8-B is a side view of the alternative embodiment mobile deposit kit of FIG. 8-A ; and
[0026] FIG. 8-C is a front view illustrating another alternative embodiment of a mobile deposit kit.
DETAILED DESCRIPTION
[0027] A mobile deposit assistance kit, for acquiring check images via smart phones and other mobile communication devices for remote deposit into a user's (customer) bank account, is disclosed.
[0028] Banks are encouraging customers to take advantage of depositing checks remotely via computer. Such a deposit requires a digital image of the check be captured via digital camera, smart phones, and such like. In particular, many banks have developed applications that can be downloaded to a user's (customer) smart phone for securely capturing an image of the check and then depositing the funds into the user's account.
[0029] However, capturing a clean image of a check is not always a simple process. Many individuals can have problems maintaining the smart phone steady enough to take a clean picture. For example, the elderly, individuals with Alzheimer's disease, Parkinson's, and other conditions that affect steadiness of hand, may sometimes have difficulty holding a smart phone steady at least part of the time. Other's may just have difficulty holding a camera or smart phone steady enough for capturing a good image.
[0030] FIG. 1 is a perspective view of a mobile deposit kit 100 . In the illustrated embodiment, the mobile deposit kit 100 is a box type container that includes a top 110 , a bottom 120 , opposing sides 130 a , 130 b each attached to the top 110 , to the bottom 120 , and to a back 140 . Multiple type trays 150 are available for placement of a check within the mobile deposit kit 100 . Once a tray 150 enclosing a check is placed within the mobile deposit kit 100 , a smart phone is used to capture an image of the check. Each tray 150 includes an area for placement of the check so that the check is properly positioned within the viewfinder of the smart phone camera.
[0031] The mobile deposit kit 100 has the general shape of a box with an open front so as to create a drawer or closet type effect. In this way, the lighting is controlled primarily by the flash (or lack thereof) of the smart phone being utilized for capturing images. In one embodiment, the mobile deposit kit 100 is assembled from a lightweight plastic type material. The top 110 , bottom 120 , sides 130 a , 130 b , and back 140 are adjoined such that the back connects to both sides 130 a , 130 b , the top 110 , and the bottom. In the illustrated embodiment, the back 140 is the only piece that connects to each of the remaining portions (top 110 , bottom 120 , sides 130 a , 130 b , and back 140 ). The pieces are interconnected in a manner that provides for folding the mobile deposit kit 100 into a flat assemblage for ease of transport. It should be appreciated that the pieces of the mobile deposit kit 100 may be made from varying types of plastic, cardboard, lightweight wood, and varying lightweight metals and alloys. The top 110 , bottom 120 , sides 130 a , 130 b , and back 140 of the mobile deposit kit 100 may constructed from a single interconnected piece adjoined so that the mobile deposit kit 100 may be disassembled by folding. The mobile deposit kit 100 , may also be constructed from multiple pieces (top 110 , bottom 120 , sides 130 a , 130 b , and back 140 ) interconnected via various fastener and or hinge devices such as are know in the art.
[0032] The top 110 includes a pair of outlines 112 a , 112 b for placement of a smart phone, and an opening 114 for the camera lens of the smart phone. The opening is situated to accommodate a wide variety of smart phones, including iPhone ®, Motorola ®, Samsung ®, and LG ®, among many other available models. With the lens of a smart phone facing toward the opening 114 , the opening is situated near the center of the top 110 .
[0033] In the illustrated embodiment, the inside of both sides 130 a , 130 b are black or a suitably dark color. The inside of the top 110 , bottom 120 , and the back 140 are white or a suitable light color. It is expected that experimentation may produce other color combinations that provide good or desirable results for capturing the check images.
[0034] FIG. 2 is a perspective view of an alternative mobile deposit kit 100 that makes use of alternative type trays 158 a , 158 b , 158 c . The alternative trays 158 a , 158 b , 158 c of FIG. 2 have varying thicknesses and may be stacked in varying locations within the mobile deposit kit 100 to achieve the best results for clear focus and desired size of the image obtained.
[0035] FIG. 3-A is a view of the top 110 of the mobile deposit kit 100 and FIG. 3-B is a view of the top 110 ′ of an alternative mobile deposit kit 100 . The top 110 illustrated in FIG. 3-A includes a pair of outlines 112 a , 112 b for placement of a smart phone, and an opening 114 for the camera lens of the smart phone. The top 110 ′ illustrated in FIG. 3-B includes a pair of outlines 112 a ′, 112 b ′ for placement of a smart phone, and an opening 114 ′ for the camera lens of the respective smart phone. Both tops 110 , 110 ′ have an opening that is situated to accommodate a wide variety of smart phones, including iPhone ®, Motorola ®, Samsung ®, and LG ®, among many other available models. With the lens of a smart phone facing toward the respective opening 114 , 114 ′ the opening 114 , 114 ′ is situated near the center of the respective top 110 ′.
[0036] In FIG. 3-A , the outlines 112 a , 112 b , correspond roughly to the size of an iPhone 5 and other similarly sized smart phones. FIG. 3-B includes outlines 112 a ′, 112 b ′ that correspond roughly to the size of an iPhone 6 and other similarly sized smart phones that have a larger footprint. It should be appreciated that the size of the respective outlines 112 a , 112 b , and outlines 112 a ′, 112 b ′ are suggestive of the location for placing a smart phone to achieve an optimal image of a respective check. Larger or smaller smart phones may also be used with the mobile deposit kit 100 .
[0037] FIG. 4 is a tray 150 for placement of checks within the mobile deposit kit 100 and FIG. 5 is a base 156 for use with respective stencils to assemble the tray 150 . In the illustrated embodiment, the tray 150 includes a base 156 and one stencil (template) 152 ( 152 a , 152 b , or 152 c below). The respective stencil 152 rests on the base 156 for insertion into the mobile deposit kit 100 . As with the above pieces of the mobile deposit kit 100 , the base 156 in the illustrated embodiment is made from lightweight plastic, though other lightweight materials will also serve the purpose.
[0038] FIG. 6-A is a stencil 152 a for placement of checks within the tray of the mobile deposit kit 100 , FIG. 6-B is another embodiment of a stencil 152 b for placement of checks within the tray of the mobile deposit kit 100 , and FIG. 6-C is another embodiment of a stencil 152 c for placement of checks within the tray of the mobile deposit kit 100 .
[0039] The stencils 152 a , 152 b , 152 c (collectively 152 as noted above and in FIG. 4 ), represent varying size checks for which an image may be captured. In the illustrated embodiments, the stencil is black for best results. As noted above, it is expected that experimentation may produce other color combinations that provide good or desirable results for capturing the check images. Utilizing a stencil 152 provides for stabilizing the check with respect to the smart phone 10 , and also eliminates the need for moving the smart phone 10 back and forth toward and away from the check in an attempt to garner the entire check image at a desired size and focus.
[0040] In one embodiment, the stencil 152 a provides a check opening 154 a measuring 6″×2⅞″. Such an opening provides for sufficient space for most standard size personal checks used by individuals. The stencil 152 a is placed atop the base 156 to form a tray 150 , and so that a check within these measurements fits within the stencil and rests on the base. Utilizing a single base with each of the stencils 152 reduces cost of production and reduces the weight of the mobile deposit kit 100 . The assembled tray 150 is placed within the mobile deposit kit 100 at a desired height above the bottom 120 to provide for a clear image for capture by the smart phone 10 . It is generally expected that placing the tray 150 with the personal or standard stencil 152 a nearer the top 110 of the mobile deposit kit 100 will provide a better image of the check. However, the tray 150 may, of course, be placed at any available height according to the desired results.
[0041] In one embodiment, the stencil 152 b provides a check opening 154 b measuring 8⅝″×3½″. Such an opening provides for sufficient space for most business size checks. The stencil 152 b is placed atop the base 156 to form a tray 150 , and so that a check within these measurements fits within the stencil and rests on the base. The assembled tray 150 is placed within the mobile deposit kit 100 at a desired height above the bottom 120 to provide for a clear image for capture by the smart phone 10 . It is generally expected that placing the tray 150 with the business stencil 152 b nearer the middle or bottom 120 of the mobile deposit kit 100 will provide a better image of the check. However, the tray 150 may, of course, be placed at any available height according to the desired results.
[0042] In another embodiment, the stencil 152 c provides a check opening 154 c measuring 8¾″×3 3/10″. Such an opening provides for sufficient space for most remaining large or oversized checks. The stencil 152 c is placed atop the base 156 to form a tray 150 , and so that a check within these measurements fits within the stencil and rests on the base. The assembled tray 150 is placed within the mobile deposit kit 100 at a desired height above the bottom 120 to provide for a clear image for capture by the smart phone 10 . It is generally expected that placing the tray 150 with the oversized business stencil 152 c nearer the bottom 110 of the mobile deposit kit 100 will provide a better image of the check. However, the tray 150 may, of course, be placed at any available height according to the desired results.
[0043] FIG. 7-A is a front view illustrating the use of the mobile deposit kit 100 with a smart phone 10 , and FIG. 7-B is a front view illustrating the smart phone 10 in place for the use of the mobile deposit kit 100 . An endorsed check is placed with the stencil 152 of the tray 150 , and the assembled tray 150 is placed within the mobile deposit kit 100 at the desired distance above the bottom 120 and in view of the opening 114 . In some embodiments, it is desirous to capture images of both sides of the endorsed check. This is accomplished by simply turning the check over after capturing the image of the first side. The smart phone 10 is placed on the top 110 of the mobile deposit kit 100 according to one of the outlines 112 a , 112 b and with the camera lens aligned over the opening 114 . Once the tray 150 is in place with the check, the smart phone 10 mobile deposit application is utilized to capture the image or images necessary for deposit with the respective banking institution. The operation of the particular smart phone 10 mobile deposit application may vary according to the respective banking institution.
[0044] In the illustrated embodiment, the tray 150 rests on a series of brackets 132 extending around the sides 130 a , 130 b , and back 140 of the mobile deposit kit 100 . It should be appreciated that many type brackets, pegs, grooves, and other fasteners may be utilized for supporting the tray 150 within the mobile deposit kit 100 . Brackets 132 and other such fasteners are installed at various heights according to the desired results. In the illustrated embodiment, there are two levels of brackets 132 in addition to the bottom 120 of the mobile deposit kit 100 that may be used as available heights for the tray 150 .
[0045] After the tray 150 is situated within the mobile deposit kit 100 , the smart phone 10 application is opened and then utilized to enter the required information, capture the images of the check, and finalize the deposit. Of course, multiple check images may be captured in the same manner according to the situation. As above, the operation of the particular smart phone mobile deposit application may vary according to the respective banking institution. The user should consult with their respective banking institution for instructions regarding their particular mobile deposit application.
[0046] FIG. 8-A is a front view illustrating an alternative embodiment of a mobile deposit kit 100 and FIG. 8-B is a side view of the same alternative embodiment mobile deposit kit 100 . In the illustrated embodiment, the tray 150 is securable within grooves 160 a , 160 b , 160 c and grooves 162 a , 162 b , 162 c around the back 140 and respective sides 130 a , 130 b of the mobile deposit kit 100 . The tray 150 easily slides within the respective groove 160 a , 160 b , 160 c or 162 a , 162 b , 162 c . In this manner, the tray 150 is secure within the mobile deposit kit 100 and the chances for bumping the tray 150 out of the mobile deposit kit 100 while capturing the check images is reduced.
[0047] FIG. 8-C is a front view illustrating another alternative embodiment of a mobile deposit kit 100 . In the illustrated embodiment, the tray 150 is secured by bracket pegs 170 . The pegs 170 are inserted into holes at the desired tray elevations within the mobile deposit kit 100 and the tray rests upon the pegs 170 much like shelves within a cabiner.
[0048] Those skilled in the art will recognize that many type fasteners and brackets can be used to support the tray 150 without departing from the spirit and scope of the present invention.
[0049] From the foregoing description, it will be recognized by those skilled in the art that a mobile deposit kit 100 for securing a check within a tray 150 at a desired and stable height above the bottom 120 and below the opening 114 within the top 110 , and for securing a clear and in-focus image of the check image via a smart phone 10 mobile deposit application has been provided.
[0050] It should be emphasized that the above-described embodiments of the present disclosure are merely possible examples of implementations set forth for a clear understanding of the principles of the disclosure. Many variations and modifications may be made to the above-described embodiment(s) without departing substantially from the spirit and principles of the disclosure. All such modifications and variations are intended to be included herein within the scope of this disclosure and protected by the following claims.
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A mobile deposit kit for use with a mobile deposit application of a mobile device provides a container having (1) a top, a bottom, and a back, and further includes two sides each adjoining to the top, the bottom, and the back, (2) at least one series of fasteners along back and the two sides at a specified distance from the bottom, (3) a tray supported by the fasteners, and including (a) a base, (b) a stencil, and (c) an opening within the stencil corresponding to specified check measurements, (4) an opening in the top sufficiently sized to correspond to a camera lens of a mobile device, and wherein the top includes outline markings for placement of the mobile device, whereby the mobile device is utilized for securing at least one check image for use in a mobile deposit application.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Patent Application No. U.S. 62/333,812 titled MULTI-FUNCTION TRAVEL-FRIENDLY WORKSTATION WITH COOLING AND VENTILATION, filed May 9, 2016, the entire contents of which are hereby incorporated by reference herein.
BACKGROUND OF THE INVENTION
Field of the Invention
[0002] This invention relates to workstations. More particularly, this invention relates to collapsible space saving, multi-function travel-friendly workstation with cooling and ventilation for supporting electronic systems, written reading material and the like.
Prior Art
[0003] Mobility is ingrained in our lives and has become central to both individuals and businesses to the extent it has changed the way we interact with our surroundings, and particularly equipment and devices. There's no denying that the portability of laptops, as an alternative to bulkier, space consuming electronic systems such as desktop computers which required computer workstations having flat horizontal surfaces upon which a desktop computer is placed for work, have made life on-the-go a lot easier and have become an indispensable part of the human experience, and ultimately a part of the home and work life. Generally, workstations are not portable and occupy a lot of space, often within the confines of a room or building. The use of this space by a workstation prevents the use of such space for other purposes and limits the available workspace. In spite of their portability, laptops require the use of peripherals. However, the numerous peripherals a laptop user must carry can be a part time job trying to keep up while on-the-go.
[0004] U.S. Pat. No. 8,225,724 to O'Brien shows a portable folding workstation having closed and operating positions that can easily be installed or removed by one person without tools. The workstation has two walls that are hingedly connected to either side of an elongated member with a foldable work surface, the work surface being shaped to provide a continuous work surface when unfolded. The workstation also has one or more foldable shelves. All of the components of the workstation remain connected to the workstation in the closed position and in the operating position, and no assembly is required.
[0005] U.S. Pat. No. 6,053,588 to Biggel et al shows a workstation that has work surfaces and especially desk surfaces in a body which can be opened up. To attain a spacious interior, two opposing side walls are connected via hinges to a transverse wall to allow the body to be unfolded as a workplace with a large area.
[0006] U.S. Pat. No. 6,048,044 to Biggel et al shows a collapsible workstation, a system for providing a work environment for multiple users and a system and method for providing work environments at multiple and varying remote locations. A transporting means transports the workstations.
[0007] U.S. Pat. No. 5,584,546 to Robert N. Gurin, Cynthia S. Gurin shows a transportable office work station enclosure with door and retractable casters, adequate interior room to stow a chair when closed, a desktop that is a level, full size, load bearing, wheelchair-accessible work surface but incorporates a front section that is alternatively vertically adjustable for use with a keyboard, overhead storage for major computer components with an elevator for raising and lowering them to user height, internal plug-in outlets prewired to external connectors for phone and power hookups, and interior cabinets for storage.
[0008] U.S. Pat. No. 5,607,214 to Pierce et al shows an improved portable workstation or office that is storable within a transportable trunk-like enclosure which functions as part of the workstation when in an open position and permits other office fixtures as stored in the enclosure to be opened outwardly or extended from the open enclosure to define an office-like workstation. A height-adjustable braking roller assembly mounted on a lower free corner of a door is adapted for load-bearing engagement with a floor.
[0009] U.S. Pat. No. 5,803,562 to Jacobs et al shows an improved self-contained portable workstation that is storable within a transportable trunk-like enclosure having covers and doors that open to stably support and function as part of the workstation when in an open position.
[0010] U.S. Pat. No. 6,578,708 to Barnett shows a suitcase-like portable laptop workstation that combines a carrying case and workstation for computer components and can be folded and transported as a carry-on luggage for aircraft in a retracted position. In workstation mode, shells extend perpendicularly from the stand in order to hold the laptop on a flat surface.
[0011] U.S. Pat. No. 8,172,077 to Gray shows a suitcase-like portable workstation. The unit includes a first half-shell pivotally connected to a second half-shell, each half shell having a rectangular portion. The first half-shell includes a cylindrical rod attached to a tripod, as well as an extension portion of the cylindrical rod with corresponding fastener openings so that a fastener device secures the portable container to the cylindrical rod. The portable container is rotatable upon the cylindrical rod.
[0012] U.S. Pat. No. 8,459,734 to Herschler shows an equipment case, briefcase sized or larger, for carrying a laptop computer or other equipment, that opens and separates into two compartments, one forming a seat, the other a table; said equipment case as seat and table stabilized by their coupling.
[0013] U.S. Pat. No. 7,314,248 to Mabon et al shows an enhanced version of a collapsible portable workstation apparatus having a scissors linkage lift mechanism allowing adjustment of the seating height, a collapsible frame, wheels, a seat, and work surface, whereby collapsing the frame and manipulating an articulated work surface attachment, permits the apparatus to be utilized as a hand truck.
[0014] U.S. Pat. No. 6,604,720 to Wilson shows a portable laptop computer work station comprising a first work space that includes a planar table of rectangular cross section having upper and lower surfaces. The upper surface receives a laptop computer and terminates in a lip along one of the long sides of the table. The lower surface is fitted as a Tee-shaped receiver having a pair of longitudinal legs parallel to the lip at the upper surface and a transverse leg normal to the lip. The planar table is threadably attached at its lower surface to a receiver pad of a conventional camera tripod and provides for additional work spaces to be mechanically supported via the Tee-shaped receiver.
[0015] U.S. Pat. No. 6,604,783 to Goodson shows a chair-like collapsible workstation that includes a seat and table. The table is connected to the seat and defines a working surface adapted for supporting articles above the lap of a user in an in-use position spaced apart from the seat. The table is movable from the in-use position to a non-use collapsed position adjacent the seat for storage and transport. An elongated connecting arm interconnects the seat and the table to enable movement of the table between the in-use position and the non-use collapsed position.
[0016] U.S. Pat. No. 6,098,936 to Birrell shows a portable ergonomic work station that allows for convenient computer component placement for an individual in a non-conventional work environment. The work station includes multiple adjustable support elements that can independently support the computer components including the keyboard, video monitor and CPU. The work station can be adjusted to position a pair of support arms on which the components are placed to be accessible to the user in a reclining chair or other non-conventional work environment.
[0017] U.S. Pat. No. 7,870,937 to Arnao shows a combination computer workstation, cosmetic desk, casual/open tote and luggage set device. The device is easily transported and the area to push or pull luggage may be expanded to stow various pieces of luggage. Luggage may be partially filled yet secured by the divider device.
[0018] U.S. Pat. No. 5,529,322 to Barton shows a combination transport device and portable work surface having a collapsible support member and base member. Essentially, it features a suitcase with wheels that can be configured into a workstation.
[0019] PCT International Application PCT/US1999/012546 Publication No. WO 1999062375 to Holbrook et al shows a height adjustable workstation which includes a vertical column adapted to be supported on a floor; a height adjustment mechanism adapted to travel up and down the height of the column and to be fixed at desired heights; and a horizontal work surface having a rear edge and a front edge, the work surface attached to the height adjustment mechanism so that the column is adjacent a point generally midway along the rear edge of the work surface. The workstation preferably includes a counterbalance system.
[0020] The comfort and well-being of users of workstations are concerns of much importance. While the prior art has attempted to provide portable workstations that can safely be set up or taken down, they fail to resolve major heating problems associated with electronic systems such as laptops, and positioning that permit user adjustments which ergonomically support healthy body postures that alleviate wrist, arm, neck and back pain while sitting or standing, especially for those who have to use them every day. Current workstations can only be used while sitting.
[0021] Further, they are not space saving, and too bulky to fit into a backpack, purse or overnighter, and are not suitable for traveling business men and women or people on-the-go. Also, current workstations cannot be used in their folded or collapsed state, even briefly at the airport while waiting to board a plane, or while one is constantly on-the-go for business trips or for presentations. Further, they do not adequately address the sources and causes of the above described user problems. Thus, it is apparent that there exists a need for an ergonomically designed space saving, safe and easily portable, reasonably equipped, small office or collapsible multi-function travel-friendly modular workstation that compactly folds easily, can be set up or deployed instantly without the use of tools, can be used while standing or sitting or on-the-go, provide needed cooling and ventilation for electronic devices, support healthy postures that alleviate wrist, arm, neck and back pain, collapses and stores wherever and whenever it is needed such as at home, at the office, at the airport, on business trips, for presentations, support of written reading material, or use anywhere while on-the-go, or just stored in a backpack, a purse or an overnighter, and fits in anywhere, anytime. The present invention is directed toward providing such a workstation that is nonconventional, yet handy!
SUMMARY OF THE INVENTION
[0022] The collapsible space saving, multi-function travel-friendly workstation of the present invention provides a versatile workspace to a user in many different environments. The invention comprises three sub-assembly modules: a support unit, a telescopic rod and a tripod. Each sub-assembly comprises pre-equipped mating connectors. The three sub-assemblies are detachably coupled together via their pre-equipped mating connectors: the support unit detachably mounted on the telescopic rod, and the telescopic rod detachably mounted on the tripod. The invention supports a broad range of electronic systems, reading materials and the like which are to be held in a convenient position in a variety of environments for everyday use by individuals of every age with a view of ease of transportation, set up, provision of cooling and ventilation, comfortable usage while standing or sitting, storage and support of healthy postures that alleviates wrist, arm, neck and back pain while being used, and fitting in anywhere, anytime. Everyday use is myriad and not limited to note taking, writing, reading, presentations, performing arts and rehearsing while playing a musical instrument, or serve as a traveling music or conductor stand, or staying connected.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] FIG. 1 shows a perspective view of an exemplary deployed multi-function workstation in a standing position according to an embodiment of the present invention;
[0024] FIG. 2 shows a perspective view of FIG. 1 in a sitting position;
[0025] FIG. 3 shows a right side view of the deployed multi-function workstation of FIG. 2 ;
[0026] FIG. 4 shows a left side view of the deployed multi-function workstation of FIG. 2 ;
[0027] FIG. 5 shows a perspective view of an exemplary collapsed multi-function workstation for storage or transportation according to an embodiment of the present invention;
[0028] FIG. 6A shows another perspective view of the collapsed multi-function workstation of FIG. 5 ;
[0029] FIG. 6B shows a section of first and second group of elliptically shaped ventilation cooling holes of the multi-function workstation of FIG. 5 according to an embodiment of the present invention;
[0030] FIG. 7 shows a partial exploded perspective view of a collapsed multi-function workstation according to an embodiment of the present invention;
[0031] FIG. 8 shows a perspective view of an exemplary deployed support unit according to an embodiment of the present invention;
[0032] FIG. 9A shows a partial exploded perspective view of FIG. 8 ;
[0033] FIG. 9B shows another partial exploded perspective view of FIG. 8 ;
[0034] FIG. 9C shows an exploded perspective view of FIG. 8 showing the annular snap cavity;
[0035] FIG. 10A shows an exemplary right side view of the upper housing of the support unit according to the present invention;
[0036] FIG. 10B shows an exemplary right side view of the anti-skid mechanism of the support unit according to the present invention;
[0037] FIG. 10C shows an exemplary right side view of the lower housing of the support unit according to the present invention;
[0038] FIG. 10D shows a section view of showing the annular snap cavity in the lower housing of the support unit according to the present invention;
[0039] FIG. 11A shows an exemplary four-bar self-locking tilt mechanism of the support unit with the upper housing angularly oriented at 15° to the lower housing according to the present invention;
[0040] FIG. 11B shows the exemplary four-bar self-locking tilt mechanism of FIG. 11A with the upper housing angularly oriented at 75° to the lower housing according to the present invention;
[0041] FIG. 12A shows an exemplary pawl link according to the present invention;
[0042] FIG. 12B shows an exemplary ratchet hub link according to the present invention;
[0043] FIG. 13A shows an exemplary pawl link head according to the present invention;
[0044] FIG. 13B shows an exemplary ratchet hub link head according to the present invention;
[0045] FIG. 14A shows an exemplary interactive pawls-ratchet pair relationship between the pawls, ratchet and pawl spring according to the present invention;
[0046] FIG. 14B shows an exemplary self-locking pawl-ratchet pair mechanism of FIG. 14A ;
[0047] FIG. 14C shows another alternate self-locking pawl-ratchet pair mechanism of FIG. 14A ;
[0048] FIG. 15 shows an alternate four-bar self-locking tilt mechanism of the support unit according to the present invention;
[0049] FIG. 16A shows an exemplary six-bar linkage self-locking tilt mechanism showing the upper housing having a planar end flange according to the present invention;
[0050] FIG. 16B shows a right side view of a collapsed support unit having the six-bar linkage self-locking tilt mechanism of FIG. 16A ;
[0051] FIG. 16C shows a back view of FIG. 16B showing the planar end flange;
[0052] FIG. 17 shows an exemplary gas spring self-locking tilt mechanism;
[0053] FIG. 18 shows an exemplary support unit with no retractable mouse pad;
[0054] FIG. 19A shows a perspective view of an exemplary embodiment of a partially deployed telescopic rod according to the present invention;
[0055] FIG. 19B shows a perspective view of an exemplary embodiment of a collapsed telescopic rod according to the present invention;
[0056] FIG. 20 shows an exploded perspective view of an exemplary embodiment of a telescopic rod revealing the major elements of a positive locking mechanism and a view of the top portion of the base telescoping member recess for receiving a positive locking mechanism as viewed by the reference arrow A according to the present invention;
[0057] FIG. 21 shows side and front views of an exemplary embodiment of a partially deployed telescopic rod, a cross-sectional view of an exemplary discontinuous annular snap-fit protrusion of the top telescoping member as viewed along reference line B-B and a cross-sectional view of an exemplary positive locking mechanism as viewed along reference line C-C according to the present invention;
[0058] FIG. 22 shows an exemplary embodiment of a cross-sectional view of a releasable annular snap joint lock according to the present invention;
[0059] FIG. 23 shows an exploded perspective view of an exemplary embodiment of a tripod according to the present invention;
[0060] FIG. 24 shows a cut-away perspective and side views of embodiments of the free end of leg element 183 exposing an exemplary swivel caster wheel assembly in deployed and collapsed positions according to the present invention;
[0061] FIG. 25 shows a perspective view of an exemplary embodiment of a deployed tripod showing an extended leg element 183 of telescopic leg assembly 177 with non-deployed swivel wheel according to the present invention;
[0062] FIG. 26 shows a perspective view of FIG. 25 showing a collapsed leg element 183 of telescopic leg assembly 177 with non-deployed swivel wheel according to the present invention;
[0063] FIG. 27 shows a perspective view of FIG. 26 showing a deployed swivel wheel assembly according to the present invention;
[0064] FIG. 28 shows a side view of an embodiment of a collapsed tripod according to the present invention;
[0065] FIG. 29A shows a perspective view of a cut away section of an exemplary circular tubular housing of the stationary leg assembly to expose first and second inverted U-shaped notches according to the present invention;
[0066] FIG. 29B show a perspective left and right views of a cut away section of an exemplary tubular barrel cam of the first moveable leg assembly to expose the first cam track, third inverted U-shaped notch, and a bottom view of the first tubular connector according to the present invention;
[0067] FIG. 29C show a perspective view of a cut away section of an exemplary tubular barrel cam of the second moveable leg assembly to expose the second cam track, and a bottom view of the second tubular connector according to the present invention;
[0068] FIG. 30 shows an alternate perspective view of an exemplary embodiment of a deployed tripod with non-deployed swivel wheel according to the present invention;
[0069] FIG. 31 shows the tripod of FIG. 30 with deployed swivel wheel according to the present invention;
[0070] FIG. 32 shows a collapsed tripod of FIG. 30 according to the present invention;
[0071] FIG. 33A shows a perspective view of an alternative embodiment of a collapsed multi-function workstation;
[0072] FIG. 33B shows a right side view of FIG. 33A ;
[0073] FIG. 34A shows a perspective view of an exemplary deployed support unit according to an embodiment of FIG. 33A ;
[0074] FIG. 34B shows the four-bar self-locking tilt mechanism of the support unit of FIG. 34A ;
[0075] The exemplary embodiments set forth in the drawings are illustrative in nature and not intended to be limiting of the invention. Moreover, individual features of the drawings and the invention will be more fully apparent and understood in view of the detailed description.
DETAILED DESCRIPTION OF THE INVENTION
[0076] The summary of the invention does not necessarily describe all necessary features of the present invention. The embodiments of the present disclosure will best be understood by reference to the drawings. These drawings are provided for illustration purposes only and merely depict typical or example embodiments of the invention and to facilitate the reader's understanding of the invention. It will be readily understood that the components of the present disclosure, as generally described and illustrated in the drawings herein, could be arranged and designed in a wide variety of different configurations. It is also understood that the elements or components of the present invention may comprise any shape, length, and/or configuration and that the shapes, lengths, and/or configurations described and shown herein are for illustrations purposes only, and not a limitation. Thus, the following more detailed description of the embodiments of the invention is not intended to limit the scope of the disclosure or its applicability, but is merely representative of possible embodiments of the disclosure. It should be noted that for clarity and ease of illustration these drawings are not necessarily made to scale, the emphasis being placed upon clearly illustrating the principles of the present invention. In some cases, well-known structures, materials, or operations are not shown or described in detail. Also, certain features of illustrated embodiments have been enlarged or distorted relative to others to facilitate visualization and clear understanding. In particular, thin features may, for example, be thickened for clarity or illustration.
[0077] As used herein, the term electronic system can refer to any of a number of configurations of portable electronic devices including laptop computers, gaming laptops, tablets, laptop-tablet hybrids, notebook computers and other electronic devices or systems. Also, the term reading material can refer to any of a number of configurations of reading material such as books, magazines, loose sheets or sheet-like material and other similar articles. As used herein, any term in the singular may be interpreted to be in the plural. Alternatively, any term in the plural may be interpreted to be in the singular. The singular and plural terms may be used interchangeably.
[0078] Also, it should also be understood that, unless expressly defined in this provisional patent using the sentence “As used herein, the term ‘______’ is hereby defined to mean . . . ” or a similar sentence, there is no intent to limit the meaning of a term, either expressly or by implication, beyond its plain or ordinary meaning. As such the term should not be interpreted to be limited in scope based on any statement made in any section of this non-provisional patent (other than the language of the claim of the invention).
[0079] The following text provides a broad description of numerous different embodiments of the present invention that should be construed as exemplary only and does not describe every possible embodiment since it would be impractical to describe every possible embodiment, if not impossible. It should be understood that any feature, characteristic, component, product, step or methodology described herein can be deleted, combined with or substituted for, in whole or part, any other feature, characteristic, component, product, step or methodology described herein. Further, numerous alternative embodiments could be implemented, using either current technology or technology developed after the filing date of this non-provisional patent, which would still fall within the scope of the claims of this invention.
[0080] Referring to FIGS. 1-4 , an exemplary embodiment of a deployed multi-function workstation with cooling and ventilation of the present invention is generally shown as 1 . Multi-function workstation with cooling and ventilation 1 (“workstation 1 ”) may comprise a support unit assembly 2 (“support unit 2 ”) pre-equipped with a mating connector, a telescopic rod assembly 3 (“telescopic rod 3 ”) pre-equipped with a mating connectors, and a tripod assembly 4 (“tripod 4 ”) pre-equipped with a mating connector. Workstation 1 is modular in design such that support unit 2 , telescopic rod 3 , and tripod 4 are detachably connected to each other, via their pre-equipped mating connectors, permitting multiple configurations/design changes and or component replacement without having to do a complete re-design of its entire configuration and/or components with every design change ( FIGS. 1-4 ). In this exemplary embodiment, support unit 2 is detachably mounted on telescopic rod 3 via their pre-equipped mating connectors, and telescopic rod 3 is detachably mounted on the tripod 4 via their pre-equipped mating connector. Support unit 2 , telescopic rod 3 and tripod 4 have pre-equipped mating connectors. Further, the modular design permits an individual modular unit to be used as a standalone device. For example, the support unit 2 may be used as a standalone laptop stand that may be placed on a user's lap, on a surface such as a table top, etc, or may be used coupled as shown in FIG. 1 . Telescopic rod 3 may be used as a standalone fishing rod. Telescopic rod 3 may also be detachably connected to tripod 4 and used as a camera support device by connecting a camera mount, to the upper end of telescopic rod 3 to which a camera may be secured, the camera mount having a means for rotating the camera about the vertical axis of said telescopic rod 3 , and about a horizontal axis for tilting a camera attached to the mount. The camera mount may also be stored in the support unit when not in use. Workstation 1 may be used for supporting an electronic device of any suitable variety or reading material, and may be adjusted for height and comfortable use while standing or sitting. It should be appreciated that workstation 1 may have different configurations and may be configured in a variety of sizes depending on the size and dimensions of the electronic device or reading material with which workstation 1 is to be used and/or on user preferences.
[0081] Referring to FIGS. 5-7 , workstation 1 may be collapsed for storage or put away when not in use or transported in a purse, suitcase, laptop bag, backpack, carry-on luggage for aircraft or an overnighter for easy travel. In order to transport workstation 1 , telescopic rod 3 and tripod 4 and/or other peripherals may be collapsed, stored and secured in form-fitted storage cavities 56 within support unit 2 . In this way storage is provided for the respective components or component assemblies and/other peripherals in the collapsed configuration of support unit 2 . Thus, workstation 1 is a sleek, slim and lightweight easy to transport, setup and store, perfect work and travel friendly space saving companion for any person to enjoy all the benefits of the ergonomic comfort of a permanent workstation regardless of locale or while traveling or on-the-go.
[0082] Referring to FIGS. 8-10 , support unit 2 may comprise upper housing 5 , lower housing 6 , anti-skid mechanism 7 , hinge mechanism 8 , self-locking tilt mechanism 9 , cooling and ventilation system 10 , retractable mouse pad 11 , power management system 12 and cable management system 13 (not shown). One or more of the components of support unit 2 may be modular in design (e.g. power management block 12 ) such that they may be removably connected to support unit 2 , permitting multiple configurations/design changes and or component replacement without having to do a complete re-design of its entire configuration and/or components with every design change. Also, upper housing 5 , lower housing 6 and anti-skid mechanism 7 provide an aesthetic appearance. As such, upper and lower housings 5 and 6 , and anti-skid mechanism 7 permit the outer appearance (e.g., color, shape, etc.) of support unit 2 to be simply and efficiently changed without having to change its function. In addition, upper and lower housings 5 and 6 provide protection to self-locking tilt mechanism 9 , cooling fans 104 , retractable mouse pad 11 , power management block 12 and cable management system 13 from foreign elements that may cause damage, etc.
[0083] With continued reference to FIGS. 8-10 , upper housing 5 may comprise front and back ends 14 and 15 , opposite side walls 16 and 17 , top and bottom surfaces 18 and 19 , first and second group ventilation cooling holes 20 and 21 (“cooling holes 20 ” and “cooling holes 21 ”), and end flange 22 . Opposite side walls 16 and 17 may be rigidly attached to or integrally formed with upper housing 5 . Front 14 end positions adjacent to a user. Front end 14 , opposite side walls 16 and 17 , bottom surface 19 , and the end flange 22 together define a trough-like or open interior cavity 23 (“cavity 23 ”). Cavity 23 houses grated fan cover 108 within which cooling fans 104 are biased. As shown in FIGS. 9A-9C and 10A , front end 14 of upper housing 5 terminates in hinge arms 24 comprising central aperture 28 through which hinge mechanism 8 (or hinge or pivot pin) can be passed. Optionally, front end 14 may comprise a hinge end. In the embodiment of FIG. 10A , each hinge arm 24 may further comprise rim-like outer ring 25 integrally connected by a plurality of radial spokes 26 to hub-like inner ring 27 comprising said central aperture 28 . In the exemplary embodiment of FIG. 10A , end flange 22 has a partial S-shape and is rigidly attached to bottom surface 19 proximate the end of back end 15 of upper housing 5 . Thus, back end 15 of upper housing 5 takes the form and shape of a grip (or gripping area) 29 that accommodates at least a portion of several fingers of the hand as shown in FIG. 6 . End flange 22 has cut-out 30 configured to fit the top portion of power block 110 . It is understood that end flange 22 may have a variety of shapes and curvatures and thus gripping area 29 accordingly. Upper housing 5 may be angularly oriented or tilted by holding grip 29 and pulling upper housing 5 upward in a counterclockwise direction. In another exemplary embodiment, end flange 22 may be rigidly attached or integrally formed with bottom surface 19 of upper housing 5 . Gripping area 29 spans the entire width of upper housing 5 .
[0084] With continued reference to FIGS. 8-10 , top surface 18 of upper housing 5 may comprise recess 31 that nests retaining platform 62 of anti-skid mechanism 7 such that the top surface of retaining platform 62 is flush with top surface 18 of upper housing 5 when collapsed, FIGS. 5-6 . Opposite side walls 16 and 17 of upper housing 5 may comprise a wedge-shaped configuration that may comprise respectively wedge-shaped recesses 32 , 33 . Pivot hole pair 34 for receiving pivot pins 35 are biased on opposite side walls 16 and 17 of upper housing 5 as shown in FIGS. 9A-9C and 10A . Optionally, side walls 16 and 17 may comprise vents/slots that are in fluid communication with cavity 23 of upper housing 5 to allow ejected hot air sucked from the base of an electronic system by cooling fans 104 escapes through them into the atmosphere. Upper housing 5 comprises through slot 37 which is located within end flange 22 and within gripping area 29 as shown in FIGS. 9B, 9C and 10A , and configured to receive press button 89 for disengaging pawls 74 from ratchet teeth 84 of self-locking tilt mechanism 9 .
[0085] With continued reference to FIGS. 8-9 , cooling holes 20 are biased in a first region such that they are in fluid communication with cavity 23 of upper housing 5 , the cooling holes 20 being spaced apart according to a uniform geometric pattern and density, FIG. 6B . The first region includes all regions outside the location of cooling fans 104 . Upper housing 5 may also comprise a second group of elliptically shaped through ventilation cooling holes 21 that are biased in a second region such that they are in fluid communication with the cavity 23 of upper housing 5 as well as cooling fans 104 , the cooling holes 21 being spaced apart according to a uniform geometric pattern and density. Each cooling hole 21 in the second group is preferably perpendicularly orientated relative to its neighbor in the horizontal plane as shown in FIG. 6B . Such geometric arrangements promote improved cooling airflow and increase cooling air flow effectiveness to eliminate the uneven temperature distributions or undesirable temperature levels.
[0086] With continued reference to FIGS. 9 and 10 , lower housing 6 comprises front and back ends 38 and 39 , opposite side walls 40 and 41 , inner bottom and bottom surfaces 42 and 43 , and bottom portion 44 . Front end 38 for positioning adjacent to a user. Opposite side walls 40 and 41 may be rigidly attached to or integrally formed with lower housing 6 . Front end 37 , opposite side walls 40 and 41 , inner bottom surface 42 , and power block 110 together define a trough-like or open interior cavity 45 (“cavity 45 ”). Without power block 110 , cavity 45 is open at back end 39 . Optionally, back end 39 is not open. As shown in FIGS. 9A-9C and 10C , front end 38 of lower housing 6 has the shape of a truncated wedge which terminates in hinge arms 46 comprising central aperture 50 through which hinge mechanism 8 (or hinge or pivot pin) can be passed. Optionally, the front end may comprise a hinge end. In the embodiment of FIG. 10C , each hinge arm 46 may further comprise rim-like outer ring 47 integrally connected by a plurality of radial spokes 48 to hub-like inner ring 49 comprising said central aperture 50 as shown in FIG. 10C .
[0087] With continued reference to FIGS. 9 and 10 , opposite side walls 40 and 41 of lower housing 6 may comprise a wedge-shaped configuration that may respectively comprise wedge-shaped recesses 51 , 52 . Pivot hole pair 53 for receiving pivot pins 54 are biased on opposite side walls 40 and 41 of lower housing 6 as shown in FIGS. 9A-9C and 10C . Opposite side walls 40 and 41 comprise vents/slots 55 that are in fluid communication with cavity 45 of lower housing 6 such that ejected hot air sucked from the base of an electronic system by cooling fans 104 escapes through them into the atmosphere. In one embodiment, the vents may be louvered vents, or the slots may have fins. The vents/slots 55 define the greater portion of the length of opposite side walls 40 and 41 of lower housing 6 . As shown in FIGS. 9A and 9B , cavity 45 may have several form-fitted storage cavities 56 for components, component assemblies and/or other peripherals depending on user preferences. It should be understood that any number of form-fitted storage cavities 56 may be defined within cavity 45 of lower housing 6 for storing any number of components or products depending on preferences. In some embodiments an insert or tray comprising a plurality of sections that are form-fitted openings for component assemblies such as telescopic rod 3 , tripod 4 and/or other peripherals of use may be situated within lower housing 6 so that the components or products are secured in position within the sections when support unit 2 is closed.
[0088] With continued reference to FIGS. 9-10 , back end 39 of lower housing 6 may comprise recess (or cutout) 57 configured to receive power management block 12 . As shown in FIG. 10C , bottom portion 44 of lower housing 6 may comprise through slot 58 (“slot 58 ”) spanning the entire width of lower housing 6 (from left to right) configured to receive retractable mouse pad 11 . Alternatively, bottom portion 44 may have a pocket, a recess or an opening configured to receive retractable mouse pad 11 . As shown in FIG. 10C , projection 59 inside slot 58 engages with shallow slot 127 in the bottom surface of retractable mouse pad 11 . Projection 59 guides retractable mouse pad 11 . Projection 59 also acts as a stop to prevent retractable mouse pad 11 completely detaching from or falling out of the slot 58 when retractable mouse pad 11 slides in and out of slot 58 . As shown in FIGS. 9C and 10D , annular snap-fit cavity 60 integrally formed within a shallow hollow region extending from bottom surface 43 inward into projection 59 of lower housing 6 is configured to receive snap fit connector 146 of telescopic rod 3 so that support unit 2 and telescopic rod 3 are in fluid communication. As shown in FIGS. 1-4 , snap-fit cavity 60 is biased in lower housing 6 such that it will not tip over when removably connected to snap-fit connector 146 while upper housing 5 is deployed at an angle greater than 0 degree but less or equal to 75 degrees, whether in a sitting or standing position, support unit 2 . Alternatively, the shallow hollow region of support unit 2 may be adapted for fitting an adapter attachment that may comprise a snap-fit cavity or some other appropriate adapter device attachment such that the adapter attachment will establish fluid communication between support unit 2 and telescopic rod 3 . Further appropriate locking mechanisms for locking the adapter device attachment onto telescopic rod 3 end and then connecting telescoping rod 3 to support unit 2 are provided. Snap-fit cavity 60 or other adapter device attachment serves as a pre-equipped mating connector for support unit 2 . Alternatively, bottom portion 44 may comprise a detachable modular unit that is configured to house mouse pad 11 and snap-fit cavity 60 or other adapter device attachment.
[0089] Referring to FIGS. 8-10 anti-skid mechanism 7 may comprise a substantially planar retaining platform 62 comprising a front end for positioning adjacent to a user, a back end opposite said front end, top and bottom surfaces, and opposite side ends. The front end of said retaining platform 62 terminates in hinge arms 63 comprising a central aperture 67 through which hinge mechanism 8 (or hinge or pivot pin) can be passed while the other back end is free. Optionally, the front end may comprise a hinge end. In the embodiment of FIG. 10B , each hinge arm 63 may further comprise rim-like outer ring 64 integrally connected by a plurality of radial spokes 65 to hub-like inner ring 66 comprising said central aperture 67 . As shown FIG. 10B , anti-skid mechanism 7 is whistle-shaped when viewed from the right side. In operation, anti-skid mechanism 7 is pivotally movable between collapsed and deployed positions and prevents an electronic system or reading material on top surface 18 of upper housing 5 from sliding, slipping or falling. Further, in operation, anti-skid mechanism 7 has two lock positions: a deployed-lock position which is a position when platform 62 is at 90 degrees relative to top surface 18 of upper housing 5 , and a collapsed-lock position which is a position when platform 62 is at 0 (zero) degrees relative to, and substantially parallel to top surface 18 of upper housing 5 as shown in FIGS. 5 and 6 . In the collapsed-lock position, anti-skid mechanism 7 nests in recess 31 such that its top surface is flush with top surface 18 of upper housing 5 as shown in FIGS. 5 and 6 . In the deployed-lock position, anti-skid mechanism 7 rotates counterclockwise away from upper housing 5 , outwardly projects at 90 degrees relative to and substantially perpendicular to top surface 18 of upper housing 5 such that platform 62 and upper housing 5 form an L-shape as shown in FIG. 8 . In the embodiment of FIG. 8 , anti-skid mechanism 7 spans the entire width (left to right) of upper housing 5 as shown in FIG. 5 . In addition to anti-skid mechanism 7 , a skid or slip resistant material may be applied to top surface 18 of upper housing 5 to prevent sliding of an electronic system or reading material that may be resting on top surface 18 of upper housing 5 . Further, anti-skid mechanism 7 may be configured with various other changes and modifications without departing from the spirit and scope of the invention. In the deployed position, anti-skid mechanism 7 provides an ergonomic wrist support for and prevents an electronic system or reading material from sliding or falling along top surface 18 of upper housing while being used by a user.
[0090] Upper housing 5 , lower housing 6 and antiskid mechanism 7 are hinge or pivotally connected, via hinge arms 24 , 46 and 63 by hinge mechanism 8 . The hinge mounting allows upper housing 5 to be adjustable and tilted pivotally between collapsed and deployed positions as shown in FIGS. 5 and 8 . In the collapsed position, the top surface 18 of upper housing 5 is substantially parallel to bottom surface 43 of lower housing 6 . In the deployed position, top surface 18 of upper housing may angularly be oriented at an angle of φ relative to bottom surface 43 of lower housing 6 , where φ>0°. In the embodiment of FIG. 12 , 0°≦φ≦75° (i.e. φ is from 0 to 75 degrees). The angular orientation of upper housing 5 is user selected for comfortable viewing of (1) the screen of an electronic system, or (2) reading material, or (3) for working, by a user.
[0091] Referring to FIG. 9 of the exemplary embodiments of support unit 2 , hinge mechanism 8 may comprise a hinge or pivot pin mounted in central apertures 28 , 50 and 67 respectively of upper housing 5 , lower housing 6 and anti-skid mechanism 7 . Alternately, hinge mechanism 8 may be a hinge apparatus which interconnects upper housing 5 , lower housing 6 , and anti-skid mechanism 7 in such a manner that upper housing 5 is capable of rotating toward or away from lower housing 6 ; anti-skid mechanism 7 is capable of rotating toward or away from upper housing 5 . A further alternate embodiment of hinge mechanism 8 may comprise two separate hinge mechanisms, one interconnecting or coupling upper and lower housings 5 and 6 , the second interconnecting or coupling upper housing and anti-skid mechanism 5 and 7 .
[0092] Referring to FIG. 11 , an exemplary embodiment of a self-locking tilt mechanism configured to angularly orient upper housing 5 relative to lower housing 6 from a collapsed substantially horizontal position to any angular position or from one angular position to another angular position or from any angular position to a horizontal position is generally shown as 9 . Self-locking tilt mechanism 9 may comprise tilt mechanism 78 A and self-locking mechanism 78 B. Tilt mechanism 78 A comprises four-bar linkage 79 , actuator 85 , and press-to-release mechanism 88 . Four-bar linkage 79 comprises a first link being pivotally connected to a second link at a first connection point, the second link being pivotally connected to a third link at a second connection point, the third link being pivotally connected to a fourth at a third connection point, the fourth link being pivotally connected to said first link at a fourth connection point, such that the four links form four connection joints with a predetermined one degree of freedom. Further, the four-bar linkage includes a drive link and a link which maintains a substantially fixed attitude relative to the other links in space during movement. The four-bar linkage herein referred to is a locked chain linkage with four links, each link being binary, is pivotally connected to the other in a selected manner to have a predetermined one degree of freedom and four joints. In the exemplary embodiment of self-locking tilt mechanism 9 shown, a four-bar chain linkage is formed by taking upper and lower housings 5 and 6 as a links housing, and combining them with two binary links comprising pawl link 68 and ratchet hub link 80 . In the exemplary embodiment of self-locking tilt mechanism 9 shown in FIG. 11 , upper housing 5 being a drive link (first link) pivotally connects to lower housing 6 being a fixed link (second link) at pivot O (first connection point), lower housing 6 is pivotally connected to ratchet hub link 80 at pivot L (second connection point), ratchet hub link 80 is pivotally connected to pawl link 68 at pivot M (third connection point), pawl link 68 is pivotally connected to upper housing 5 at pivot N (fourth connection point).
[0093] With continued reference to FIG. 11 , self-locking mechanism 78 B comprises pawl-ratchet link pair 86 . Pawl-ratchet link pair 86 comprises pawl link 68 and ratchet hub link 80 . Referring to FIGS. 12-13 , exemplary embodiments of a pawl and ratchet hub links of the present invention are generally shown respectively as 68 and 80 . As shown in FIG. 12A , pawl link 68 may comprise pawl head 69 integrally formed with bar 70 . In another embodiment, pawl head 69 and bar 70 may be separate parts or components which are connected together. In the exemplary embodiments of FIGS. 12-13 , pawl end 71 comprises a pawl disc integrally formed with pawl head 69 . Pawl end 71 comprises three cut-out or pawl pockets 72 circumferentially spaced apart from each other at 120 degree equal angular intervals about its periphery for receiving three locking pawls 74 and three pawl spring recesses 75 adjacent pawl pockets 72 for receiving three pawl springs 76 . Further, pawl head 69 comprises pawl pivot posts 73 biased in pawl pockets 72 for pivotally mounting locking pawls 74 and pawl spring pivot pins 77 for pivotally mounting pawl springs 76 that are integrally formed with pawl head 69 . Each pawl pocket 72 comprises an abutment surface 72 A configured to prevent movement of locking pawl 74 in one direction while permitting movement in the opposite direction. Locking pawl 74 which is pivotally mounted within pawl pocket 72 is configured to move between a locked position against abutment surface 72 A and a disengaged position away from abutment surface 72 A. Each pawl spring 76 has one end coiled that pivotally mounts on pivot pin 75 within pawl spring recess 75 while the other end engages and exerts a biasing force on locking pawl 74 urging locking pawl 74 toward said locked position when locking pawl 74 is in said disengaged position. Optionally, pawl head 69 and pawl end 71 may be separate parts or components connected together.
[0094] As shown in FIG. 12B , ratchet hub link 80 may comprise ratchet head 81 integrally formed with bar 82 . Ratchet head 81 comprises ratchet cavity 83 which comprises an inner circumferential surface defined by ratchet teeth 84 integrally formed with said inner circumferential surface. Ratchet teeth 84 engage pawls 74 . Ratchet tooth 84 comprises convex top 84 A, side 84 B and concave root 84 C. Convex top 84 A, side 84 B and concave root 84 C smoothly transition into each other. In another embodiment, ratchet head 81 and bar 82 are separate parts or components which are connected together. In the exemplary embodiment of FIG. 13B , ratchet cavity 83 comprises 120 ratchet teeth arranged in three (3) degree increments around its inner circumferential surface. This allows upper housing 5 to be tilted or angularly oriented and locked into place in 3 degree increments in a counterclockwise direction relative to lower housing 6 . In action, and at any time, pawls 74 simultaneously engage with a set of ratchet teeth 84 as shown in FIG. 14A . In another embodiment, ratchet teeth 84 may have any number of teeth that allows upper housing 5 to be angularly oriented in one (1) degree increments relative to lower housing 6 .
[0095] With continued reference to FIGS. 11-13 , a pawl-ratchet link pair joint 86 A is formed at joint M of the pawl-ratchet link pair 86 between pawl head 69 of pawl link 68 and ratchet head 81 of ratchet hub link 80 . Pawl-ratchet hub link joint 86 A comprises a pawl-ratchet joint 86 B formed by engagement of locking pawl 74 and ratchet tooth 84 such that in operation locking pawl 74 slides over or snaps against ratchet tooth 84 Optionally, pawl-ratchet joint 86 B may be configured to produce an audible signal to indicate three (3) degrees of movement when locking pawl 74 slides over or snaps against ratchet tooth 84 . Self-locking is activated when locking pawl 74 engages abutment surface 72 A of pawl pocket 72 preventing reverse movement of locking pawl 74 causing locking pawl 74 to engage ratchet tooth root 86 C and thus prevent the reverse movement of ratchet tooth 86 C. Consequently, self-locking at pawl-ratchet joint 86 B is achieved by the wedging of locking pawl 74 into ratchet tooth root 84 C.
[0096] In another embodiment as shown in FIG. 14B , pawl head 69 may comprise locking pawl ring 71 A, torsion spring 76 A, at least one return stop 73 A. Locking pawl ring 71 A comprises at least one pawl 74 A and at least one return stop seat 73 B integrally formed on the outer periphery of locking pawl ring 71 A. Return stop 73 A is configured to engage return stop seat 73 B to prevent movement of locking pawl ring 71 A in one direction while permitting movement in the opposite direction. Torsion spring 76 A is configured to urge locking pawl ring 71 A to cause return stop seat 73 B to engage return stop 73 A. Locking pawl ring 71 A is pivotally mounted on pawl head 69 and is configured to move between a locked position such that return stop seat 73 B is against return stop 73 A and a disengaged position such that return stop seat 73 B is away from return stop 73 A. In yet another embodiment as shown in FIG. 14C , pawl head 69 may comprise locking pawl ring 71 B, at least one return stop 73 C, and at least one pawl return element 76 B. Locking pawl ring 71 B comprises at least one pawl 74 B, at least one pawl return element seat 76 C, and at least one return stop seat 73 D integrally formed on its outer periphery. Return stop 73 C is configured to engage return stop seat 73 D to prevent movement of locking pawl ring 71 B in one direction while permitting movement in the opposite direction. Pawl return element 76 B is configured to engage and exert a biasing force on pawl return element seat 76 C urging locking pawl ring 71 B to cause return stop seat 73 D to engage return stop 73 C. Locking pawl ring 71 B is pivotally mounted on pawl head 69 and configured to move between a locked position such that return stop seat 73 D is against return stop 73 C and a disengaged position such that return stop seat 73 D is away from return stop 73 C. In both embodiments of FIGS. 14B-14C , when locking pawl rings 71 A and 71 B are used, self-locking is activated when return seats 73 B and 73 D respectively engage return stops 73 A and 73 C preventing reverse movement of locking pawl rings 71 A and 71 B causing respectively pawls 74 A and 74 B of locking pawl rings 71 A and 71 B to respectively engage ratchet tooth root 86 C and thus prevent reverse movement of ratchet tooth 86 C. Similarly, when locking pawl rings 71 A and 71 B are used, self-locking comprises similar wedging action between a locking pawl ring and ratchet tooth root.
[0097] With continued reference to FIG. 11 , actuator 85 comprises a hand (not shown) comprising a few fingers that can be inserted into grip 29 . Press-to-release mechanism 88 comprises press button 89 and at least one release cable 90 (not shown). Release cable 90 is generally connected to locking pawl 74 or locking pawl ring 71 A or locking pawl ring 71 B in such a way that when press button 89 is pressed, the actuating push force is converted into a pull force on release cable 90 such that locking pawl 74 or locking pawl ring 71 A or locking pawl ring 71 B disengages from ratchet teeth 84 to permit reverse movement of ratchet teeth 84 . In the exemplary embodiment of self-locking tilt mechanism 9 shown in FIG. 11 , press-to-release mechanism 88 is operable upon inserting a few fingers of actuator 85 into grip 29 , slightly pulling upper housing 5 upward in a counterclockwise direction and depressing press button 89 . Press button 89 links release cable 90 and pawls 74 such that pawls 74 can be selectively disengaged from ratchet teeth 84 . Further, rotational power is transmitted to upper housing 5 by putting a few fingers in grip 29 of upper housing 5 and pulling upward in a counterclockwise direction away from lower housing 6 to angularly deploy upper housing 5 or pushing upper housing 5 downward in a clockwise direction towards lower housing 6 to collapse upper housing 5 . The pawl-ratchet joint 86 B of pawl-ratchet hub link joint 86 A provides a quick-acting self-locking mechanism that allows upper housing 5 to be adjusted to any desired inclination by merely gripping grip 29 and angularly orienting upper housing 5 to the desired angle, which when released automatically locks upper housing 5 in the instant adjusted position. Self-locking tilt mechanism 9 allows a user to selectively and angularly deploy upper housing 5 for comfortable viewing and working in a counterclockwise direction or collapse upper housing 5 in a clockwise direction so as to store support unit 2 . In the exemplary embodiment of self-locking tilt mechanism 9 shown in FIG. 11 , the minimum and maximum angular orientation of the upper housing 5 relative to the lower housing 6 between collapsed and deployed positions is respectively 0 (zero) and 75 degrees. Further, self-locking tilt mechanism 9 does not prevent the surface 18 of upper housing 5 from being substantially parallel to bottom surface 43 of lower housing 6 when upper housing 5 is in a collapsed state.
[0098] In the deployed position, the weight of upper housing 5 or the combined weight of an electronic system or reading material and upper housing 5 produces a downward force that tends to rotate ratchet hub and pawl links 80 and 68 respectively in a clockwise and counterclockwise directions. This causes a reaction force in opposition, but equal, to the downward force on pawls 74 , and consequently prevents the rotation of links 80 and 68 . Holding grip 29 and slightly pulling upper housing 5 upward in a counterclockwise direction temporarily removes the downward reaction force so that press button 89 may be actuated by being depressed. The actuating force on press button 89 is converted into a pull force on release cable 90 . This pull force in turn is converted into a clockwise rotating force on locking pawls 74 to disengage locking pawls 74 simultaneously from ratchet teeth 84 . In the released position, locking pawl 74 and ratchet teeth 84 are not engaged with each other and upper housing 5 is free to move in a clockwise direction about pivot O to orient upper housing 5 toward a collapsed position. Press-to-release mechanism 88 is configured such that its accidental depression cannot cause disengagement of pawls 74 from ratchet teeth 84 while the pawls-ratchet pair is in a locked position.
[0099] With Reference to FIG. 16A , tilt mechanism 78 A may optionally comprise a six-bar linkage and a hand lever actuator mechanism. The six-bar linkage herein referred to is a locked chain linkage with six links, each link being binary and pivotally connected to one another in a selected manner to have a predetermined degree of freedom with a total of six links and seven joints. The six-bar chain linkage is formed by taking upper and lower housings 5 and 6 as links, and combining them with four binary links comprising pawl link 68 , ratchet hub link 80 , link 93 and link 94 . Link 93 is the drive link and has one end pivotally connected to lower housing 6 at pivot J via crank pin 95 (not shown). The free end of link 93 is pivotally connected to link 94 at pivot K. The free end of link 93 is pivotally connected to links 68 and 81 at shared pivot M 1 . Pivot M 1 is considered to be a special case of two joints that are located in the same place. Bar 82 of ratchet hub link 69 connects to lower housing 6 at pivot L, ratchet head 81 of ratchet hub link 80 connects to pawl head 69 of pawl link 68 at pivot M, bar 70 of pawl link 68 connects to upper housing 5 at pivot N and upper housing 5 pivotally connects to lower housing 6 at pivot O. Lever actuator mechanism 91 provides driving power to link 93 to activate a rotation to drive the six-bar linkage mechanism to tilt upper housing 5 . Alternatively, the self-locking tilt mechanism of FIG. 16A may be thought of as a combination of two four-bar linkages, with lower housing 6 , ratchet hub link pair 80 , joint J, joint M and joint L shared.
[0100] With continued reference FIG. 16A , hand lever actuator mechanism 92 comprises hand lever 96 having free and fixed ends, press button 97 located at the free end of hand lever 96 , hand grip 98 (not shown) at the free end of the hand lever 96 , a release cable 99 (not shown), a push-to-release rod 100 (not shown) disposed between release cable 99 and press button 97 , and return spring 101 (not shown) disposed inside hand grip 98 . Hand lever 96 is pivotally connected to drive link 93 via crank pin 95 such that hand lever 96 may oscillate with respect to lower housing 6 . Push-to-release rod 100 converts the actuating force of press button 97 into a pull force on release cable 99 such that pawls 74 may selectively be disengaged from ratchet teeth 84 . Cooperation between ratchet teeth 84 and pawls 74 of pawl and ratchet hub links 68 and 80 is such that hand lever 96 can only move in a counterclockwise direction to angularly orient upper housing 5 to a deployed position from a collapsed position or in a clockwise direction to a collapsed position from a deployed position. Drive link 93 is driven by the actuation of hand lever mechanism 92 . The six-bar linkage self-locking tilt mechanism 9 of FIG. 16A essentially functions similarly as the four-bar linkage self-locking tilt mechanism 9 of FIG. 11 . While self-locking tilt mechanism 9 of FIG. 11 is operable by holding and pulling grip 29 of upper housing 5 upward in a counterclockwise direction, self-locking tilt mechanism 9 of FIG. 16A is operable by holding and pulling hand lever actuator mechanism 92 upward in a counterclockwise direction. It should be understood that the pawl-ratchet joint of the pawl-ratchet hub link joint of the four-bar of the six-bar linkage of the self-locking tilt mechanism 9 of FIG. 16A is similar in configuration and function as the pawl-ratchet joint of the pawl-ratchet hub link joint of the four bar linkage of self-locking tilt mechanism 9 of FIG. 11 , both providing a quick-acting self-locking mechanism that allows upper housing 5 to be adjusted to any desired inclination or position, which when released automatically locks upper housing 5 in the instant adjusted inclination or position.
[0101] In operation, a reaction force equal to the downward force at the teeth of pawls 74 of the self-locking tilt mechanism of FIG. 16A in opposition to the downward force caused by the weight of upper housing 5 or the combined weight of an electronic system or reading material and upper housing 5 prevents hand lever 96 from rotating clockwise. Thus, hand lever 96 is held in position by the reaction force and is configured such that it is prevented from being accidentally released from the locked position by the accidental depression of press button 97 . By slightly pulling hand lever 96 upward in a counterclockwise direction, the reaction force is temporarily removed and press button 97 can be depressed to transmit a clockwise rotating force to pawls 74 , through push-to-release rod 100 , to disengage them from ratchet teeth 84 and bring hand lever 96 into a released position. Thus, hand lever 96 is free to move in a clockwise direction about pivot J to orient upper housing 5 toward a collapsed position.
[0102] As shown in FIG. 17 , self-locking tilt mechanism 9 may optionally comprise a pair of hand or reversible motor actuated gas spring assisted system 91 (“gas spring 91 ”) for angularly orienting upper housing 5 relative to lower housing 6 . Gas spring 91 comprises cylinder 80 A, piston 68 A, a device 91 A (not shown) to hold piston 68 A in its extended position when upper housing 5 is angularly oriented, and/or a reversible motor (not shown) for actuating gas spring 91 . The system is arranged so that gas spring 91 reaches its fully retracted position when upper housing 5 is horizontal. Gas spring 91 is pivotally operably connected to upper and lower housings 5 and 6 such that upper housing 5 can be moved between deployed and collapsed positions. As used herein, the term gas spring can refer to a conventional gas spring system, hydraulic gas cylinder system, lift support system, gas cylinder system, or damper system. Alternative self-locking tilt mechanism arrangements may be a motorized mechanism, an adjustable reciprocating mechanism, user adjustable tilt adjustment apparatus having a number of discrete positions, an activation device in operative communication with upper housing 5 , or other rotational, tilting or lifting devices that permit upper housing 5 to be angularly oriented to the desired angular orientation. In any event, various tilting arrangements and support configurations may be used depending on desired characteristics.
[0103] Heat dissipating features such as cooling and ventilation system 10 of support unit 2 are configured to reduce heat transfer from an electronic system that rests on upper surface 18 of upper housing 5 . Cooling and ventilation system 10 may include active 102 and/or passive 103 cooling mechanisms. The embodiment of cooling and ventilation system 10 may comprise user controlled cooling fans 104 , cooling holes 20 and 21 in upper housing 5 as shown in FIGS. 5 to 6B , vents/slots 55 on opposite side walls 40 and 41 of lower housing 6 , on/off user actuated switch 105 and fan speed control device 106 .
[0104] In the illustrated embodiment of support unit 2 , active cooling mechanism 102 may comprise cooling fans 104 which are powered by a hardwired USB cable 107 (not shown) connected to an electronic system or by power block 110 or an external power apparatus pluggable to the mains (AC). Cooling fans 104 are biased in grated fan cover 108 to protect a user and limit foreign objects contacting the rotating fan vanes. Grated fan cover 108 biased within cavity 23 of upper housing 5 is secured to bottom surface 19 by screws 109 such that cooling fans 104 are able to suck or draw hot air entering through cooling holes 21 into cavity 23 and expel the air through the grating of grated fan cover 108 directly into the atmosphere. Thus, direct cooling by active cooling mechanism 102 is achieved this way. Active cooling mechanism 102 may also be coupled with cooling holes 20 and vents/slots 55 on opposite side walls 40 and 41 of lower housing 6 to enhance airflow through support unit 2 . Alternatively, any number of cooling fans or a variety of suitable devices such as air flow turbines may be utilized depending on user cooling needs. In the embodiment of the present invention, on/off user actuated switch 105 also serves as fans speed control device 106 . Though fan speed control device 106 is biased on right side wall 41 of lower housing 6 in the illustrated embodiment of support unit 2 , it could well be biased on left side wall 40 of lower housing 6 or any of opposite side walls 16 and 17 of upper housing 5 . The passive cooling mechanism 103 may comprise first group ventilation cooling holes 20 and vents/slots 55 on opposite side walls 40 and 41 of lower housing 6 . In another embodiment, passive cooling mechanism 103 may comprise holes 20 and 21 in upper housing 5 , vents/slots 55 on opposite side walls 40 and 41 of lower housing 6 .
[0105] Each cooling hole 21 in the second group is preferably perpendicularly orientated relative to its neighbor in the horizontal plane as shown in FIG. 6B . In one embodiment, these cooling holes 21 are generally of the same configuration and size and are arranged in a spacing the size of the major diameter of one elliptical cooling hole, FIG. 6B . Such arrangement promotes improved cooling airflow and increases the effectiveness of the cooling air flow to eliminate the uneven temperature distributions or undesirable temperature levels. In some embodiments, cooling holes 21 may be of varying sizes with the holes being spaced apart according to varying, but uniform, geometric patterns and densities to achieve the desired cooling effect.
[0106] The large number of cooling holes 20 surrounding cooling holes 21 increase the airflow preferentially around cooling holes 21 and are somewhat effective in maintaining the desired cooling airflow. When upper housing 5 is angularly oriented, the ejected hot air sucked from the base of an electronic system by cooling fans 104 expelled through the grating of grated fan cover 108 is expelled directly into the atmosphere. When upper housing 5 is in a collapsed position and is in fluid communication with lower housing 6 , the sucked ejected hot air from the base of the electronic system expelled by the cooling fans 104 through the grating of the grated fan cover 108 and trapped between cavity 23 of upper housing 5 and cavity 45 of lower housing 6 is simultaneously expelled into the atmosphere through cooling holes 20 in upper housing 5 and vents/slots 5 on opposite side walls 40 and 41 of lower housing 6 . The plurality of cooling holes provide extra ventilation for cooling and dissipating the heat generated by the electronic system in order to keep it from becoming too warm. Further, elliptical cooling holes are superior to cylindrical cooling holes in cooling performance along a flat surface and require fewer holes than cylindrical holes for the same surface area in accomplishing the required cooling performance.
[0107] Fans 104 , cooling holes 20 and 21 in upper housing 5 and vents/slots 55 on opposite side walls 40 and 41 of lower housing 6 allow greater and optimal airflow for increased heat dissipation and cooling of the heat generated by an electronic system during use. Air flow is further increased when upper housing 5 is angularly orientated. Additionally, other permeable materials may be used on the surface of upper housing 5 of support unit 2 to further increase heat dissipation from the electronic system.
[0108] Support unit 2 has a variety of power management systems and management states. The power management system 12 and its power management method comprises power block 110 that comprises rechargeable battery 111 (not shown) biased inside power block 110 , USB interface mechanism 112 comprises a plurality of USB hubs configured for connecting electronic devices and other peripherals such that USB cable 113 may be connected to draw power, AC power input source 114 into which an external power apparatus 115 could be connected to provide a power source for support unit 2 , and a control unit 116 (not shown) and an on/off switch 117 (not shown) disposed conveniently in or around support unit 2 for managing the power sources. Power consumption of support unit 2 is managed in accordance with a plurality of defined active power management states 118 . Three possible active power management states 118 for powering support unit 2 are defined: a “normal” state 119 where power is provided to the support unit 2 by the hardwired USB-out connector and pluggable into an electronic system's USB port to draw power, a “battery” state 120 where power is provided to support unit 2 by a rechargeable battery (DC) 111 source inside power block 110 , and a “mains” state 121 where power is provided to support unit 2 by the mains (AC) source from external power apparatus 115 . The external power apparatus 115 is pluggable to the mains (AC) and supplies current directly to support unit 2 as well as charges rechargeable battery 111 inside power block 110 . Active power status 122 (not shown) and battery level indicator 123 (not shown) may also be incorporated into the support unit 2 . The active power management state 118 is user selectable. A user can only select one power state to be active at a time since one active power management state precludes other power management states from becoming active. These active power management states 118 are determined by a user context such as use at the user's office, at home, in a meeting, or during travel. In one embodiment, a set of control buttons that may include power switch 124 (not shown) configured to change a power state (normal state, battery state, or mains state) of the support unit 2 may be provided.
[0109] Cable management system 13 may comprise cable-routing guides, straps or clips for neatly organizing the service cables that power the active cooling mechanism 102 , the “mains” cable when not in use or other USB cables. Alternately, cable management system 13 may comprise or include a receptacle where power and/or cables for the support unit 2 may be concealed or hidden from view when the support unit 2 is in use. Further, support unit 2 may include a structure that facilitates cable management.
[0110] As shown in the exemplary embodiments of support unit 2 , retractable mouse pad 11 may comprise top and bottom surface 125 and 126 that slides in and out of slot 58 of lower housing 6 . A user may use a mouse on top surface 125 or as a writing surface if desired. Bottom surface 126 may comprise shallow slot 127 configured to engage projection 59 inside slot 58 of lower housing 6 and prevents retractable mouse pad 11 from detaching from or falling off support unit 2 when retractable mouse pad 11 slides in and out of slot 58 . Retractable mouse pad 11 can readily be extended or pulled out from either side of support unit 2 by a left-handed or right-handed user into an operating position for use with a mouse or to write on. Appropriate locking device is provided for locking retractable mouse pad 11 in place when in use or completely retracted into lower housing 6 . In another embodiment, lower housing 6 may be configured to exclude retractable mouse pad 11 as shown in FIG. 18 as not all users may have need or use for a mouse pad. Inner bottom surface 42 of lower housing 6 may be configured to have insulation such that heat emitted from an electronic system on surface 18 of upper housing 5 and expelled through grated fan cover 108 into cavities 23 and 45 is prevented from passing through to retractable mouse pad 11 . In some embodiments, lower housing 6 may not have projection 59 and therefore retractable mouse pad 11 will not have shallow slot 127 . In this case an appropriate mechanism for guiding and stopping retractable mouse pad 11 from detaching from or falling off support unit 2 when retractable mouse pad 11 slides in and out of slot 58 will be provided.
[0111] Support unit 2 may further comprise a carrying handle (not shown) that is partially defined by upper and lower housings 5 and 6 to allow workstation 1 or support unit 2 to be carried with relative ease. Alternatively, the carrying handle may comprise a separate carrying handle that may be attached to the outside of the support unit 2 : the back end of support unit 2 for example. Other suitable handle arrangements are also possible. As mentioned above, upper housing 5 , lower housing 6 and anti-skid mechanism 7 provide an aesthetic appearance. As such, other alternative configurations of the support unit 2 are also possible. For example, support unit 2 may have a substantially rectangular shaped appearance as shown in FIGS. 33 and 34 , with upper and lower housings 5 and 6 being casing halves respectively, each comprising a substantially shallow rectangular pan which is hinged together to one another to allow movement between collapsed and deployed positions.
[0112] Referring to FIGS. 19A and 19B , exemplary perspective views of the embodiments of partially deployed and collapsed telescopic rods 3 are illustrated. Telescopic rod 3 comprises a plurality of tubular telescoping members comprising a top, base, and several intermediate telescoping members of differing diameters such that they can be nested in one another in a telescopically coupled manner and movable longitudinally with respect to one another between extended and retracted positions. Each telescoping member comprises tube walls and longitudinal axis. In the exemplary embodiments shown in FIGS. 19A and 19B , telescopic rod 3 consists of base 128 , intermediate 129 and top 130 members, first and second positive locking mechanisms 131 and 132 , and first and second springs (not shown) 133 and 134 . Springs 133 and 134 are suitably sized and biased between two adjacent telescoping members and configured to assist the extension of an intermediate or top telescoping member to its fullest extended capacity or a user desired length. In the exemplary embodiment of telescopic rod 3 , intermediate and top telescoping members 129 and 130 are two adjacent telescoping. Further, springs 133 and 134 are configured to reduce the force needed to extend an intermediate or top telescoping member. Telescoping members 128 , 129 and 130 may be readily extended or adjusted to the required height or encased into one another in a collapsed or retracted position for storage out of the way when not in use. Springs 133 and 134 respectively allow intermediate and top telescoping members 129 and 130 to be automatically drawn out upwards when respective push button actuators 156 and 166 of first and second positive locking mechanism 131 and 132 are depressed. Telescopic rod 3 has a simple, strong, light, durable and efficient construction, rigid in support, and capable of sustaining the adjustment against the combined weight of an electronic system or reading material and support unit 2 .
[0113] As illustrated in FIG. 20 of the exploded perspective view of an exemplary embodiment of telescopic rod 3 , base and intermediate telescoping members 128 and 129 have top and bottom ends. The lower portion of base telescoping member 128 has a reduced diameter, the reduced diameter having a U-shaped race-like external annular groove 135 (“groove 135 ”) for receiving quick connect-disconnect device 175 . The inner surfaces of the top ends of base and intermediate telescoping members 128 and 129 have recesses 136 (view A of FIGS. 20 ) and 142 configured to receive respectively housings 153 and 163 of first and second positive locking mechanisms 131 and 132 . Proximate the respective bottom portions of recesses 136 and 142 are through holes 137 and 141 extending from the surfaces of recesses 136 and 142 to the respective outer surfaces of base and intermediate telescoping members 128 and 129 configured to receive push button actuators 156 and 166 of first and second positive locking mechanisms 131 and 132 . Proximate the respective top portions of recesses 134 and 142 are through holes 138 and 143 (not shown) extending from the respective surface of recesses 136 and 142 to the respective outer surfaces of base and intermediate telescoping members 128 and 129 configured to receive screws 138 (not shown) for locking respective first and second positive locking mechanism 131 and 132 .
[0114] As shown in FIG. 20 , intermediate and top telescoping members 129 and 130 have flat rotation prevention engagement surfaces 139 and 144 that extend from their bottom ends upward and toward their top ends but not the entire distance for respectively engaging the flat backs of housings 431 and 436 of first and second positive locking mechanisms 131 and 132 and prevent rotation of the intermediate and top telescoping members 129 and 130 respectively relative to base telescoping member 128 and intermediate telescoping member 129 . Flat rotation prevention engagement surfaces 139 and 144 each have a plurality of pin locking holes 140 and 145 that engage with the respective fore ends or locking pins 158 and 168 of rocker arms 155 and 165 of first and second positive locking mechanisms 131 and 132 to lock intermediate and top telescoping members 129 and 130 in the desired fully deployed or extended, partially deployed or extended, or retracted positions. It is understood that several intermediate telescoping members may be employed based on user need. Each new intermediate telescoping member added would comprise a rotation prevention engagement surface and a plurality of holes on the rotation prevention engagement surface.
[0115] As further illustrated in FIG. 20 , top telescoping member 130 has a bottom end. The top end of telescoping member 130 optimally terminates in a discontinuous annular snap-fit connector 146 . The top telescoping member 130 is configured to nest inside intermediate telescoping member 129 and movable longitudinally in a telescoping manner between extended or deployed and collapsed or retracted positions. As shown in view B-B along reference line B-B of FIG. 21 , snap-fit connector 146 may comprise a discontinuous annular snap-fit joint or an annular snap-fit joint or the like. The snap-fit connector includes at least one snap-fit protrusion 147 . Snap-fit protrusion 147 interlocks with snap-fit cavity 60 of lower housing 6 to form a releasable annular snap joint lock 60 A as shown in FIG. 22 . To connect telescopic rod 3 to support unit 2 , snap-fit protrusion 147 is slid through the hollow region of cavity 60 in lower housing 6 to engage snap-fit cavity 60 . Snap-fit protrusion 147 contracts while being slid through the hollow region, encounters snap-fit cavity 60 and resiliently expands to form snap joint lock 60 A and connector. Snap-fit protrusion 147 , snap-fit cavity 60 , or both snap-fit protrusion 147 and snap-fit cavity 60 temporarily deform during the assembly process. The dimensions, geometry, and material of snap-fit protrusion 147 are selected to deform without significant strain damage during the assembly process. Once assembled, at least one snap-fit protrusion 147 engages snap-fit cavity 60 in lower housing 6 in a stress-free manner. Alternatively, the top end of top telescoping member 130 may be adapted for fitting an adapter attachment that may comprise a snap-fit connector end or some other appropriate adapter device attachment such that the adapter attachment will establish fluid communication between telescopic rod 3 and support unit 2 . Further appropriate locking mechanisms for locking the adapter device attachment onto telescopic rod 3 end and then connecting telescoping rod 3 to support unit 2 are provided. Snap-fit connector 146 or other adapter device attachment serves as a pre-equipped mating connector for telescopic rod assembly 3 . Snap joint lock 60 A allows telescopic rod 3 to be easily and quickly connected to and disconnected from the base of lower housing 6 of support unit 2 without having to thread and unthread telescopic rod 3 each time telescopic rod 3 is connected to or disconnected from the base of lower housing 6 of support unit 2 and without the aid of tools. Annular snap joint 60 A is designed to prevent telescopic rod 3 from separating from the base of lower housing 6 of support unit 2 when deployed in the connected state by a user and allow ready disconnection from the base of lower housing 6 of support unit 2 when desired.
[0116] Referring to FIG. 21 , snap-fit connector 146 may comprise radial group of snap-fit protrusions 147 . Each snap-fit protrusion 147 is an arched or semi-annular ridge that extends radially from the top of top telescoping member 130 . As illustrated by view B-B along reference line B-B of FIG. 21 , snap-fit connector 146 preferably has tapered edge 148 which rests against or near a snap-fit ledge 61 ( FIG. 10D ) of snap-fit cavity 60 in lower housing 6 when assembled. Tapered edge 148 permits snap-fit protrusion 147 to be disengaged and removed from snap-fit cavity 60 when desired. Snap-fit protrusion 147 optimally has a triangular-shaped head 150 and a beveled exterior 149 . The triangular head is designed to allow enough radial movement yet prevent radial flexing of at least one snap-fit protrusion 147 to prevent disassembly of telescopic rod 3 from the base of lower housing 6 of support unit 2 in the connected state while deployed in use. The beveled exterior 149 is sloped to allow the top portion of top telescopic member 130 to be easily inserted into the snap-fit cavity 60 . Alternatively, a locking means (not shown) may be provided to prevent radial flexing of at least one snap-fit protrusion 147 of telescopic rod 3 and thus prevents disassembly of the telescopic rod 3 from the base of lower housing 3 of support unit 2 in the connected state while deployed in use. As illustrated in view B-B along reference line B-B of FIG. 21 , the top portion of top telescopic member 130 has axial slots 151 that divide the top portion of top telescopic member 130 into a series of semi-annular arms 152 with arched cross-sections. Semi-annular arms 152 have top and bottom ends, the top end biased near or coextensive with snap-fit protrusion 147 and the bottom end biased near the lowest point of the axial slot 152 . Snap-fit connector 146 has a locking means (not shown) for locking snap-fit connector 146 in a connected state, the locking means being part of, or distinct from top telescoping member 130 . When in a locked connected state, snap-fit protrusion 147 engages and interlocks with snap-fit cavity 60 and the locking means substantially restricts radial movement of snap-fit protrusion 147 within the snap-fit cavity 60 .
[0117] Referring to FIG. 20 , first and second positive locking mechanisms 131 and 132 may comprise major elements first and second housings 153 and 163 , first and second pivot pins 154 and 164 , first and second rigid rocker arms 155 and 165 , first and second push button actuators 156 and 166 , and first and second energized cantilever springs 157 and 164 (or finger springs). Preferably, the major elements of first and second positive locking mechanisms 131 and 132 have similar configurations and dimensions. Whether fully extended, partially extended or collapsed, telescoping members 128 , 129 and 130 need to stay affixed in some manner to the adjoining members so telescopic rod 3 will remain in place once positioned to a desired length. First and second positive locking mechanisms 131 and 132 respectively located at the top ends of base and intermediate telescoping members 128 and 129 are used to achieve this when activated and respectively lock intermediate and top telescoping members 129 and 130 in a continuum of positions along their respective lengths to effectively and securely engage it to intermediate and top telescoping members 129 and 130 in a partially extended, fully extended or collapsed positions. This provides a solid predictable load bearing lock mechanism that locks and interconnects the base and intermediate telescoping members 128 and 129 or the intermediate and top telescoping members 129 and 130 between extended and retracted positions and makes it possible to maintain the telescoping members in any desired longitudinal relationships relative to each other. When fully retracted and collapsed, telescopic rod 3 is in a compact form and is stored in form-fitted storage cavity 56 in lower housing 6 of support unit 2 .
[0118] Referring to view C-C along reference line C-C of FIG. 21 , first and second rocker arms 155 and 165 are pivotally mounted intermediate between their fore and aft ends to provide a rocking movement. The fore ends of first and second rocker arms 131 and 132 respectively terminate in first and second locking pins 158 and 168 . First and second energized cantilever springs 157 and 167 are respectively biased inside first and second housings 153 and 163 such that one end of each spring is in engagement respectively with first and second abutments 160 and 170 , the other ends being in engagement respectively with first and second aft ends 159 and 169 of first and second rocker arms 155 and 165 to energize and urge first and second aft ends 159 and 169 by applying respective forces directly against first and second aft ends 159 and 169 of first and second rocker arms 155 and 165 , in respective directions outwardly of intermediate and top telescoping members 128 and 129 to force respective first and second locking pins 158 and 168 of first and second rocker arms 155 and 165 inwardly respectively of intermediate and top telescoping members 128 and 129 into locking engagement respectively with any of the plurality of pin locking holes 140 and 145 on intermediate and top telescoping members 129 and 130 . Thus, telescoping members 129 and 130 are locked in the desired extended longitudinal configuration when first and second locking pins 158 and 168 of first and second rocker arms 155 and 165 respectively engage any of the respective plurality of pin locking holes 140 and 145 respectively on respective rotation prevention engagement surfaces 139 and 144 . First and second positive locking mechanisms 131 and 132 are designed to prevent unintended unlocking caused by accidental depression of first and second push buttons 156 and 166 .
[0119] The desired longitudinal relationship between the telescoping members 128 , 129 and 130 can be changed by depressing either of first or second push button 156 or 166 . Depression of either first or second push button 156 or 166 pushes first and second aft ends 159 and 169 of first and second rocker arms 155 and 165 respectively inwardly of base and intermediate telescoping members 128 and 129 , rotates respectively first and second rocker arms 155 and 165 about pivot pins 154 and 164 and compresses respectively first and second cantilever springs 157 and 167 inwardly of base and intermediate telescoping members 128 and 129 forcing locking pins 158 and 168 respectively outwardly of intermediate and top telescoping members 129 and 130 to force disengagement of locking pins 158 and 168 from respective pin locking holes 140 and 145 of the intermediate and top telescoping members 129 and 130 , thus unlocking the intermediate and top telescoping members 129 and 130 . Whilst either of first or second push button 156 and 166 is in a depressed state, intermediate and top telescoping members 129 and 130 can be extended or collapsed by moving them telescopically against each other. When either of first or second push button 156 or 166 is released, the respective locking pins 158 and 168 of first and second rocker arms 155 and 165 engage any of the respective plurality of pin locking holes 140 and 145 on intermediate and top telescoping members 129 and 130 to lock and keep telescopic rod 3 in the new desired longitudinal relationship.
[0120] Further, the reactionary force caused by the combined weight of an electronic system or reading material and support unit 2 from the locking pins 158 and 168 during prolonged usage may deform or enlarge pin locking holes 140 and 145 which are in direct engagement with the locking pins 158 and 168 . This may cause instability in the telescopic rod 3 and may render it inoperable. This can be prevented and telescoping rod 3 made to withstand these forces and survive prolonged use before failing by doing any of the following: using similar materials for both locking pins 158 and 168 and intermediate and top telescoping members 129 and 130 , inserting a stronger reinforcing material than that of the locking pins 158 and 168 into pin locking holes 140 and 145 , or hardening intermediate and top telescoping members 129 and 130 sufficiently to resist deformation from the forces of respective locking pins 158 and 168 .
[0121] Referring to FIGS. 23-27 , tripod 4 may comprise stationary leg assembly 171 (“leg 171 ”), first moveable leg 172 (“leg 172 ”) and second moveable leg 173 (“leg 173 ”), guide pin 174 , and quick connect-disconnect device 175 . Leg 171 may comprise circular tubular housing 176 (“tubular housing 176 ”) and telescopic leg assembly 177 . Leg 172 may comprise first tubular barrel cam 178 (“barrel cam 178 ”), first circular tubular connector 179 (“connector 179 ”) and telescopic leg assembly 177 . Leg 173 may comprise second tubular barrel cam 180 (“barrel cam 180 ”), second circular tubular connector 181 (“connector 181 ”) and telescopic leg assembly 177 . Telescopic leg assembly 177 is the same for and used with legs 171 , 172 and 173 . As shown in FIG. 23 , telescopic leg assembly 177 may comprise leg elements 182 and 183 , locking device 184 (not shown) which serve to releasably lock leg elements 182 and 183 together, retractable non-marking stem swivel caster wheel 185 (“caster wheel 185 ”), press button actuator 187 , wheel well door 188 (“wheel door 188 ”), storage clip holder 189 and snap-in holder 190 .
[0122] With continued reference to FIGS. 23-27 , leg element 183 is configured to nest in leg element 182 . Leg element 183 is a stepped tube that is constructed from two rectangular tubes, the first having a cross-sectional dimension slightly smaller than the cross-sectional dimension of the second. The first and second rectangular tubes have free and fixed ends. The fixed ends of the first and second rectangular tubes are rigidly attached together so that the joint between them creates an abutment 191 (or stop). Thus, a stepped tube, which is leg element 183 , is created. Leg element 183 has two free ends, one end having a slightly smaller dimension than the other. The free end of the first rectangular tube of leg element 183 nests into leg element 182 , and the free end of the second rectangular tube of leg element 183 has a beveled exterior. Leg element 182 has fixed and free ends. The free end of leg element 182 is configured to receive the smaller free end of leg element 183 . Together, they form a telescopic leg assembly 177 . To increase the stability of tripod 4 , press button 187 is depressed and locking device 184 unlocks and releases leg element 183 for it to be telescopically extended.
[0123] As shown in FIG. 24 and view E of FIG. 23 , the free end of leg element 183 may comprise wheel well 192 that houses caster wheel 185 that is movable between deployed and retracted positions, socket hinge 193 , storage clip holder 189 for holding caster wheel 185 in a collapsed or stowed position and snap-in holder 190 for locking caster wheel 185 when said caster wheel 185 is in a deployed position. Wheel well 192 is provided wheel door 188 that is adapted to slide open and close between collapsed and deployed positions of caster wheel 185 . Appropriate locking mechanism 194 (not shown) to hold wheel door 188 in position when open or closed is provided. Further, leg element 183 is configured to have a skid-proof sole to keep tripod 4 from sliding on smooth surfaces when caster wheel 185 is retracted or stowed away.
[0124] As illustrated in FIG. 23 , tubular housing 176 of leg 171 has top and bottom ends. Disposed coaxially inside, to a proximal end of top end of tubular housing 175 of leg 171 , is a U-shaped race-like internal annular channel 195 (“U channel 195 ”) circumscribing the inner diameter of tubular housing 175 for receiving quick connect-disconnect device 196 as shown in view F-F of FIG. 23 . Quick connect-disconnect device 196 , operably positioned inside U channel 195 locks and coaxially couples telescopic rod 3 to tripod 4 such that telescopic rod 3 is placed in fluid communication with tripod 4 . Quick connect-disconnect device 196 permits the easy and quick connection and disconnection of telescopic rod 3 to or from tubular housing 176 of tripod 4 . As used herein, “quick connect-disconnect device” 196 is defined as a device that permits the easy and quick connection and disconnection of telescopic rod 3 to and from tripod 4 without having to thread or unthread telescopic rod 3 to or from tripod 4 each time telescopic rod 3 is connected to or disconnected from tripod 4 without the aid of tools. Quick connect-disconnect device 196 may alternatively comprise conventional quick connect-disconnect device as known to one of ordinary skill in the art.
[0125] As shown in FIG. 29A , first and second inverted U-shaped notches 197 and 198 (“notch 197 ” and “notch 198 ”) which are similar in configuration and size are located at the bottom end of tubular housing 176 . The axis of notch 197 is oriented 120 degrees clockwise from the axis of leg element 182 of leg 171 . The axis of notch 198 is oriented 120 degrees clockwise from the axis of notch 197 and 120 degrees counterclockwise from the axis of leg element 182 of leg 171 . As shown in FIGS. 29B-29C , notches 197 and 198 respectively engage connectors 179 and 181 of legs 172 and 173 . As shown in FIG. 29A , the fixed end of leg element 182 of leg 171 is rigidly attached to the bottom end of tubular housing 176 . Further, telescopic leg assembly 177 is angularly oriented to the vertical axis of tubular housing 176 of leg 171 at angle φ 1 .
[0126] As illustrated in VIEW D of FIG. 23 , quick connect-disconnect device 175 may comprise first and second semi-circular cam locking devices 199 (“cam lock 199 ”) and 200 (“cam lock 200 ”), pivot pin 201 , first and second springs 202 and 203 , and actuator 204 . Cam locks 199 and 200 each have a free end and inner end, the inner end having a pivot hole through which a pivot pin can be passed. The inner ends of cam locks 199 and 200 are pivotally connected to each other by pivot pin 201 such that cam locks 199 and 200 are oppositely disposed to each other, and the free ends of cam locks 199 and 200 are in contact with actuator 204 . Cam locks 199 and 200 are positioned in U channel 195 of tubular housing 176 such that the cam surface of cam lock 199 is adjacent to the cam surface of cam lock 200 as shown in view F-F of FIG. 23 . In operation, first and second springs 202 and 203 respectively press against and force cam locks 199 and 200 inwardly into a lock position 205 within groove 135 such that cam locks 199 and 200 completely circumscribe the inner surface of groove 135 and thus lock telescopic rod 3 in tripod 4 . In the locking position 205 , as shown in VIEW F-F of FIG. 23 , cam locks 199 and 200 partially protrude into channel 195 of tubular hosing 176 of leg 171 . Quick connect-disconnect device 175 serves as a pre-equipped mating connector for tripod 4 .
[0127] Actuator 204 having axis perpendicular to the axis of tubular housing 176 may be positioned between the free ends of cam locks 199 and 200 . When a user pushes inwardly on actuator 204 in operation, actuator 204 engages and moves the free ends of cam locks 199 and 200 outwardly about the pivot into an unlock position 206 within U channel 195 of tubular housing 176 . In the unlock position 206 , cam locks 199 and 200 are disposed such that they do not protrude into groove 135 of tubular housing 176 , thus permitting bottom end of telescopic rod 3 to be inserted into tubular housing 176 of tripod 4 . As the end of telescopic rod 3 is inserted further into tubular housing 176 of tripod 4 , cam locks 199 and 200 move adjacent to groove 135 in a circumscribing manner at the bottom end of telescopic rod 3 . When the user releases the inward force applied to actuator 204 , cam locks 199 and 200 are forced inwardly respectively by first and second springs 202 and 203 into contact with the inner surface of groove 135 at the bottom end of telescopic rod 3 . As such, telescopic rod 3 is locked, connected, and/or mounted onto tripod 4 .
[0128] As illustrated in FIG. 23 , barrel cam 178 of leg 172 has top and bottom ends. The diameter of barrel cam 178 of leg 172 is adapted to nest inside tubular housing 176 of leg 171 . One end of connector 179 is rigidly attached to the fixed end of leg element 182 of telescopic leg assembly 177 . The other end of connector 179 is rigidly connected to the lower end of barrel cam 178 of leg 172 . Telescopic leg assembly 177 of leg 172 is angularly oriented to the vertical axis of the barrel cam 178 of leg 172 at angle φ 1 . As shown in FIG. 29B , third inverted U-shaped notch 207 (“notch 207 ”), preferably having similar configuration and size as that of notches 197 and 198 of tubular housing 176 of leg 171 , is located at the bottom end of barrel cam 178 of leg 172 . The axis of notch 207 is oriented 120 degrees clockwise from the axis of leg element 182 of telescopic leg assembly 177 of leg 172 and 240 degrees counterclockwise from the axis of leg element 182 of telescopic leg assembly 177 of leg 172 . When tripod 4 is deployed in operation, notches 198 and 207 are aligned and simultaneously engage connector 181 of leg 173 . Rotational power is transmitted to barrel cam 178 through rotation of telescopic leg assembly 177 of leg 172 . Leg 172 is collapsible from a deployed position or deployable from a collapsed position by rotation in the same plane about common axis 220 relative to leg 171 . In the collapsed position, leg 172 lies horizontally and parallel to, but beneath, leg element 182 of telescopic leg assembly 177 of leg 171 in the same plane, FIG. 28 . In the deployed position, leg 172 is displaced 120 degrees clockwise from its collapsed position and engages notch 197 of tubular housing 176 of leg 171 . Appropriate locking mechanisms are provided for locking leg 172 in either the deployed or collapsed position.
[0129] As illustrated in FIG. 23 , barrel cam 180 of leg 173 has top and bottom ends. The diameter of barrel cam 180 of leg 173 is adapted to nest inside barrel cam 178 of leg 172 . As shown in FIG. 29C , one end of connector 181 is rigidly attached to the fixed end of leg element 182 of telescopic leg assembly 177 . The other end of connector 181 is rigidly connected to the lower end of barrel cam 180 of leg 173 . Telescopic leg assembly 177 of leg 173 is angularly oriented to the vertical axis of barrel cam 181 of leg 173 at angle φ 1 . Rotational power is transmitted to barrel cam 180 through rotation of the telescopic leg assembly 177 of leg 173 . Leg 173 is collapsible from a deployed position or deployable from a collapsed position by rotation in the same plane about common axis 220 , relative to legs 171 and 172 . In the collapsed position, leg 173 lies horizontally and parallel to, but beneath, leg element 182 of telescopic leg assembly 177 of leg 172 in the same plane, FIG. 28 .
[0130] As shown in exploded view of FIG. 23 , the nesting of barrel cam 180 in barrel cam 178 and barrel cam 178 in tubular housing 176 is such that they rotate about common axis 220 . Further, as shown in FIGS. 23 and 29B , barrel cam 178 of leg 172 has a first cam track 208 and a first particular cam profile 209 . First cam profile 209 is made so that its law of motion is a function of the angle of rotation of barrel cam 178 . First cam profile 209 is continuous up to a 120 degree angle of rotation of barrel cam 178 . When leg 172 rotates to a deployed or collapsed position, barrel cam 178 also rotates about common axis 220 . When barrel cam 178 rotates, first cam track 208 interacts with guide pin 174 , follows first cam profile 209 and simultaneously moves in a vertical direction, upward or downward, along common axis 220 . Also, as shown in FIGS. 23 and 29C , barrel cam 180 of leg 173 has a second cam track 210 and a second particular cam profile 211 . The second cam profile 211 is made so that its law of motion is a function of the angle of rotation of barrel cam 180 . The second cam profile 211 is continuous up to a 240 degree angle of rotation of barrel cam 180 . When leg 173 rotates to a deployed or collapsed position, barrel cam 180 also rotates about common axis 220 . When barrel cam 180 rotates, the second cam track 210 interacts with guide pin 174 , follows the second cam profile 211 and simultaneously moves in a vertical direction, upward or downward, along common axis 220 .
[0131] As illustrated in view G of FIG. 23 , guide pin 174 may comprise knurled head 212 rigidly attached to shank 213 . Knurled head 212 has diameter substantially larger than the diameter of shank 213 . Knurled head 212 facilitates the manual turning of the guide pin 174 . Shank 213 begins with threaded portion 214 below knurled head 212 and terminates in pin end 215 . Threaded portion 214 threads into threaded hole 221 (“hole 221 ”) on tubular housing 176 of leg 171 . Pin end 215 projects through, fits in, and engages cam tracks 208 and 210 respectively of barrel cams 178 and 180 of legs 172 and 173 . By so placing guide pin 174 , rotation of legs 172 and 173 causes respective barrel cams 178 and 180 of legs 172 and 173 about common axis 220 to move either vertically upward while being rotatably deployed or move vertically downward while being rotatably collapsed. In another alternative embodiment, guide pin 174 may be a press-in pin or other appropriate pin that guides barrel cam 178 and 180 .
[0132] In the deployed position, legs 171 , 172 and 173 are circumferentially displaced 120 degrees from each other so that tripod 4 stably supports the combined weight of an electronic system or reading material, support unit 2 and telescopic rod 3 . Each movable leg is locked in place by an appropriate locking mechanism (not shown) once it is positioned in the respective deployed or collapsed positions. Further, as shown in FIG. 27 , caster wheel 185 provides mobility for workstation 1 . Where the possibility of rolling must be avoided, and where it is desirable not to use caster wheel 185 , each caster wheel 185 is easily and quickly retracted into wheel well 192 and caster wheel 185 remain clear of the ground or floor to permit the tripod legs to rest directly on the floor as shown in FIGS. 25 and 26 . When retracted, each caster wheel 185 is housed in wheel well 192 located in each of leg element 183 . For users who prefer more stability, telescoping leg assembly 177 may be extended as shown in FIGS. 25 and 27 . FIGS. 30-32 show alternate embodiments tripod 4 .
[0133] The invention as described is illustrative in manner and it should be understood that terminologies used are intended to be in the nature of words of description rather than of limitation. Obviously, it is apparent that many modifications and variations of the present invention are possible in light of the above descriptions and consequently, changes may be made to the details of the embodiments of the described invention above by those skilled in the art without departing from the broad inventive concept and the underlying principles thereof of the disclosure described herein. It is, therefore, to be understood that the description of this invention is not limited to the particular embodiments disclosed in any way but is intended to cover all modifications which are in the spirit and scope of the disclosed invention. It is also to be understood that the invention may be accomplished otherwise than as specifically described within the scope of the appended claim. The invention is defined by the claim.
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An ergonomically designed space saving, collapsible multi-function travel-friendly modular workstation for supporting a broad range of electronic systems, reading materials and the like for users while standing, sitting or on-the-go, and fits in anywhere, anytime is presented. The workstation comprises a support unit, telescopic rod and tripod and is designed to provide needed cooling and ventilation for electronic systems, support healthy postures, and complete comfort and versatility of a multi-function workstation with all the important things needed when working at a desk, thereby improving a user's comfort when using the workstation. Further, the workstation is designed for easy transportation, storage and set up, as well as provide a versatile workspace for a user in many different environments, for everyday use such as note taking, writing, reading, presentations, performing arts and rehearsing while playing a musical instrument, music or conductor stand, etc.
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BACKGROUND OF THE INVENTION
This invention relates generally to protection of underwater surfaces from fouling by aquatic organisms. This invention was made with government support awarded by the Office of Naval Research under contract No. N00014-86-K-0261. The government has certain rights in the invention.
DESCRIPTION OF THE PRIOR ART
In marine, brackish, and freshwater environments, organisms collect, settle, attach, and grown on submerged structures. Organisms which do so can include algae, and aquatic animals, such as tunicates, hydroids, bivalves, bryozoans, polychaete worms, sponges, and barnacles. Submerged structures can include the underwater surfaces of ships, docks and piers, pilings, fishnets, heat exchangers, dams, piping structures, such as intake screens, and cooling towers. The presence of these organisms, known as the "fouling" of a structure, can be harmful in many respects. They can add to the weight of the structure, hamper its hydrodynamics, reduce its operating efficiency, increase susceptibility to corrosion, and degrade or even fracture the structure.
The common method of controlling the attachment of fouling organsims is by protecting the structure to be protected with a paint or coating which contains an antifouling agent. Exemplary antifouling coatings and paints are described in U.S. Pat. No. 4,596,724 to Lane, U.S. Pat. No. 4,410,642 to Layton, and U.S. Pat. No. 4,788,302 to Costlow. Application of a coating of this type inhibits the attachment, or "settling", of the organism, by either disabling the organism or providing it with an unattractive environment upon which to settle.
Of the fouling organisms noted above, barnacles have proven to be among the most difficult to control. Typically, commercial antifouling coatings and paints include a toxic metal-containing compound such as tri-n-butyl tin (TBT), or cuprous oxide, which leaches from the coating. Although these compounds exhibit moderate success in inhibiting barnacle settlement, they degrade slowly in marine enviornments, and therefore are ecologically harmful. In fact, TBT is sufficiently toxic that its release rate is limited by legislation in some countries.
Some experimental non-toxic compounds have been tested with limited success in barnacle settlement inhibition. See, e.g., Gerhart et al., J. Chem. Ecol. 14:1905-1917 (1988), which discloses the use of pukalide, epoxypulkalide, and an extract produced by the octocoral Leptogorgia virgulata, to inhibit barnacle settlement, and Sears et al., J. Chem. Ecol. 16:791-799 (1990), which discloses the use of ethyl acetate extracts of the sponge Lissodendoryx isodictylais to inhibit settlement.
Japanese Patent Disclosure No. 54-44018A of Apr. 7, 1979 (Patent Application No. 52-109110 of Sep. 10, 1977, discloses gamma-methylenebutenolide lactone and alkyl gamma-methylenebutenolide lactone derivatives having the general structure ##STR1## wherein R 1 and R 2 are hydrogen or saturated or unsaturated alkyl groups of 1-8 carbon atoms. The compounds are natural products from terrestrial plants.
In view of the foregoing, it is an object of the present invention to provide an antifouling composition which is effective in inhibiting the settlement of fouling organisms on an underwater surface.
Another object of the present invention is to provide an antifouling paint or coating composition which is effective in protecting underwater structures from fouling by barnacles, and other aquatic organisms.
A further object is to provide structures which are effectively protected against fouling by aquatic organisms.
SUMMARY OF THE INVENTION
These and other objects are accomplished by the present invention which in one aspect comprises a composition for use as a marine or freshwater antifoulant comprising a protective carrier component functioning to release antifouling agent and, as an antifouling agent, at least one furan compound of Formula I or II ##STR2## wherein R 1 , R 2 , R 3 , and R 4 are independently selected from --C(O)R 5 , --C(O)OR 6 , (C 1 -C 8 )alkyl, phenyl, phenyl substituted with (C1-C 4 )alkyl, (C 1 -C 4 )alkoxy, (C 2 -C 8 )alkenyl, (C 2 -C 8 )alkynyl, halogen, and hydrogen, provided that at least one of R 1 , R 2 , R 3 , and R 4 is not hydrogen; R 5 is R 6 or NR 7 R 8 ; R 6 is (C 1 -C 8 )alkyl, (C 2 -C 8 )alkenyl, (C 2 -C 8 )alkynyl, phenyl, phenyl substituted with (C 1 -C 4 )alkyl, (C 1 -C 4 )alkoxy, or halogen; R 7 and R 8 are independently selected from hydrogen or R 6 .
A second aspect of the present invention comprises a method of protecting a marine or freshwater structure against fouling by marine or freshwater fouling organisms comprising applying a compound of Formula I or II on and/or into said structure.
Another invention is a marine or freshwater structure protected against fouling organisms wherein said protection is afforded by at least one furan compound of Formula I or II having been applied on and/or into said structure.
DETAILED DESCRIPTION OF THE INVENTION
The present invention is directed to controlling the attachment of unwanted organisms to submerged surfaces by contacting the organisms with an antifouling compound of Formula I or II. It has been discovered that furan compounds of Formula I or II inhibit the settlement of fouling organisms, particularly barnacles. As used herein, "settlement" refers the attachment of aquatic organisms to an underwater structure. Contacting an organism with a compound of Formula I or II in the area adjacent a submerged surface prevents the settling of the organism on that submerged surface.
In the practice of the method of the present invention, the antifouling compound may be contacted to the organism by coating the object to be protected with a coating containing the antifouling compound, which then releases the compound into the aquatic environment immediately adjacent the external surfaces of the article, by including the antifouling compound within material formed into an aquatic article which then releases the compound, by releasing the compound directly into the aquatic environment surrounding the protected object, or by any other method wherein the compound contacts the organism prior to its attachment to the surface. As used herein, the term "contacting" means that an amount of antifouling compound sufficient to inhibit settlement of the organism on the surface of interest physically contacts the organism, whether by direct external contact, inhalation, respiration, digestion, inhibition, or any other process.
Preferred furan compounds are 2-ethylfuran; 2-methylfuran; methyl-2-furanoate; ethyl-3-furoate; 2-furyl-n-pentyl ketone; 2-acetylfuran; and khellin (Formula II).
The amount of compound to be used in the method will vary depending on a number of factors, including the identity of the antifouling compound, the identity of the organism to be inhibited, and the mode of contact. In addition, the rate at which the compound is released into the surrounding aquatic environment can be a major factor in determining both the effectiveness of the method and the duration of protection. If the compound is released too rapidly, it will be exhausted quickly, and the coating must be re-applied for the surface to be protected. If on the other hand the release rate of the antifouling compound is too slow, the concentration of the compound in the aquatic environment immediately surrounding the surface to be protected may be insufficient to inhibit settlement. Preferably, the antifouling compound is released into the environment adjacent the protected surface at the rate of between about 0.0001 and 1000 μg/cm 2 -hr, and more preferably is released at a rate of between about 0.01 and 100 μg/cm 2 -hr. Compositions of the invention preferably comprise furan compound(s) in a concentration of about 0.01 weight percent to about 50 weight percent based on said composition, more preferably in a concentration of about 0.1 to 20 weight percent based on said composition.
The organisms against which a surface can be protected by the present method can be any organism which can attach to a submerged surface. Exemplary organisms include algae, including members of the phyla Chlorophyta and Phaeophyta, fungi, microbes, tunicates, including members of the class Ascidiancea, such as Ciona intestinalis, Diplosoma listerianium, and Botryllus sclosseri, members of the class Hydrozoa, including Clava squamata, Hydractinia echinata, Obelia geniculata, and Tubularia larnyx, bivalves, including Mytilus edulis, Crassostrea virginica, Ostrea edulis, Ostrea chilensia, and Lasaea rubra, bryozoans, including Ectra pilosa, Bugula neritinia, and Bowerbankia gracilis, polychaete worms, including Hydroides norvegica, sponges, and members of the class Cirripedia (barnacles), such as Balanus amphitrite, Lepas anatifera, Balanus balanus, Balanus balanoides, Balanus hameri, Balanus crenatus, Balanus improvisus, Balanus galeatus, and Balanus eburneus. Organisms of the genus Balanus are particularly frequent foulers of aquatic structures. Specific fouling organisms to which this invention is especially directed include barnacles, zebra mussels, algae, bacteria, diatoms, hydroids, bryzoa, ascidians, tube worms, and asiatic clams.
In addition to the lactone compound, the composition can comprise additional antifouling agents which may act in combination or synergistically; said additional antifouling agent can be, for example: manganese ethylene bisdithiocarbamate; a coordination product of zinc ion and manganese ethylene bisdithiocarbamate; zinc ethylene bisdithiocarbamate; zinc dimethyl dithiocarbamate; 2, 4, 5, 6-tetrachloroisophthalonitrile; 2-methylthio-4-t-butylamino-6-cyclopropylamino-s-triazine; 3-(3,4-dichlorophenyl)-1,1-dimethyl urea; N-(fluorodichloromethylthio)-phthalimide; N,N-dimethyl-N'-phenyl-(N-fluorodichloromethylthio)-sulfamide; tetramethylthiuram disulfide; 2, 4, 6-trichlorophenyl maleimide; zinc 2-pyridinthiol-1-oxide; copper thiocyanate; Cu-10% Ni alloy solid solution; and 4,5-dichloro-2-n-octyl-4-isothiazolin-3-one.
The protective carrier component functioning to release antifouling agent can be a film-forming component, an elastomeric component, vulcanized rubber, or a cementitious component. The protective carrier component can be any component or combination of components which is applied easily to the surface to be protected, adheres to the submerged surface to be protected, and permits the release of the antifouling compound into the water immediately surrounding the coated surface. Different components will be preferred depending on the material comprising the underwater surface, the operation requirements of the surface, the configuration of the surface, and the antifouling compound. Exemplary film-forming components include polymer resin solutions. Exemplary polymer resins include unsaturated polyester resins formed from (a) unsaturated acids and anhydrides, such as maleic anhydride, fumaric acid, and itaconic acid; (b) saturated acids and anhydrides, such as phthalic anhydride, isophthalic anhydride, terephthalic anhydride, tetrahydrophthalic anhydride, tetrahalophthalic anhydrides, chlorendic acid, adipic acid, and sebacic acid; (c) glycols, such as ethylene glycol, 1,2 propylene glycol, dibromoneopentyl glycol, Dianol 33®, and Dianol 22®; and (d) vinyl monomers, such as styrene, vinyl toluene, chlorostyrene, bromostyrene, methylmethacrylate, and ethylene glycol dimethacrylate. Other suitable resins include vinyl ester-, vinyl acetate-, and vinyl chloride-based resins, elastomeric components, vulcanized rubbers, and urethane-based resins. The cementitious compounds are used to protect certain types of underwater structures, as are the elastomeric materials and vulcanized rubber.
The percentage of the antifouling compound of Formula I or II in the coating required for proper release of the compound into the aquatic environment surrounding the surface to be protected will vary depending on the identify of the antifouling compound, the identity of the film-forming component of the coating and other additives present in the coating which may affect release rate. As described above, the release rate of the antifouling compound can be a major factor in determining both the effectiveness of the method and the duration of protection. It is preferred that the coating be released into the surrounding water at a rate of between about 0.0001 and 1,000 μg/cm 2 -hr; more preferably, the compound comprises between about 0.01 and 100 μg/cm 2 -hr. Preferably, the antifouling compound comprises between about 0.001 and 80 percent of the coating by weight, and more preferably comprises between 0.01 and 20 percent of the coating.
Those skilled in this art will appreciate that a coating of the present invention can comprise any number of forms, including a paint, a gelcoat, or varnish, and the like. The coating can include components in addition to the antifouling coating and film-forming component which confer a desirable property, such as hardness, strength, rigidity, reduced drag, impermeability, or water resistance.
The present invention encompasses any article which contains a surface coated with a coating containing a compound of Formula I or II. Those articles which are particularly suitable for protection with the coating are those which, either intentionally or inadvertently, are submerged for a least the duration required for an organism to settle on a submerged object. Coated articles can comprise any material to which aquatic organisms are know to attach, such as metal, wood, concrete, polymer, and stone. Exemplary articles which may require antifouling protection include boats and boat hulls, fish nets, recreational equipment, such as surfboards, jet skis, and water skis, piers and pilings, buoys, off-shore oil rigging equipment, and decorative or functional stone formations.
The composition of the invention can be a cementitious composition which includes at least one of said antifouling compounds and a cementitious matrix. Such a composition is suitable for use in submerged structures, such as piers, pilings, and offshore oil rigging equipment and scaffolding, upon which fouling organisms tend to settle. Exemplary cementitious matrix compositions include portland cement and calcium aluminate based compositions. As those skilled in this art will appreciate, the cementitious matrix should be able to release the antifouling compound, and the antifouling compound must be present in sufficient concentration that the release rate of the compound into the surrounding aquatic environment inhibits settling of organisms on the submerged surface of an article formed from the composition.
The invention is now described in more detail in the following examples which are provided to more completely disclose the information to those skilled in this art, but should not be considered as limiting the invention.
EXAMPLES
Collection and Culture of Experimental Specimens
Adult individuals of the acorn barnacle Balanus amphitrite Darwin were collected from the Duke University Marine Laboratory seawall in Beaufort, N.C. Collected specimens were crushed, and the nauplius stage larvae released therefrom were cultured to cyprid stage for cyprid-stage assays according to the methods of Rittschof et al., J. Exp. Mar. Biol. Ecol. 82:131-146 (1984).
Settlement Assay for Cyprid-Stage Larvae
Settlement assays were performed as previously described by Rittschof et al. J. Chem. Ecol. 11:551-563 (1985). Three-day old cyprid larvae were used.
All compounds were tested for their ability to inhibit settlement by cyprid larvae of the barnacle Balanus amphitrite. Larvae were added to 50×9 mm polystyrene Petri dishes containing 5 ml of aged seawater that had been passed through a 100 kDa cut-off filter and varying levels of test compound. Controls consisted of barnacle larvae and filtered seawater added to the dishes without test compound. Dishes were then incubated for 20-24 hrs at 28° C. with light for approximately 15 hours and in darkness for approximately 9 hours. The dishes were then removed from the incubator, examined under a dissecting microscope to determine whether larvae were living or dead. Larvae were then killed by addition of several drops of 10% formalin solution. Settlement rate was quantified as number of larvae that had attached to the dish surface, expressed as a percentage of total larvae in the dish. Experiments were performed in duplicate. The lower the percent settlement, the more efficacious the test compound.
EXAMPLE 1
Ethyl-3-furoate (9.63 μl) was diluted to 20 ml with seawater. Aliquots of this stock solution were added to separate dishes containing seawater to provide the concentrations shown in Table 1. The larvae were added and the test conducted as described above. T1 TABLE 1- Control of Barnacle Settlement with Ethyl-3-furoate? - Concentration? % Settlement? - 0 (Control) 53 - 500 μg/ml 0 - 50 μg/ml 11 - 5 μg/ml 18 - 500 ng/ml 52 -
EXAMPLE 2
Methyl-2-furoate (8.48 μl) was diluted to 20 ml with seawater. Aliquots of this stock solution were added to separate dishes containing seawater to provide the concentrations shown in Table 2. The larvae were added and the test conducted as described above.
TABLE 2______________________________________Control of Barnacle Settlement with Methyl-2-furoateConcentration % Settlement______________________________________0 (Control) 53500 μg/ml 250 μg/ml 465 μg/ml 53______________________________________
EXAMPLE 3
2-Ethylfuran (6.94 μl) was diluted to 20 ml with seawater. Aliquots of this stock solution were added to separate dishes containing seawater to provide the concentrations shown in Table 3. The larvae were added and the test conducted as described above.
TABLE 3______________________________________Control of Barnacle Settlement with 2-EthylfuranConcentration % Settlement______________________________________0 (Control) 53500 μg/ml 4150 μg/ml 54______________________________________
EXAMPLE 4
2-Methylfuran (10.98 μl) was diluted to 20 ml with seawater. Aliquots of this stock solution were added to separate dishes containing seawater to provide the concentrations shown in Table 4. The larvae were added and the test conducted as described above.
TABLE 4______________________________________Control of Barnacle Settlement with 2-MethylfuranConcentration % Settlement______________________________________0 (Control) 5350 μg/ml 395 μg/ml 61______________________________________
EXAMPLE 5
2-Acetylfuran (9.11 μl) was diluted to 20 ml with seawater. Aliquots of this stock solution were added to separate dishes containing seawater to provide the concentrations shown in Table 5. The larvae were added and the test conducted as described above.
TABLE 5______________________________________Control of Barnacle Settlement with 2-AcetylfuranConcentration % Settlement______________________________________0 (Control) 53500 μg/ml 54______________________________________
EXAMPLE 6
2-Furyl-n-pentyl ketone (0.909 μl) was diluted to 20 ml with seawater. Aliquots of this stock solution were added to separate dishes containing seawater to provide the concentrations shown in Table 6. The larvae were added and the test conducted as described above.
TABLE 6______________________________________Control of Barnacle Settlement with 2-Furyl-n-pentyl ketoneConcentration % Settlement______________________________________0 (Control) 42500 μg/ml 050 μg/ml 15 μg/ml 2500 ng/ml 1450 ng/ml 265 ng/ml 20500 pg/ml 22______________________________________
EXAMPLE 7
2-Furyl-n-pentyl ketone (0.909 μl), 2-ethylfuran (6.94 μl) and 2-acetylfuran (9.11 μl) were each diluted to 20 ml with seawater. Aliquots of these stock solutions were added to separate dishes containing seawater to provide the respective test substances in concentrations of 500 μg/ml. The larvae were added and the test conducted as described above. These data are presented in Table 7.
TABLE 7______________________________________Control of Barnacle Settlement with FuranCompounds at 500 μg/mlCompound % Settlement______________________________________Control 612-Furyl-n-pentyl ketone 02-Ethylfuran 342-Acetylfuran 41______________________________________
While the invention has been described with reference to specific examples and applications, other modifications and uses for the invention will be apparent to those skilled in the art without departing from the spirit and scope of the invention as defined in the following claims.
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Certain furan compounds are disclosed as being useful as marine or fresh water antifoulant compounds to be used in protective carrier compositions such as film forming polymer to protect fish nets, boats, pilings, and piers.
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[0001] This application is a divisional application of U.S. application Ser. No. 12/808,272, §371(c) date of Feb. 25, 2011, which is a National Stage of PCT/DK2008/000434, filed Dec. 16, 2008, and claims the benefit of Denmark PA 2007 01797, filed Dec. 17, 2007, all of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] The invention relates to a method of transferring a piece of cloth from a pair of spreader clamps to a conveyor via a transverse boom, wherein the piece of cloth is first suspended and straightened between the spreader clamps, then supplied to the transverse boom and subsequently delivered from the transverse boom to the conveyor.
[0003] This technique relates to the operation of laundry apparatuses, wherein a large amount of moist pieces of cloth are to be straightened individually and supplied to a conveyor that transfers the pieces of cloth to eg a rotary ironer.
[0004] Such known handling of laundry will appear from eg PCT/DK2007/00022
[0005] The known technique is associated with the drawback that the fore edge of the clothing, ie the edge that sits foremost on the conveyor, seen in the direction of conveyance thereof, will curve downwards between the spreader clamps even if they are in an extreme position, due to the own weight of the clothing and its water content pulling the clothing downwards. By the known technique, this undesired curve on the fore edge is transferred to the clothing when it is situated on the conveyor and transferred to the rotary ironer, and the most significant drawback of this manifests itself when the clothing is folded following the ironing in which case the end result will have a sloppy or unprofessional appearance.
[0006] It is the object of the invention to provide a method for straightening the fore edge of the piece of cloth to the effect that the fore edge will be completely straight when the piece of cloth has been supplied to the conveyer.
SUMMARY OF THE INVENTION
[0007] This object is obtained by an alignment of the fore edge of the piece of cloth being performed, seen in the direction of conveyance of the conveyor, following initiation of the delivery from the clamps to the transverse boom, but before it has been supplied to the conveyor.
[0008] The alignment can be provided in two different ways, on the one hand by time-controlling the mutually movable parts and, on the other, by a change of shape of some of the mutually movable parts. The preferred embodiments of the invention are exercised either by the transverse boom being moved in the direction of said direction of conveyance during the period of time when the clothing is delivered from the spreader clamps to the transverse boom, or by the transverse boom being provided with a supporting area; and that the shape of that area is changed after the piece of cloth has been supplied to the transverse boom, but before it is supplied to the conveyor. The transverse boom can be configured in one piece or may be divided into sections, eg three or more.
[0009] The invention also comprises a first apparatus for exercising the method and comprising a conveyor and comprising a pair of spreader clamps for receiving a pair of adjacent corners of a piece of cloth and for spreading the piece of cloth and for supplying it onto a transverse boom that extends transversally to the direction of conveyance of the conveyor and is shiftable in the latter direction.
[0010] The apparatus is characterised in that the apparatus comprises a control unit which is configured for controlling, on the one hand, the spreading movement of the spreader clamps and, on the other, the shifting of the transverse boom in the direction of the direction of conveyance of the conveyor in concordance with a pattern of movement which is stored in the control unit. The pattern of movement may have all degrees of complexity—from a simple linear course to a complex movement that depends on time, a number of sensors for detecting the shape of the clothing as well as on further parameters, if any.
[0011] The invention also comprises another apparatus of the kind just related which is, according to the invention, characterised in that the transverse boom comprises an alignment profile that extends essentially in parallel with a movement path for the spreader clamps a distance lower than the spreader clamps, which alignment profile comprises a form-changeable support area for a rim area of the piece of cloth and comprises means for temporarily retaining the piece of cloth.
[0012] The means according to the latter apparatus may be combined with the means in the first apparatus for obtaining a completely straight fore edge of the piece of cloth.
[0013] It is noted that the undesired downwardly curving part of the piece of cloth known from the prior art is very difficult to calculate in advance, it depending on the elasticity and weight of the clothing and the amount of water absorbed by the clothing. Therefore, in some cases, it will not be possible to accurately calculate in advance the mutual time-control of the machine parts or the shape-change of the alignment profile; rather one would operate with a number of fixed settings that an operator can choose from. In practice, a series of typically largely identical pieces of cloth will be run, and, in the course of a fairly small number of test runs, the method and the apparatus according to the invention will be adjusted to achieve a completely straight fore edge. However, the invention also encompasses that means may be provided for detecting the shape of the fore edge and for setting the time control and/or the form change of said machine parts in such a way as to dynamically compensate for the unintended, downwardly curving part of the piece of cloth.
[0014] The transverse boom has means for retaining the piece of cloth. Those means may be mechanical, but typically they are vacuum means which is why the transverse boom will also be designated a vacuum boom.
[0015] According to one embodiment, the vacuum boom is flexible transversally to its own plane, which may be accomplished eg by curving the central part of the boom upwards, whereby the major and freely suspended part of the piece of cloth is lifted to compensate for the downwardly directed curve. Alternatively, the central part of the boom is curved downwards before the piece of cloth is delivered from the clamps. When the central part is subsequently curved back to its resting position, the fore edge of the piece of cloth becomes aligned.
[0016] According to another embodiment, the vacuum boom is shape-changeable in its own plane, which, according to one embodiment, can be accomplished by the boom being divided into two or more sections that are connected to each other by means of hinges and are carried and controlled by mechanisms configured therefor.
[0017] The more water absorbed by the clothing, the heavier it is, and the deeper is the curve formed when suspended between the spreader clamps. It is therefore an advantage to be able to adjust the form-changeability, and hence, according to one embodiment, detector means may be provided for detecting the shape of the edge of the piece of cloth before—during—and/or after it is transferred from the spreader clamps to the boom.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] The invention will be explained in further detail n the description that follows of a number of embodiments, reference being made to the drawing, wherein
[0019] FIGS. 1-3 illustrate the prior art,
[0020] FIGS. 4 and 5 show a first embodiment of the apparatus according to the invention;
[0021] FIGS. 6A and 6B show details of the embodiment shown in FIGS. 4 and 5 ;
[0022] FIGS. 7 and 8 show an alternative embodiment of the invention; while
[0023] FIGS. 9-13 show further examples of embodiments according to the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0024] FIGS. 1-3 show the essential parts of a known apparatus to which the invention is related. By 1 is shown a conveyor belt that runs around a number of rollers of which the roller 2 is seen. The function of the apparatus is to deliver a laundry item 3 to the conveyor belt 1 , and, according to the prior art, it is accomplished by means of a pair of spreader clamps 4 , 5 that are journalled on a machine part 6 to the effect that the clamps 4 , 5 can be moved along the machine part 6 essentially transversally to the direction of conveyance of the conveyor belt 1 , see the arrow in FIG. 1 . The spreader clamps 4 , 5 can be closed and opened (open position in FIG. 2 ), and the apparatus can be configured such that the spreader clamps 4 , 5 receive a piece of cloth either automatically or manually. When the piece of cloth 3 is extended between the clamps 4 , 5 as is shown in FIG. 1 , the fore edge 7 of the piece of cloth will curve downwards due to the own weight of the clothing and the weight of the amount of water contained in the clothing. By the prior art, the piece of cloth is transferred from the position shown in FIG. 1 to the position shown in FIG. 2 , where the piece of cloth 3 is supplied to a vacuum boom 8 . Then the spreader clamps are opened as shown in FIG. 2 and moved completely to one side to the effect that they release the piece of cloth completely. The undesired downwardly curving shape of the fore edge 7 is thus maintained when the piece of cloth has been handed over to the vacuum boom 8 .
[0025] The above explanation of the downwardly curving fore edge 7 of the piece of cloth is slightly simplified in relation to FIGS. 1-3 . In reality, the highest load due to the weight of the clothing will occur between the tips of the spreader clamps, which is, however, difficult to illustrate. By the clamps in FIG. 1 being forcefully influenced to move away from each other, the fore edge 7 can straightened almost simultaneously with the clothing between the tips of the clamps still curving downwards, and this will cause the fore edge 7 to still curve when the clothing has been deposited onto the conveyor belt. It will also be understood that the position of the clamps relative to the horizontal is of consequence. The above detailed explanation is most relevant in the context of horizontal clamps, while the explanation given in relation to FIGS. 1-3 suffices when the clamps point vertically downwards.
[0026] Therefore, the present invention generally speaks of the shape of the fore edge of the piece of cloth, albeit the problem concerns the complete piece of cloth that is situated between the clamps and in particular between the tips of the clamps.
[0027] FIG. 3 will show (for the sake of clarity the spreader clamps are not shown) that the vacuum boom 8 is moved rearwards, see the shown arrows, by which the piece of cloth is deposited onto the belt 1 , the vacuum in the vacuum boom 8 being relieved at some point. Therefore, the prior art entails that the curved shape of the fore edge 7 still exists when the piece of cloth 3 is advanced by means of the conveyor belt 1 , typically to a rotary ironer. Therefore, the fully ironed clothing will also have that inexpedient shape, and the major drawback manifests itself later, when the clothing is folded in an automated process. The curved edges will reveal an unfinished and unprofessional laundry result.
[0028] FIGS. 4 and 5 show a first embodiment of an apparatus according to the invention where, instead of the vacuum boom 8 described above, a transverse boom 9 is provided which is provided with a pair of support areas in the shape of perforated sheets 10 , 11 . The perforated sheets 10 , 11 are pivotally journalled at their respective outer ends, and actuator means are provided that are configured to shift the ends of the perforated sheets 10 , 11 that face towards each other as will be explained in further detail in the context of FIGS. 6A and B. The fore edge 7 of the piece of cloth 3 has the same inexpedient shape in FIG. 4 as was shown in FIG. 2 , but the perforated sheets 10 , 11 being, according to the invention, able to turn to the position shown in FIG. 5 , the fore edge 7 can be aligned to be completely straight. When, at a later stage, the transverse boom 9 is moved back in the same manner as described in the context of FIG. 3 , the piece of cloth 3 will be supplied onto the conveyor belt 1 with a straight fore edge 7 or an approximately straight fore edge. The final shape will depend on how many sections of perforated sheets that are provided and how they are controlled relative to each other; see the embodiments described at a later stage. First, in the context of FIGS. 6A and 6B , a number of details of the embodiment shown in FIGS. 4 and 5 will be explained.
[0029] FIG. 6A shows the transverse boom 9 , and more specifically that end where the perforated sheet is journalled, which is shown by L. The opposite end of the same perforated plate 10 will appear from FIG. 6B which also shows a drive mechanism for moving the perforated plate 10 back and forth. The drive mechanism comprises a pneumatic cylinder 12 that drives an actuator arm 13 connected to the perforated sheet 10 via a free clearance in the transverse boom 9 . FIG. 6 further shows a detector 14 configured for receiving light from a light source 15 which is situated between the perforated plates 10 and 11 . The location is configured such that the detector 14 is able to receive light from the light emitter 15 when the clothing is situated on the perforated sheets 10 , 11 as shown in FIG. 4 . In that case, propellant air is supplied to the cylinder 12 to the effect that the perforated sheets 10 , 11 are moved to the position shown in FIG. 5 where the fore edge 7 is straightened, and where the clothing precisely blocks the light beam from the light emitter 15 to the detector 14 . It will be understood that the perforated sheet 11 can be driven by a separate cylinder identical to the cylinder 12 ; or that the cylinder 12 can also be configured to operate both perforated sheets.
[0030] Another apparatus for exercising the invention is shown in FIGS. 7 and 8 , wherein the same perforated sheet 8 can be used as is shown in FIGS. 1-3 . By the embodiment shown in FIGS. 7 and 8 , the fore edge 7 is aligned by the vacuum boom 8 being moved rearwards (see the arrow) simultaneously with the clothing being deployed (see the arrows) on the vacuum boom 8 by means of the clamps 4 , 5 . By the piece of cloth 3 being deployed gradually towards the vacuum boom 8 , while simultaneously the latter is conveyed backwards, the fore edge 7 could end up with a completely rectilinear course which is shown in FIG. 8 without the vacuum boom having to be modified from a technical point of view. In practice, the described pattern of movement requires a control unit in which a control program is stored that defines the mutual patterns of movement of the movable parts. Such control programs may comprise everything from a simple linear pattern of movement to complex patterns of movement that depend on one or more detectors and/or manual adjustment options on the apparatus.
[0031] It will be understood that the mutually shifting in time of parts in accordance with the embodiment shown in FIGS. 7 and 8 can be combined with the machine parts described in the context of FIGS. 4 and 5 , and to further describe the many options that are entailed by the invention, FIGS. 9-13 show further embodiments of the invention.
[0032] By the embodiment shown in FIG. 9 , a vacuum boom is provided which is divided into three sections 16 , 17 , 18 . As will appear from FIG. 10 , the section 17 is configured for being movable in the direction of the arrow relative to sections 16 and 18 . Section 17 may alternatively be configured to be movable as shown by the arrow in FIG. 11 for straightening the curve of the fore edge 7 of the piece of cloth 3 . It will be understood that the sections 16 - 18 shown in FIGS. 10 and 11 are—apart from being movable relative to each other—also configured for being moved in unison in order for them to deliver the piece of cloth 3 to the conveyor belt 1 as is shown and explained in the context of FIG. 3 .
[0033] FIGS. 12 and 13 show a further embodiment where vacuum sections 19 , 20 are configured to be movable relative to each other as is shown by the arrows in FIG. 13 . It will readily be understood that it is possible to thereby rectify the disadvantageous shape of the fore edge 7 . It will also be understood that the more sections are provided, the straighter a correction can be made. An ideal scenario is when a perforated sheet is used that can be curved evenly with a view to an even straightening of the downward curve of the fore edge 7 of the piece of cloth 3 . It will also be understood that the other embodiments shown in FIGS. 7-13 and others can be supplemented with one or more detectors, see the detector 14 , 15 in FIG. 6B . Thereby it is possible to emit control signals to an electronic control circuit which is configured for controlling the mutual movement of the described machine parts.
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The invention concerns a method and corresponding apparatus of transferring a piece of cloth from a pair of spreader clamps to a conveyor via a transverse boom, where the piece of cloth is first suspended and straightened between the spreader clamps, then delivered to the transverse boom, and subsequently delivered from the transverse boom to the conveyor. Apart from that, a straightening of the fore edge of the piece of cloth is performed, seen in the direction of conveyance of the conveyor, after its delivery from the clamps to the transverse boom has been initiated, but before it is delivered to the conveyor.
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