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FIELD OF THE INVENTION
The present invention relates to garments for animals, and particularly to a protective garment for a dog working in a cleanroom.
BACKGROUND OF THE INVENTION
Four-legged animals, particularly dogs, have long worn simple garments to protect them from cold or wet weather. Dogs have a wide assortment of sweaters, rain jackets, hats, and boots to keep them comfortable outdoors. Dogs that work often wear distinguishing uniforms, such as the colored capes or vests worn by assistance dogs. Dogs that work in law enforcement or the military may even wear armored apparel.
Dogs that have been groomed for a show may wear some sort of coverall suit to keep them clean, such as to keep them from accidentally rubbing against a dusty surface. Containment suits to keep insecticidal dust in contact with a dog's fur for a period of time are also known.
Both types of “cleanliness” garment for a dog are typically designed with air vents to keep the dog from overheating while wearing the coverall. Thus they prevent bulk transfer of dirt or insecticide between the inside and the outside of the suit, but do not totally prevent material, especially small particles and hairs, from entering or leaving the suit.
One very specialized job that dogs can perform is to identify and locate various harmful materials, such as bacteria, molds, and allergenic chemicals. Colonies of mold, yeast, or bacteria often create chemical products of their metabolism that have an odor that is diagnostic of the type of organism. Dogs can be trained to respond to these characteristic odors and to indicate the location of the strongest source of a detected odor.
For example, a dog trained to recognize characteristic odors from molds can locate infestations that are not visible, such as on the inner surface of wallpaper or underneath floor covering in houses. Dogs can also find colonies of harmful fungi and bacteria in restaurants, hospitals, and manufacturing areas such as semiconductor fabrication cleanrooms.
Bacterial types that can be identified by their odors include E. Coli, Salmonella , and Listeria . These genera include several pathogenic species that are health hazards to animals and humans. Bacteria and fungi can also cause various types of defects and yield loss in manufacturing.
It is desirable that dogs that perform jobs in restaurants, hospitals or other health care facilities, and manufacturing areas wear distinctive garments to indicate that they are service dogs and not unauthorized pets. Such garments are preferably also protective for the dogs and for the facility.
For example, dogs typically shed hairs, dander, and other materials when they move. These are allergenic to some people and are never seen as benign when found in a restaurant meal or on a semiconductor wafer. Thus, a garment for a dog working in a facility that prepares food, provides health care, or manufactures microscopic or sterile articles would preferably envelop the dog and keep hair and dander inside.
It is desirable that a work garment for a dog be constructed somewhat like “cleanroom” garb for humans: made of lintfree fabric that does not allow passage of small particles in either direction, composed of parts that overlap sufficiently that movement does not open a gap between parts or create a “bellows” effect to puff particles out between parts of the garment, and covering substantially all of the body.
However, human cleanroom garb typically either leaves the face bare or covers the face with a paper or fabric covering that air can penetrate. In the case of extremely “clean” applications, a human cleanroom suit may contain its own air source, such that the person may be totally enclosed in an impermeable unit.
A dog that is trained to detect certain odors uses a special type of breathing that maximizes the sensitivity of the sense of smell. The dog breathes more air in and out than is generally used for simple respiration and the air is preferably not filtered or obstructed. Filtration of the atmosphere through a permeable mask can add spurious odors and obscure the directionality of a scent. Thus, a cleanroom suit for a dog would have special requirements for the design of the face covering.
A dog trained to locate odors typically detects an odor then gradually approaches the strongest source of the odor. To signal the center of the odor, the dog may point to the source of odor with a paw, sit down directly in front of it, or stand close to it and wag the tail. Thus, an odor-detecting dog typically comes close to the source of an odor, which may be a pathogen or substance that may be harmful to the dog.
It would be desirable that a work suit for a dog protect the dog from hazards the dog encounters. Although the dog's nose must be relatively free to process air, it is desirable that the nose also be protected against accidental or careless contact with harmful substances. In fact, it would be desirable that the dog's entire body, including the pads of its paws, be protected from contact with pathogens or harmful chemicals.
There is a need for an identifying garment that a dog can wear while locating characteristic odors in restaurants, hospitals, laboratories, skilled nursing facilities, and cleanrooms. There is further a need for a garment that prevents particles from being shed by the dog while in the controlled facility. There is further a need for a garment that protects the dog from contact with dangerous materials. There is further a need for a protective garment for a dog that does not impede the dog's breathing or interfere with the dog's sense of smell.
SUMMARY OF THE INVENTION
The present invention is “clean” garb for a dog that uses the sense of smell to locate harmful bacteria or fungi in controlled environments such as hospitals and cleanroom manufacturing areas. The coverall covers nearly all of the dog's body and feet while providing a clear airway to the nostrils.
The garb generally includes a body covering suit with integral booties and a hood for covering the head. The body portion includes a back zipper for entry into the suit. Elongated portions enclose each leg separately for easy walking. An elastic band secures each leg portion above the foot to form a bootie, which may include a flexible sole for walking on.
Another elongate portion surrounds the tail. An elastic band holds the tail portion firmly near the base of the tail so that wagging or waving of the tail may be clearly seen by the dog's handler.
A hood for covering the head is donned after the body portion and overlaps it in the head and neck area. An elastic band secures the hood tightly against the base of the neck. The front of the hood is transparent plastic to allow the dog to see. The transparent portion surrounds the snout and extends slightly beyond it. The end of the transparent portion is open to allow free passage of air, but the extended end of the hood prevents the dog's nose from contacting any surface.
The invention will now be described in more particular detail with respect to the accompanying drawings in which like reference numerals refer to like parts throughout.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective, partly exploded view of the dog wearing work garb of the present invention.
FIG. 2 is a top view of the work garb alone.
FIG. 3 is a top view of the dog and work garb of FIG. 1 .
FIG. 4 is a side view of the dog and work garb of FIG. 1 .
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows a dog 100 wearing the work garb 10 of the present invention. Work garb 10 includes two main parts: coverall 20 for covering the body and hood 50 for covering the head.
FIG. 2 shows the parts of work garb 10 in top view. FIG. 3 is a top view of the dog of FIG. 1 . FIG. 4 is a side view of the dog of FIG. 1 .
Coverall 20 covers the dog's entire body except for the front part of the head. Body portion 40 covers dog 100 's torso and includes a long zipper 43 that selectively opens up back 42 of coverall 20 for dog 100 to don coverall 20 . Neck/head portion 44 covers dog 100 's neck and the back part of the head. Preferably, neck/head portion 44 terminates near the ears and preferably, as shown, terminates between dog 100 's ears and eyes.
Neck/head portion 44 includes a cinching means, such as elastic band 45 , for holding the edge of neck/head portion 44 snugly against the dog's head.
Coverall 20 includes a leg covering 22 for each leg. Each leg covering 22 is an elongated sleeve with a closed end. The closed end of leg covering 22 forms an integral bootie 24 for the foot. Cinching means, such as an elastic band 25 , located just above the dog's foot, holds bootie 24 in place so that dog 100 may walk easily. Alternatively, elastic band 25 may be replaced with other cinching means for holding the bootie in place, such as a strap that is tied or otherwise secured above dog 100 's foot.
Coverall 20 preferably includes a tail pouch 30 for enclosing dog 100 's tail. Tail elastic 35 secures tail pouch 30 close to dog 100 's tail about an inch or two from the base of the tail. Tail elastic 35 ensures that the tail does not slip inside coverall 20 . Because some dogs 100 are trained to indicate the location of an odor by wagging the tail, it is necessary that the tail remains within tail pouch 30 so that wagging is easily seen.
Work garb 10 also includes a hood 50 for covering dog 100 's head without interfering with dog 100 's senses of vision or smell. Hood 50 generally comprises a bonnet portion 52 and a face shield 56 .
Bonnet portion 52 is for covering the rear part of dog 100 's head and overlapping neck/head portion 44 of coverall 20 . Bonnet portion 52 includes neck elastic 55 to hold bonnet portion 52 tightly overlapped over neck/head portion 44 .
Face shield 56 is attached to bonnet portion 52 and covers the front portion of dog 100 's head. Face shield 56 is generally in the shape of a truncated cone and constructed from transparent, flexible plastic. Face shield 56 is open at the end near dog 100 's nostrils to allow for unobstructed breathing and sampling of air for odors. Face shield 56 extends slightly beyond dog 100 's snout so that dog 100 cannot touch any surface with unprotected nose 101 , lips, or tongue.
Face shield 52 is preferably constructed of sheet material that is flexible enough to form into the general shape of a truncated cone that fits fairly snugly around the dog's snout. The preferred material is also sufficiently rigid when rolled into a conical shape that it extends past dog 100 's nose 101 in a sufficiently rigid manner that dog 100 will not be able to easily dislodge or mash opening 57 and be able to contact dangerous materials with nose 101 .
Face shield 56 may be permanently attached to bonnet portion 52 , such as by adhesive or by sewing. Alternatively, face shield 56 may be detachable so that it is easily replaced if scratched or contaminated. For example, face shield 56 may be attached with snaps (not shown) that are covered by a placket.
In an alternative embodiment, not illustrated, face shield 56 comprises a transparent portion of hood 50 sufficient for dog 100 to see through. In such case, opening 57 in the distal end of hood 50 is rigidified, such as by including a plastic armature around opening 57 .
Coverall 20 and bonnet portion 52 are constructed of suitable woven, knit, or non-woven sheet material that prevents passage of particles and microorganisms. Tyvek is an example of a non-woven material that is suitable for a single wearing. Suitable fabrics woven from synthetic fibers can be used to make work garb 10 that can be laundered and re-used many times. Zipper 43 must be of a type that does not generate free particles when operated. Alternative closure means include ties, snaps, hook and loop fastener, or similar.
Dog 100 must be appropriately prepared before donning work garb 10 . Dog 100 is thoroughly brushed and bathed. After drying, dog 100 is vacuumed to remove loose hairs and dander. The vacuuming is done before entering the “gowning area” that is typically adjacent to the clean work area.
The vacuumed dog 100 then enters the gowning area. The human handler with dog 100 dons gloves before helping dog 100 don work garb 10 . Zipper 43 is fully opened and coverall 20 is spread open for dog 100 to step into. Each of dog 100 's feet goes into an appropriate leg cover 22 and the handler ensures that the foot is fully engaged into bootie 24 , with elastic 25 disposed above the foot. Dog 100 's tail is similarly placed into tail pouch 30 . Then zipper 43 is closed and neck/head elastic 45 is smoothed in front of dog 100 's ears.
Hood 50 is then pulled over dog 100 's head from the front. Dog 100 's snout goes into conical face shield 52 and neck elastic 55 is overlapped over neck/head portion 44 of coverall 20 . The handler checks that dog 100 's nostrils and lips are protected by face shield 52 and cannot touch any external surface.
This garbing process is typically performed with dog 100 and handler standing on a tacky mat so that any lint or bacteria stirred up by the process is eventually collected by the tacky mat. The human handler typically replaces the gloves with fresh ones after assisting dog 100 don work garb 10 .
While work garb 10 has been described for use by a dog 100 , it may be seen that work garb 10 can be adapted for use by a similar animal, such as a pig, without loss of the benefits of the invention.
Although particular embodiments of the invention have been illustrated and described, various changes may be made in the form, composition, construction, and arrangement of the parts herein without sacrificing any of its advantages. Therefore, it is to be understood that all matter herein is to be interpreted as illustrative and not in any limiting sense, and it is intended to cover in the appended claims such modifications as come within the true spirit and scope of the invention | Protective suit for a dog allows a dog to work in a cleanroom or other controlled environment. Suit 10 includes particle-blocking coverall 20 and hood 50 . Hood 50 includes transparent face shield 52 to cover dog's eyes and snout. Face shield 52 is open at the end to allow air and odors to reach dog's nose unimpeded. Face shield 52 extends slightly beyond dog's nostrils to prevent dog from contacting hazardous chemicals or pathogens. Coverall 20 includes fitted sleeves 22 with integral boots 24 ; also a tail pouch 30 to keep tail separate and visible. | 0 |
FIELD OF THE INVENTION
The invention is concerned with a first responder system for predictively modeling contaminant transport during an environmental threat or a Chemical, Biological, or Radiological (CBR) threat or obscurant threat and for effective response after the threat.
DESCRIPTION OF THE PRIOR ART
The effective defense of cities, large bases, and military forces against chemical, biological, or radiological (CBR) incidents or attack requires new prediction/assessment technology to be successful. The existing plume prediction technology in use in much of the nation is based on Gaussian similarity solutions (“puffs” or “plumes”), an extended Lagrangian approximation that only really applies for large regions and flat terrain where large-scale vortex shedding from buildings, cliffs, or mountains is absent. These current plume methods are also not designed for terrorist situations where the input data about the source (or sources) is very scant and the spatial scales are so small that set-up, analysis and situation assessment of a problem must take place in seconds to be maximally effective. Both greater speed and greater accuracy are required.
The CBR defense of a fixed site or region has a number of important features that make it different from the predictive simulation of a contaminant plume from a known set of initial conditions. The biggest difference is that very little may be known about the source, perhaps not even its location. Therefore any analysis methods for real-time response cannot require this information. It is a crucial requirement to be able to use anecdotal information, qualitative data, and any quantitative sensor data we may be lucky enough to have and instantly build a situation assessment suitable for immediate action.
A software emergency assessment tool should be effectively instantaneous and easy to use because we require immediate assessment of new data, instantaneous computation of exposed and soon-to-be exposed regions, and the zero-delay evaluations of options for future actions. The software should also be capable of projecting optimal evacuation paths based on the current evolving situation assessment.
To meet these requirements, a new tool is required that is much faster than current “common use” models with accuracy comparable to three-dimensional, physics-based flow simulations for scenarios involving complex and urban landscapes. The focus is on situation assessment through sensor fusion of qualitative and incomplete data.
Typical hazard prediction and consequence assessment systems have at their heart a plume simulation model based on a Gaussian plume/puff model. These systems typically employ Gaussian plume simulation models and require accurate velocity fields as input. The Gaussian plume method, while relatively fast, tends to be inaccurate, especially for urban areas. The setup for all these systems tends to be complicated, and require a-priori knowledge of the source characteristics.
Some examples of common-use hazard prediction and assessment systems are as follows:
CATS (Consequences Assessment Tool Set) is a consequence management tool package, developed by the U.S. Defense Threat Reduction Agency, U.S. Federal Emergency management Agency, and Science Applications International Corp, that integrates hazard prediction, consequence assessment, emergency management tools, including the Hazard Prediction and Assessment Capability (HPAC) system, and critical population and infrastructure data within a commercial Geographical Information System. (CATS: Consequences Assessment Tool Set, U.S. Defense Threat Reduction Agency, U.S. Federal Emergency management Agency, and Science Applications International Corp.; SWIATEK et al. “Crisis Prediction Disaster Management, SAIC Science and Technology Trends II, Jun. 24, 1999)
CAMEO® (Computer Aided Management of Emergency Operations) is a system of software applications used widely to plan for and respond to chemical emergencies. It is one of the tools developed by EPA's Chemical Emergency Preparedness and Prevention Office (CEPPO) and the National Oceanic and Atmospheric Administration Office of Response and Restoration (NOAA), to assist front-line chemical emergency planners and responders. (CAMEO®: Computer Aided Management of Emergency Operations, EPA's Chemical Emergency Preparedness and Prevention Office (CEPPO) and NOAA; CAMEO “Computer Aided Management of Emergency Operations,” U.S. Environmental Protection Agency, May 2002, pp. 1-306)
MIDAS-AT™ (Meteorological Information and Dispersion Assessment System—Anti-Terrorism), a product of ABS Consulting Inc. is the all-in-one software technology that models dispersion of releases of industrial chemicals, chemical and biological agents, and radiological isotopes caused by accidents or intentional acts. MIDAS-AT is designed for use during emergencies and for planning emergency response drills. Its Graphical User Interface (GUI) is designed for straightforward user entry of information required to define a terrorist scenario with enough detail to provide critical hazard information during the incident. (MIDAS-AT™: Meteorological Information and Dispersion Assessment System—Anti-Terrorism: ABS Consulting)
HPAC (Hazard Prediction and Assessment Capability), developed by Defense Threat Reduction Agency, is a forward-deployable, counter proliferation-counterforce collateral assessment tool. It provides the means to predict the effects of hazardous material releases into the atmosphere and its impact on civilian and military populations. It models nuclear, biological, chemical, radiological and high explosive collateral effects resulting from conventional weapon strikes against enemy weapons of mass destructions production and storage facilities. The HPAC system also predicts downwind hazard areas resulting from a nuclear weapon strike or reactor accident and has the capability to model nuclear, chemical and biological weapon strikes or accidental releases. (HPAC: Hazard Prediction and Assessment Capability, DTRA, HPAC Version 2.0 and HASCAL/SCIPUFF Users Guide, Defense Special Weapons Agency, July 1996; “Hazard Prediction and Assessment Capability” Fact Sheet, Defense Threat Reduction Agency Public Affairs, pp. 1-2)
VLSTRACK (Vapor, Liquid, and Solid Tracking), developed by Naval Surface Warfare Center, provides approximate downwind hazard predictions for a wide range of chemical and biological agents and munitions of military interest. The program was developed to be user-friendly and features smart input windows that check input parameter combinations to ensure that a reasonable attack is being defined, and simple and informative output graphics that display the hazard footprint for agent deposition, dosage, or concentration. The model also features variable meteorology, allowing for interfacing the attack with a meteorological forecast; this feature is very important for biological and secondary evaporation computations. (VLSTRACK: Vapor, Liquid, and Solid Tracking, [U.S. Pat. No. 5,648,914] Naval Surface Warfare Center, Bauer, T. J. and R. L. Gibbs, 1998. NSWCDD/TR-98/62, “Software User's Manual for the Chemical/Biological Agent Vapor, Liquid, and Solid Tracking (VLSTRACK) Computer Model, Version 3.0,” Dahlgren, Va.: Systems Research and Technology Department, Naval Surface Warfare Center.)
ALOHA (Areal Locations of Hazardous Atmospheres), from EPA/NOAA and a component of CAMEO, is an atmospheric dispersion model used for evaluating releases of hazardous chemical vapors. ALOHA allows the user to estimate the downwind dispersion of a chemical cloud based on the toxicological/physical characteristics of the released chemical, atmospheric conditions, and specific circumstances of the release. Graphical outputs include a “cloud footprint” that can be plotted on maps to display the location of other facilities storing hazardous materials and vulnerable locations, such as hospitals and schools. (ALOHA®—Areal Locations of Hazardous Atmospheres, EPA/NOAA; “ALOHA Users Manual”, Computer Aided Management of Emergency Operations, August 1999, pp. 1-187)
FASTD-CT (FAST3D—Contaminant Transport) is a time-accurate, high-resolution, complex geometry computational fluid dynamics model developed by the Naval Research Laboratory in the Laboratory for Computational Physics and Fluid Dynamics. The fluid dynamics is performed with a fourth-order accurate implementation of a low-dissipation algorithm that sheds vortices from obstacles as small one cell in size. Particular care has been paid to the turbulence treatments since the turbulence in the urban canyons lofts ground-level contaminant up to where the faster horizontal airflow can transport it downward. FAST3D-CT has a number of physical processes specific to contaminant transport in urban areas such as solar chemical degradation, evaporation of airborne droplets, re-lofting of particles and ground evaporation of liquids. (FAST3D-CT: FAST3D—Contaminant Transport, LCP & FD, NRL Boris, J. “The Threat of Chemical and Biological Terrorism: Preparing a Response,” Computing in Science & Engineering, pp. 22-32, March/April 2002.)
NARAC (National Atmospheric Release Advisory Center) maintains a sophisticated Emergency Response System at its facility at Lawrence Livermore National Laboratory. The NARAC emergency response central modeling system consists of a coupled suite of meteorological and dispersion models that are more sophisticated than typical Gaussian models. Users access this system using a wide variety of tools, also supplied by NARAC. With this system NARAC provides an automated product for almost any type of hazardous atmospheric release anywhere in the world. Users must initiate a problem through a phone call to their operations staff or interactively via computer. NARAC will then execute sophisticated 3-D models to generate the requested products that depict the size and location of the plume, affected population, health risks, and proposed emergency responses. (NARAC: Atmospheric Release Advisory Capability, Lawrence Livermore National Laboratory, “Forewarning of Coming Hazards,” Science & Technology Review, pp. 4-11, June 1999, Lawrence Livermore National Laboratory.)
State-of-the-art, engineering-quality 3D predictions such as FAST3D-CT or the NARAC Emergency Response System that one might be more inclined to believe can take hours or days to set up, run, and analyze.
All of the above-mentioned systems take several minutes, hours, or even days to return results. Simplified systems such as PEAC® (Palmtop Emergency Action for Chemicals [U.S. Pat. No. 5,724,255] originally developed by Western Research Institute provide the necessary emergency response information to make quick and informed decisions to protect response personnel and the public. PEAC-WMD 2002 provides in hand information compiled from a number of references with very fast recall. PEAC provides emergency responders with instant access to vital information from a number of sources and evacuation distances based on several sets of guidelines. This system, can return results within seconds, requires less detailed knowledge of the source, but the resulting fixed-shape plume does not take into account any effect of complex terrain or buildings.
Waiting even one or two-minutes for each approximate scenario computation can be far too long for timely situation assessment as in the current common-use hazard prediction systems. Overly simplified results can result in inaccurate results. The answer to this dilemma is to do the best computations possible from state-of-the-art 3D simulations well ahead of time and capture their salient results in a way that can be recalled, manipulated, and displayed instantly.
SUMMARY OF THE INVENTION
Greater accuracy and much greater speed are possible at the same time in an emergency assessment system for an environmental threat or airborne chemical biological and radiological (CBR) threats. The present invention is a portable, entirely graphical hazard prediction software tool that exploits the new dispersion nomograph technology in order to achieve its speed and accuracy. The Nomograph technology has been filed as a provisional application at the U.S. Patent and Trademark Office, provisional application No. 60/443,530 on Jan. 30, 2003. The use of the dispersion nomograph representation and processing algorithms also allow some new features not available in existing systems. Multiple sensor fusion for instantaneous situation assessment is an automatic consequence of the nomograph technology. Reports from sensors about a contaminant can used to determine the affected area downwind. Using three or four appropriate sensor readings, the present invention can also backtrack and locate an unknown source graphically with zero computational delay. The present invention can accept qualitative and anecdotal input and does not require knowledge of a source location or a source amount.
The present invention provides an easy to use graphical user interface (GUI) to manipulate sensor, source, or site properties (i.e. location) and immediately provides an updated display of potential CBR hazards from a contaminant plume. The implementation has fast forward and fast reverse for the plume envelope displays, direct sensor fusion, and the ability to vary environmental properties in mid scenario. The present invention also plots evacuation routes automatically. The capability appears to the user as an infinite library of scenarios with a graphical controller to select, morph, and manipulate the CBR scenarios directly.
With the development of networked chemical sensors, and their possible deployment in cities and bases, it is vital to deploy them in optimal locations to provide the most beneficial effect. The characteristics of a sensor network, and the placement of sensors within the network, need to be evaluated for performance for a given situation. A sensor network should be capable of minimizing the detection delay of a source release. This maximizes the response time of people within the effected area, allowing them to take the appropriate measures to limit their exposure to the release.
The costs and logistics of running, building, and maintaining a sensor network makes it difficult to provide zero detection delay if point detectors are used exclusively. While some delay may be tolerated, the present invention minimizes this delay within other constraints of the situation. To find an optimal sensor network, the present invention uses a genetic algorithm using features of the present invention is an attractive solution.
An approach using genetic algorithms was selected for sensor optimization because the characteristics making up a robust sensor network were largely unknown. This approach also made it easy to modify specific characteristics while leaving the search method intact. Furthermore, advances in contaminant transport modeling made it possible for this search technique to be utilized.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram showing the overall structure, and main components of the present invention.
FIG. 2 is an Event Flow diagram illustrating how the components of the present invention respond to events generated internally, and externally.
FIG. 3 is a diagram representing the components of the graphical user interface of the present invention.
FIG. 4 is a diagram showing the presentation of Nomograph displays generated by the Nomograph library.
FIG. 5 is a detailed scenario using the present invention.
FIG. 6 is a block diagram of the various events generated externally, and internally in the present invention.
FIG. 7 shows a block diagram representing the main event loop, a component of the present invention to Nomograph Interface.
FIG. 8 is a functional block diagram of the interface used to communicate with the Nomograph libraries, a component of the present invention to Nomograph Interface.
FIG. 9 a is an exemplary Nomograph display of the upwind danger zone in accordance with the present invention.
FIG. 9 b is another exemplary Nomograph display of the upwind danger zone in accordance with the present invention.
FIG. 10 is a graph showing the fractional area covered versus number of sensors for detection delay of three, six, and nine minutes in accordance with the present invention.
FIG. 11 a is an exemplary Nomograph display showing 40 sensors within a domain in accordance with the present invention.
FIG. 11 b is an exemplary Nomograph display showing 10 sensors within a domain in accordance with the present invention.
FIGS. 12 a and 12 b are exemplary Nomograph displays showing plume envelopes for the release of two sources within a domain in accordance with the present invention.
FIG. 13 is a graph depicting the coverage of the sensor network versus a random sensor placement run for the same number of intervals in accordance with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Refer to FIG. 1 for the overall data flow of the invention. There are two main components to analyzer 1000 , the Graphical User Interface (GUI) 100 , and the Nomograph Interface 101 . This modular configuration allows manipulation either from analyzer 1000 , or an External Interface 107 . This flexibility enables analyzer 1000 to be a stand-alone system or as a component of larger command and control system. This modular approach is used throughout analyzer 1000 , which allows it to be flexible, robust, and easily extendable.
Nomograph Interface 101 translates from the data format used in GUI 100 , and External Interface 107 to the data format used by a Nomograph Library 102 . Within analyzer 1000 , the properties of each sensor, source, and site (SSS) are represented as an object. An object is defined as the set of properties that comprise a sensor, source or site. The number of properties for each sensor, source, or site object may vary, depending on what type of sensor, source, or site the object represents. Each SSS is represented as a state vector in Nomograph Library 102 . A state vector is defined as the properties Nomograph Library 102 uses for a sensor, source, or site to calculate a Nomograph Display 106 . An object will always have a corresponding state vector. The SSS objects will include at a minimum the properties represented by its corresponding state vector. An object may be modified by: 1) user of GUI 100 ; 2) by an outside program, script, network, or other connection via External Interface 107 ; or 3) by the reconciliation of the properties between an object and its state vector counterpart after a new set of Nomograph displays has been generated. Similarly, an environment object exists that contains the overall properties used by Nomograph Library 102 . Any changes 103 - 105 to a property of any object, made by External Interface 107 , or GUI 100 are reported to Nomograph Interface 101 . Depending on the object property changed, Nomograph Library 102 would be called, and new displays 106 would be generated. The change of a property of an object will send out a notification that the object has been changed to GUI 100 , and to External Interface 107 .
All SSS objects have the following properties, position of the object, and a property, which includes, or excludes the object from the generation of Nomograph Display 106 .
Sensor objects typically represent external sensors 203 (sensor in external mode). A sensor object in external mode will have most of its properties determined by a connection to a real sensor via External Interface 107 . The sensor state can be either hot or cold. A sensor in a hot state is defined as a sensor that has detected a contaminant at its location, while a sensor in a cold state has not. Sensor objects have all of the general properties of an object, along with additional properties depending on the type of sensor represented. This includes sensor modes, its current state, the timestamp of its last state change, the concentration, mass, type and other relevant properties of the contaminant detected. The additional sensor modes include manual, and simulation modes. A sensor object in manual mode has all of its properties determined by the user and are typically used for anecdotal reports entered by the user in GUI 100 . In the simulation mode, a sensor's state is determined by the contaminant plume as determined by Nomograph Library 102 . For example, sensors in simulation mode within the contaminant footprint will change its state from cold to hot, while a sensor in manual or external mode would not. Depending on the information provided by the external, or manual sensor, additional sensor states showing intermediate states between hot and cold might be represented by the sensor object. However, the additional sensor states would be translated into hot and cold states in the corresponding state vector depending on the sensitivity of the sensor network, and user preference. Multiple sensor objects could represent one real sensor. An example would be a mobile sensor taking sensor readings at fixed interval in time. Sensor objects can be grouped together. Examples of sensor groups include a sensor group for a fixed sensor network, and a sensor group for mobile sensors.
Source objects represent a contaminant release at a location. The number of properties can vary in a Source object. At a minimum, it has the general properties of a standard object. Additional properties can include the concentration, mass, type, and other relevant properties of the contaminant. These additional properties would increase the level of detail provided by Nomograph Displays 106 , but are not required. Multiple source objects can be grouped together to form other types of contaminant releases. This includes line sources.
Site objects represent a region, or area of interest. A site object is used to provide detailed properties about that area. They are typically used to generate additional Nomograph displays 106 specifically pertaining to that site. A site object has the general properties of a standard object. Additional properties could include building parameters, or other relevant information used to protect that site.
An environmental object exists for analyzer 1000 . The properties in an environmental object consist of temperature, time, season, wind speed, and direction, and other meteorological properties. These properties may be set by the user manually, or updated automatically via External Interface 107 .
Nomograph Library 102 takes the SSS state vectors, and the environmental vector as input and outputs Nomograph displays 106 . These state vectors only include the properties used to generate Nomograph display 106 . Properties common to SSS state vectors are its position, and a flag that allows the vector to be excluded from the calculation of Nomograph Displays 106 .
The sensor state vectors 109 consist of the current state, the timestamp of its last state change, its mode, the concentration, mass, type, and other relevant properties of the contaminant detected. Source state vector properties include the amount of contaminant released, timestamp of release, mass, type, and other relevant properties of the contaminant. Site state vectors contain the special properties pertaining to that site. The environmental state vector 108 consists of the time of day, season, current temperature, wind direction, and speed, and other meteorological properties.
The Nomograph Options 110 passed to Nomograph Library 102 include the requested size of Nomograph Display 106 , the selected area of the Nomograph, and which set of Nomograph tables to be used in the generation of Nomograph Display 106 .
A more detailed description of the invention is found in FIG. 2 which depicts the event flow between GUI 100 , External Interface 107 , and Nomograph Interface 101 . An event is defined as a notice communicated to a component of analyzer 1000 that an object, or a component of analyzer 1000 has been modified. Upon receipt of an event, the recipient will take the appropriate action. For example, if a user changes a manual sensor's state from cold to hot, the sensor object would post a SSS Altered event ( FIG. 6 , 602 ). This is received by Nomograph Interface 101 , which calls Nomograph Library 102 to generate an updated Nomograph Display 106 . Nomograph Interface 101 would then post an event notifying GUI 100 that an updated Nomograph Display 106 is available. If necessary, this change will be shown to a user. The use of events in analyzer 1000 allow for uniform handling of internal and external changes. This allows objects, and components of analyzer 1000 to synchronized regardless of the source of the change, internal or external.
Nomograph Interface 101 receives events from the components of analyzer 1000 , and from all the objects in analyzer 1000 . A change in a property of an object from any component of analyzer 1000 would be sent to Nomograph Interface 101 . From this component, other objects and components would be notified of the change via events. Examples of actions from Nomograph Interface 101 that post events are: 1) a modification of an SSS object, or the environmental object by External Interface 107 or GUI 100 , 2) modification of a SSS object, or the Environmental object after a reconciliation of an object with its corresponding state vector after the generation of an updated Nomograph Display 106 . Depending on the type of event received, Nomograph Interface 101 will call Nomograph Library 102 to generate a new Nomograph Display 106 , or will wait some period of time for more events to arrive before updating Nomograph Display 106 .
GUI 100 posts events through actions of the user, and reacts to events from Nomograph Interface 101 . Examples of user actions that generate events through GUI 100 are: 1) the addition or removal of SSS objects, 2) A modification of a property of an SSS object, 3) modification of properties in the Environment object, 4) saving/loading of SSS objects and the Environmental object from a storage device, 5) a change in how Nomograph Displays 106 are presented, 6) changing the set of nomograph tables used to generate Nomograph Displays 106 . The events that GUI 100 reacts to are changes in the properties of SSS objects, changes to properties in the environment object, and updates to Nomograph Displays 106 .
External Interface 107 posts events through changes to SSS objects, and the environment object via connections 203 to External Interface 107 . External Connections 203 to External Interface 107 typically include sensors, meteorological information, an external program, or network connections. External Interface 107 reacts to events from Nomograph Interface 101 . Examples of actions from External Interface 107 that generate events are: 1) modifying a property of a SSS objects, 2) modifying a property of the environmental object, 3) a generation of updated Nomograph Displays 106 .
As shown in FIG. 3 , the user and monitor of Chemical, Biological or Radiological Attacks interacts with present invention through a graphical user interface. GUI 100 displays the SSS objects as graphical elements. GUI 100 is one of the key components of analyzer 1000 , through which the user ( FIG. 2 , 200 ) interacts with analyzer 1000 . The simplicity, and ease of use of GUI 100 is in stark contrast to other emergency response systems. The user has to merely point and click to manipulate properties of SSS objects, or environmental properties. The user is not required to input detailed information about the contaminant prior to obtaining a useful result. Additional information can be added as it becomes available. Because of its simplicity of use, training in the use of analyzer 1000 is minimal.
Using GUI 100 , the user can add, remove, or modify the properties of the SSS objects. The various environmental properties can also be modified 302 . The user may also load, and save scenarios, run simulations, and change how Nomograph Displays 106 are presented 303 . GUI 100 translates Nomograph Displays 106 into a display format 300 , which is viewable by the user. This includes translating Nomograph Displays 106 into the required coordinate system, adding maps, or other graphical layers ( FIG. 1 , 111 ) representing buildings, terrain features, or other relevant geographical information about the area ( FIG. 1 , 111 ), and merging the selected Nomograph Displays 106 into an image, or images.
The graphical representation of each object is dependant on some or all of its properties 304 - 307 . For example, a source object that is included in the Nomograph generation is depicted as a star 304 . Sensor objects are depicted using different colors and shapes, depending on their properties. Examples of sensor depictions are shown 305 - 307 . For instance, a simulation sensor 305 , in a hot state, which is included in the generation of Nomograph Display 106 , is easily identified from a manual sensor 306 , whose state is cold, which is also used in the generation of Nomograph Display 106 .
GUI 100 can provide multiple views of SSS objects, or the environment object. For example, a sensor object 306 is depicted in a main GUI 300 and an auxiliary GUI 301 . Main GUI 300 is used to display some information about all of the objects on the screen, as well as a presentation of Nomograph Displays 106 . Auxiliary GUI 301 is used to present the properties in an object in a different, or expanded format. Auxiliary GUI 301 may display the same information as main GUI 300 , but typically shows more detail about one or more SSS objects, the Environment object, or the Nomograph Options. Multiple auxiliary GUI's may be used depending on user preference. In this figure, two portions of the auxiliary display are shown, a GUI portion 302 to control the environment object's properties, and an auxiliary GUI portion 303 to control the Nomograph Options.
FIG. 4 shows diagrams of the main Nomograph Displays 106 generated by Nomograph Library 102 . This figure shows some of the unique diagnostic capabilities of analyzer 1000 . For example, the Backtrack display 401 is unique to analyzer 1000 due to the use of Nomograph Library 102 . The speed with which the displays are generated contribute to the usefulness of analyzer 1000 .
The Nomograph tables used to generate Nomograph Displays 106 are typically selected based on the properties of the state vector, and the area of interest. The main types of Nomograph tables generated are 1) the consequence display 400 , 2) the backtrack display 401 , 3) the footprint display 402 , 4) the simulation display 403 , 5) escape display 404 , 6) danger zone display 405 , and 7) the leakage display 406 . Nomograph Library 102 may generate specialized displays for a particular state vector, if requested.
Sensor vector states are used to generate two types of Nomograph Displays 106 , consequence and backtrack displays. The consequence display 401 consists of a region downwind, with an upwind safety radius from a sensor that could potentially be exposed to a contaminant. This is dependant on the whether the sensors states are hot or cold. The Backtrack display 402 shows the probability of a contaminant source location for different regions. The Backtrack display will display regions by different values, depending on the probability that a source originated from that area.
Source vector states are used to generate simulation 403 , footprint 402 , and escape route 404 displays. The footprint display shows the area downwind, with an upwind safety radius that could become exposed to the contaminant from the source. The simulation display shows a time evolution of a plume. The escape display shows the optimal escape routes, based on the footprint display from the source.
Site vector states are used to generate danger zone 405 , and leakage 406 displays. The danger zone display shows the area upwind from a site where a contaminant placed in that area could reach the site. The leakage display shows the area downwind of the site that could potentially be exposed to a contaminant if the site itself was exposed.
FIG. 5 is a block diagram detailing a user's response to information displayed by analyzer 1000 . In this scenario, a chemical agent has been released in an urban environment 500 . A fixed sensor net has been deployed in the urban area, and several of the sensors alarm 501 indicating that a chemical release has occurred in the area. The sensors are connected to External Interface 107 , and their change in status is received 502 . Nomograph Display 106 is generated 503 , which is displayed by GUI 100 , which also shows the change in status of the effected sensors. The user sees the change in state, and selects backtrack display 303 from GUI 100 . Sensor readings can also be obtained from mobile sensors, or other sources like first responder radio reports, or people becoming ill from the chemical release. If this information exists 505 , it can be entered into analyzer 1000 as a manual sensor reading 510 .
If any manual sensors, or automatic sensors are hindering the ability of analyzer 1000 to limit an area where the chemical release has occurred, the user can exclude 506 the sensor readings from the backtrack. The user can now determine if they have enough information to determine where the source is located 507 . If the backtrack area displayed by analyzer 1000 is not narrowed to a small region, the user has several options. They can wait for more information to come in via the fixed sensor network, or by manual sensor input 508 . They can also send mobile sensors to the potential chemical source area displayed by the backtrack 509 , with the goal of finding the edges of the chemical plume.
When the backtrack display from analyzer 1000 has narrowed the location of the chemical release to a small region, a source object can be placed in the backtrack region 511 . With the source object displayed in analyzer 1000 , the area downwind that could be contaminated by the chemical release is known. The user can now setup escape routes based on the source object 512 , and send out this information out to areas downwind of the source 513 . The escape route information can be sent out to remote sites via External Interface 107 of analyzer 1000 , or through other methods external to analyzer 1000 .
FIG. 6 is a functional block diagram showing the creation of events typically created in analyzer 1000 . These events are routed through analyzer 1000 to Nomograph Interface 101 to other components in analyzer 1000 . An event may affect multiple components of analyzer 1000 , or none at all.
Environmental Objects usually generate events by changing environmental parameters 600 , or changing the Nomograph tables used 601 . Changing the environment parameters generates a metEvent 606 . The environment parameters that are most frequently altered are the wind direction, and velocity 604 . Other miscellaneous parameters 605 that would generate a metEvent include time of day, season, and weather conditions, and other meteorological parameters. Changing the nomograph tables used or a change in the location viewed analyzer 1000 608 , will generate an areaEvent.
The two types of events that occur with Sensor, Source, or Site objects are a change in the properties of an SSS object 602 , and the addition/removal of an SSS object 603 . Changing a property of an SSS object 609 will generate an SSS Object Event 610 . The properties that typically create an SSS Object Event include altering the objects location, the type of object it represents, whether it is included in the calculation of Nomograph Displays 106 , and its state. Adding or removing an SSS Object 611 will generate an SSS Add/Remove Object Event 612 .
FIG. 7 is a functional block diagram of the Event Loop. This is an internal component of Nomograph Interface 101 . The Event Loops is started 700 when Nomograph Interface 101 is initialized. It first checks see if any SSS events have occurred 701 . If an SSS event was generated, it is checked to determined what type of event it is 706 - 707 , and sets the updateFlag to true if the event is valid. If an environment object event has occurred 702 , a new nomograph table will be loaded depending of the parameters of the Environmental object 709 , and the updateFlag will be set. If the updateFlag has been set 703 , the NG Interface will be called 711 , which will update Nomograph Displays 106 . If the program hasn't finished, it will continuously process this loop 704 , otherwise the loop will exit 705 .
FIG. 8 is a functional block diagram of the NG Interface. This is an internal component of Nomograph Interface 101 , which translates the SSS objects, and Environmental objects into the format that Nomograph Library 102 can use, and outputs updated SSS objects, and updated Nomograph Displays 106 .
First, the SSS objects, and the Environmental object are converted into their state vector equivalent 800 - 801 . Next, Nomograph Library 102 is called, and new Nomograph Displays 106 are generated 802 . Since Nomograph Library 102 can potentially alter the state vectors, each vector is checked to see if it has been altered 803 - 805 . If it has been altered, the SSS object and SSS vector are reconciled by updating the properties of the SSS object using the properties from the state vector 807 . New Nomograph Displays 106 are sent out to the other components of analyzer 1000 806 , and the NG Interface returns.
To maximize accuracy and speed in assessing an environmental threat or airborne CBR threat within a domain, e.g., a city, the city should be saturated with sensors. Such a system may be impractical with respect to financial budgets and data management. Therefore, it is a goal to optimize sensor placement based on a usable number of sensors that fit a particular financial budget and data management system. To find an optimal sensor network, a genetic algorithm using features of the present invention provides this ability.
Since its development in the 1960's, the genetic algorithm has been used successfully in many different fields. Genetic algorithms are a type of search algorithm that works particularly well if the search space is too large to run every potential case and when local maxima exist. For example, to exhaustively search every possible location of a group of 20 sensors in a grid of 350×350 potential locations at a rate of 20 evaluations per second would take months if not years. While the answer generated by a genetic algorithm might not be the best solution, it will typically be a very close approximation to it. The main disadvantage of genetic algorithms is that they potentially require a lot of time and computing resources, depending on the rate of convergence and the computational cost of a fitness function. However, given the amount of time required to evaluate a typical population, many examples of parallelized genetic algorithms exist.
A genetic algorithm evaluates the fitness of genomes in a population, and generates the next population based on the fitness of the previous generation. Each genome is a potential solution to the problem, where the elements of the solution are equivalent to chromosomes in the genome. The initial population is usually chosen randomly, but the initial population can also be seeded with solutions that are known to produce good results. The next population of genomes is determined by combining members of the current population to produce offspring that are based on the scores of each parent genome's fitness function. This is known as crossover. During crossover, individual chromosomes within the offspring can potentially mutate, giving the offspring slightly different characteristics that are unique from its parents. This is particularly useful in later generations of the population, where the population is fairly homogeneous. The user determines the fitness function of a genome, in which the performance of a genome is evaluated, and a fitness score is assigned. Members with a high fitness score will typically have many offspring in the next generation while those with a low fitness score could have few or none. New populations are generated, and evaluated until one of several requirements is met. This includes the desired fitness level of a member of the population, the average fitness of the population has reached some level, or the maximum number of generations has been calculated.
An approach using genetic algorithms was selected for sensor optimization because the characteristics making up a robust sensor network were largely unknown. This approach also made it easy to modify specific characteristics while leaving the search method intact. Furthermore, advances in contaminant transport modeling made it possible for this search technique to be utilized.
The use of computational fluid dynamics models or Gaussian plume models are not suitable for use as the fitness evaluation of a genetic algorithm due to their relatively long times to generate plumes, and the sheer number (many millions) of fitness evaluations and iterations required for a solution to converge. Even if the time to generate a Gaussian plume decreased significantly, the plumes generated would not take into account the 3 D geometry of an urban region. The plume capability of analyzer 1000 is well-suited for this type of evaluation because it produces plumes comparable to the computational fluid dynamics calculation as stated above while producing this result in about one millionth of the time. The speed of analyzer 1000 allows fitness functions to be evaluated for performance quickly. Table 1 shows the approximate amount of time required to run a genetic algorithm for 1000 generations using various plume models.
TABLE 1
Approximate time to run a fitness
evaluation for 1000 generations
Plume model
Computer
(population = 1000)
CFD(FAST3D-CT)
Supercomputer
~9000 hours (random sources)
Gaussian
Workstation
~500 hours (random sources)
Present
Laptop
~33 hours (random sources)
Invention
Present
Laptop
~4 hours (time dependent
Invention
sensor coverage, 20 sensors)
A genetic algorithm has been used where the members of the population with the highest fitness scores were kept in the next population. This ensures that the population's maximum fitness score will not decrease and also reduces the number of generations required to converge to an answer. The rate of crossover was set at 0.95 with the rate of mutation set at 0.25 percent, where the mutation increased if the rate of convergence decreased by a threshold. In one example, the genome was the set of locations of the sensors in the sensor network with the chromosomes consisting of (x, y) coordinates of the sensors. The population size was set to 1000. While the individual fitness function is now relatively fast, the algorithm was distributed over multiple processors using a message passing interface. The evaluations of the population are spread out over multiple processors, with the best results of a generation saved as candidates for the solution. This algorithm is computer bound so a high-speed interconnect is not necessary. Several different approaches were examined for the fitness function.
The first approach uses a plume model to generate plumes from randomly placed sources and then analyzes the sensor network's ability to detect the plume within time t of release. In this case, if a least one sensor is located within the plume, it counts as a detection of the plume. The sensor network individually evaluates a sequence of randomly located sources, with the fitness score based on the total number of sources detected. A new set of random sources must be calculated for each generation. If the set of source locations is fixed, the sensor network's solution would converge on the coverage of that set of fixed sources, but not on a optimal coverage of sources located anywhere in the region. This method has the advantage of being able to use a variety of plume prediction tools like Gaussian plume models, computational fluid dynamics models (e.g. FAST3D-CT), and Dispersion Nomograph tools (e.g. analyzer 1000 ). However analyzer 1000 is the best choice due to its speed and accuracy (Table 1, lines 1-3).
While this approach is acceptable, a much more efficient procedure was developed using the unique upwind capability of analyzer 1000 . FIG. 9 a is an exemplary Nomograph display 900 of the upwind danger zone in accordance with the present invention. In the figure, display 900 of a portion of a city, i.e., the domain, includes buildings, roads and trees. Display 900 additionally includes a site 902 of a sensor. The corresponding upwind zone 904 for the sensor at site 902 represents the upwind area where the contaminant from a source could hit the sensor. This upwind, probable source zone or “backtrack” zone is time-dependent and can also be described as an “anti-plume”. Sensor coverage is the union of the “anti-plumes” for all of the sensors in the region. FIG. 9 b illustrates this updated display. Specifically, FIG. 9 b is an exemplary Nomograph display 906 of the upwind danger zone in accordance with the present invention. In the figure, display 906 is of the same portion of the city as display 900 . Display 906 additionally includes a site 908 of a first sensor and a site 910 of a second sensor. The corresponding upwind zone 912 for the sensor at site 908 represents the upwind area where the contaminant from a first source could hit the first sensor, whereas the corresponding upwind zone 914 for the sensor at site 910 represents the upwind area where the contaminant from a second source could hit the second sensor. Using the union of anti-plumes as the fitness function decreases the time to evaluate a sensor network for a region drastically (see Table 1, line 4). The new fitness function is now the total area of sensor coverage for a given region ranging from zero to one, which could be calculated with a single call to analyzer 1000 .
Because of the increase in efficiency, the second approach was selected for the main optimization trials. To determine the optimal amount of sensors required for this region, sensor networks from five to forty sensors, in five sensor number increments were evaluated for total sensor coverage on a 2 km by 2 km region for a typical city. The wind was from the northwest, with a speed of three meters per second. The region itself is an urban area with varying degrees of building density ranging from open areas free of structures to city blocks with high building density. A dispersion nomograph utilized for this region was generated using FAST3D-CT, which includes all of the effects of buildings, streets, trees, etc. Analyzer 1000 is used to evaluate sensor configurations for a detection delay of three minutes, six minutes, and nine minutes. These times were selected based on results obtained from the walk away program. Nine minutes warning delay has been found to be maximum delay to be tolerated if at least 50% of a population in an area affected by a moderately large plume is to be saved.
FIG. 10 shows the fractional area covered versus number of sensors for detection delay of three, six, and nine minutes. The number of sensors required producing adequate coverage increases significantly as the plumes size decreases. Only 10 to 15 sensors are required to obtain 90% coverage for a nine-minute time delay, contrasted with over 40 for a three-minute detection delay. Even with 50 sensors, complete coverage of the region cannot be obtained for the three-minute delay while additional sensors became completely redundant past 30 sensors for these six- and nine-minute warnings.
FIGS. 11 a and 11 b are exemplary Nomograph displays 1100 and 1104 , respectively, of the same portion of the city as display 900 . FIGS. 11 a and 11 b represent the minimal sensor network required to detect at least 90% of the region for three- and nine-minute detection delays. For a nine-minute delay ( FIG. 11 b ), sensors are placed at sites 1106 towards the edge of the region, opposite of the wind direction because at nine minutes the “anti-plumes” are very large, and sensors are wasted if they are placed further upwind. If the time delay for detecting a plume is increased beyond nine minutes, the eventual result is a sensor network with all of the sensors placed along the edge of the domain. 40 sensors are required To provide the same coverage for a three-minute detection delay, 40 sensors at sites 1102 must be provided as illustrates in FIG. 11 a . The density of sensors for a given area in the region varied. More sensors were required for relatively open areas and where the plume funneled through gaps between buildings. This was particularly noticeable when the time delay allowed for detecting plumes was short.
The shape of the plume envelope can explain this result. In areas with few buildings, the plume envelopes are narrow and elongated, looking very much like their Gaussian plume counterparts. In areas with many buildings, the shape of the plume envelope is broader, depending on the geometry of the buildings and wind angle. FIGS. 12 a and 12 b are exemplary Nomograph displays 1200 and 1210 , respectively, of the same portion of the city as display 900 . FIGS. 12 a and 12 b depict plume envelopes for the release of two sources at sites 1202 and 1204 , respectively, in the domain after three and after nine minutes. The first source is released at site 1202 , which is in an open region, while the second source is released at site 1204 , which is in an area with high building density. Note that a plume 1208 illustrated in FIG. 12 a develops into plume 1214 in FIG. 12 b , whereas plume 1206 illustrated in FIG. 12 a develops into plume 1212 in FIG. 12 b . Plume 1214 has a shape that starts to change at point 1216 as it encounters a city block with high building density 1218 . In order to detect a narrow plume more sensors are required.
FIG. 13 is a graph that shows the coverage of the sensor network versus a random sensor placement run for the same number of intervals. The random (brute force) sensor placement is evaluated in the same manner as the genetic algorithm with the best candidate produced of each generation reported as the maximum coverage attained. For the same amount of effort, here two million calls to analyzer 1000 , the generic algorithm covered over 90% of the region while the random-placement approach's best answer results in coverage of about 72% of the region.
The use of a genetic algorithm to produce a plausible and useful sensor optimization has been shown. This approach was not possible until the low-latency evaluation of contaminated regions of analyzer 1000 was developed. To calculate 1000 generations requires 1 million calls to analyzer 1000 and many millions of individual sensor backtrack “anti-plume” evaluations. With more complex fitness functions, and more stringent requirements for a sensor network, the time to calculate an optimal network will only increase. Use of other plume models is prohibitive. This approach is one technique for determining the optimal sensor placement. It has also shown that to provide guaranteed short detection delays will require many sensors.
Although this invention has been described in relation to an exemplary embodiment thereof, it will be understood by those skilled in the art that still other variations and modifications can be affected in the preferred embodiment without detracting from the scope and spirit of the invention as described in the claims. | Networked groups of sensors that detect Chemical, Biological, and Radiological (CBR) threats are being developed to defend cities and military bases. Due to the high cost and maintenance of these sensors, the number of sensors deployed is limited. It is vital for the sensors to be deployed in optimal locations for these sensors to be effectively used to analyze the scope of the threat. A genetic algorithm, along with instantaneous plume prediction capabilities meets these goals. An analyzer's time dependant plumes, upwind danger zone, and sensor capabilities are used to determine the fitness of sensor networks generated by the genetic algorithm. | 6 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to refractory metal carbide grade powders. Such powders contain a refractory metal carbide, a matrix metal and a pressing aid.
It also relates to a process for producing cemented carbides from such grade powders.
2. Prior Art
Grade powders are defined herein as an intimate mixture of refractory metal carbides powder plus a metallic cementing phase or matrix. Generally the grade powders include a binder which also serves as a pressing lubricant. The most common example of a grade powder is a mixture of tungsten carbide, cobalt, and paraffin wax. The carbide powder can consist of other carbides or mixtures thereof and are generally the refractory carbides as used herein include carbides of metals from the groups IV, V, and VI metals that have a melting point above about 1895° C. Cobalt is the most common matrix, at least for WC, but, nickel, iron, and molybdenum either singly, in combination, or in combination with cobalt are sometimes used particularly when refractory metals other than tungsten are used. For example, the matrix phase for TiC is either nickel or a nickel-molybdenum alloy, thus as used herein the matrix metal is selected from the iron group of metals and alloys of the iron group of metals.
The most common practice for producing carbide grade powders involves a sequence of operations consisting of ball milling, drying and granulation. While this seems relatively straightforward, there are many intermediate processes and handling steps that complicate the operation. Typically, as an example, powders of WC and cobalt are weighed in the appropriate proportions and charged into a ball mill. To prevent oxidation of the powders, milling is always done in the presence of a milling fluid. Organic fluids such as hexane, heptane, primary alcohol, acetone, and the like are used. Depending on the particular grade of powder and desired powder characteristics milling times are from many hours to several days. After milling the fluid must be removed such that a dried powder is obtained. Drying generally involves some type of distillation process so that the fluid can be recovered and reused. A typical process would be to discharge the slurry into another vessel and then with the combination of heat and vacuum remove the fluid.
More recently, a process involving close-cycle spray drying has been used to remove and recover the milling fluid.
If the spray drying process is not used, several additional steps are required after conventional drying of the powders. Typically a wax, and most commonly paraffin wax, is added to the ball mill. If wax is not added to the mill, it must be incorporated into the dried powder. This step is called waxing and is done in a variety of ways.
The dried grade powders containing wax are generally fine and fluffy and have very poor flow characteristics. It is important that the powders have good flow to facililtate transfer from a powder hopper to the die cavity during pressing. Therefore, these fine, fluffy powders are converted by an operation called granulation to a flowable powder. One common method is to press the fine powders at low pressures into a loose compact or slug. This slug is then forced through a screen. The screened product is in the form of small, irregular shaped granules which will conveniently flow into compacting dies in a more controlled manner. If the spray drying process is used a free flowing powder is obtained directly as this is one of the purposes of spray drying. That is, in addition to drying a free flowing spherical powder is obtained.
Over the years, the following process has evolved as the most used method for preparing carbide grade powders. It involves the following steps, ball milling with alcohol or acetone, tungsten carbide, cobalt and paraffin wax and drying in a close-cycle spray dry system.
While this process is a considerable improvement from the previous practice it still has disadvantages compred to the process that will be described in this invention. Some of the disadvantages are the lengthy ball milling cycle. If this type of milling is used, a flammable solvent, the use of paraffin wax and an expensive drying system.
Additionally, the products produced from ball milling contain a relatively high level of sub-micron refractory metal carbide particles. During the subsequent sintering process, the fine particles preferentially and quickly dissolve in the binder and upon cooling become deposited upon the surfaces of the undissolved carbide. This procedure is known as grain growth and lowers the strength of the subsequently produced cemented carbide articles. Various techniques for reducing the amount and level of grain growth have been developed. The most commonly used technique for reducing grain growth is to use an additive which interferes with the grain growth mechanism. Another method not now widely used is a hot pressing technique. The hot pressing technique is described in U.S. Pat. No. 3,451,791.
Attritor milling has been used recently for particle size reduction in place of ball milling because a given particle size reduction can be achieved in a shorter period of time than ball milling. In the production of grade powders of the subsequent production of cemented refractory metal carbides the purpose of ball milling is not to reduce the size of particles but rather to uniformly distribute the binder phase throughout the larger amount of the carbide phase.
The organic fluids previously used as milling aids, such as hexane, heptane, the primary alcohols, acetone and the like, are all flammable materials thus extreme safety precautions must be taken to prevent air leakage into the system used to remove the milling aid. The vapors from these milling aids also are toxic to the worker. Hence, additionally precautions in handling are required.
It is believed, therefore, a process that can be conducted in an open system without fire and health hazards and produces a carbide grade powder having improved properties and characteristics would be an advancement in the art. It is also believed that a carbide grade powder that exhibits a marked decrease in grain growth during sintering when processed by normal sintering techniques and does not contain a grain growth inhibitor is an advancement in the art.
OBJECTS AND SUMMARY OF THE INVENTION
It is an object of this invention to provide an improved refractory metal carbide grade powder.
It is a further object of this invention to provide an improved process for producing carbide grade powders.
It is another object of this invention to provide an improved process for producing cemented refractory metal carbides.
These and other objects are achieved in one aspect of this invention by a process comprising forming an aqueous slurry of water and solids consisting essentially of a refractory metal carbide and a suitable matrix metal or metal alloy in the desired ratio, the water and solids being in the weight ratio of from about 1:2 to about 1:4, attritor milling said slurry for from about 1 to about 10 hours, removing the slurry from the milling and forming a solid concentration of from about 70 to about 90% by weight, adding from about 1 to about 3% by weight, based upon the solids, of a water-soluble relatively long chain polyglycol to the slurry and spray drying the resulting slurry at a temperature sufficient to remove the water to from an improved powder consisting essentially of the refractory metal carbide, the binder and the polyglycol. The powder contains spherical particles having a relatively narrow size distribution and is capable of being pressed into shapes having an improved green strength and upon sintering the relative amount of grain growth is reduced.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
For a better understanding of the present invention, together with other and further objects, advantages and capabilities thereof, reference is made to the following disclosure and appended claims in connection with the above-description of some of the aspects of the invention.
The present invention is an improvement over the most modern practice used today for preparing carbide grade powders. It involves three basic and radical departures from the common practice.
1. The use of water as a milling fluid as opposed to flammable organics.
2. The use of an open-cycle spray-drying system as opposed to closed system.
3. The use of water soluble, long-chain polyvinyl alcohol as a mixing aid instead of paraffin wax. The basic advantages of the process of this invention are cost, safety, flexibility of operation, and product improvement.
The use of a long chain polyglycol as compared to standard paraffin is an important feature of this invention. After pressing these powders, much higher green strengths can be obtained than was possible with a paraffin wax system. The higher green strength has many ramifications which are important in the pressing of powders and handling of pressed compacts. One of the problems encountered in the pressing of grade powders is cracking upon release from the die. This cracking seems to be a direct function of the inherent strength of the compact after it is pressed. If conventional powders containing paraffin are pressed much above 25,000 psi, chances are high the cracking will occur. When the powders, spray dried into the open-cycle system with a long chain polyglycol, such as Carbowax 6000, are pressed at pressures up to 40,000 psi with no cracking occurring. This obviously allows much more flexibility in the pressing operation and more flexibility in controlling shrinkage.
Each step in this new process will be compared to the more conventional process to illustrate the differences and advantages of the new process.
As discussed, grade powders are typically prepared by ball milling. More recently attritor milling has been used. Attritor milling is used in this process because it is the quickest and most economical method for making the grade powder slurry. In common practice when using attritor milling an organic solvent is used as the milling fluid. In our process water is used as the milling fluid for its obvious advantages as far as cost and safety.
The attritor mill is commercially available from Union Process Corporation in this country and by foreign companies licensed by Union Process. Patents on the attritor have been issued to Dr. Andrew Szegvari, U.S. Patents: Nos. 2,764,359; U.S. Pat. No. 3,450,356; U.S. Pat. No. 3,149,789; U.S. Pat. No. 3,008,657; and U.S. Pat. No. 3,131,875.
Paraffin wax is the binder system that is most commonly used in all grades of carbide. As discussed, it is either incorporated in the ball mill or added to the grade powders by some method after the milled slurry has been dried. In the present invention, Carbowax 6000, a product typically known as a polyglycol and distributed by Union Carbide Corporation, is used. It is water soluble and has a relatively long chain length. It is added to the slurry after it has been discharged from the attritor mill.
The use of organic solvents as mentioned, and their flammability requires the use of a close-cycle spray drying system. This system, as inferred from its name, is closed loop and utilizes a nitrogen atmosphere. While this system works well, its two inherent drawbacks are high initial cost, because of the equipment necessary to recover the organic solvent. It is a large system and more easily operated with large lots of powder. This somewhat reduces its flexibility. Because water is used as a milling fluid, the expensive close-cycle system is not necessary but rather the relatively inexpensive open-cycle system which used air as the drying atmosphere. This type of equipment is one-fourth to one-third the cost of the close-cycle system. In addition, it has much greater flexibility in that the small lots can easily be dried. Lots as small as 15 kg can be dried. The close-cycle system generally requires a minimum lot size of 100 kg.
While the invention has been described in terms of using the refractory metal carbide grade powder to produce cemented carbides, the powder produced hereby can also have other usages such as in hard facing application e.g., plasma spray coating, mixing with brazing alloys and the like.
Normally the amount of matrix metal will be from about 2 to about 25% by weight of the refractory metal carbide and matrix metal composition and from about 5 to about 20% by weight is preferred.
The average particle size of the refractory metal carbide is generally from slightly less than 1 micron to about 25 micrometers. The most common tungsten carbide generally is between 1 to 2 micrometers. As previously mentioned, grain growth inhibitors can be employed to prevent grain growth. Materials commonly used are molybdenum carbide, vanadium carbide, and chromium carbide. If used they are incorporated into the first aqueous slurry, that is, prior to attritor milling, or can be subsequently added to the grade powder. Preferrably they are added prior to attritor milling to insure more uniform distribution.
To more fully illustrate the subject invention, the following examples are presented. All parts, proportions, and percentages are by weight unless otherwise indicated.
EXAMPLE I
The following charge is added to an attritor mill that contains WC-13 Co balls:
Wc powder -- 5,460 parts
Co Powder -- 540 parts
H 2 o -- 2,000 parts
The mill is adjusted so that the agitator shaft turns at 200 rpm. Milling time can vary from 1 to 10 hours. For this particular grade which contains 9% cobalt, and a medium particle size WC, 1 hour is sufficient time. Milling times have to be increased as cobalt content is decreased and more importantly when finer WC powders are used.
After the appropriate milling time is reached, the slurry is discharged from the mill. This generally requires the addition of some H 2 O to thin the slurry and rinse the mill. During discharging the slurry is passed through a 400 mesh screen. This allows for the removal of contamination that may have been introduced and any chips from the milling balls.
Water is decanted from the screened slurry to obtain the desired solids concentration for spray drying. Generally, this ranges from 70-90%, and for this example of WC-9% Co a solids concentration of 80% is used.
Next the slurry is transferred to the spray dryer feed tank. It is heated, to about 50° C, and agitated while the Carbowax 6000 addition is made. This addition is generally 1-3%. For this grade it is preferably 2%. At this point the spray drying process begins. A suitable spray drier is a Proctor - Schwartz spray tower with two-fluid top-nozzle atomization. Some of the important drying parameters are air pressure of 20 psi, an inlet drying temperature of 200°-230° C and an outlet temperature of 100°-130° C.
After drying the product is spherical and free flowing and ready for subsequent use. Some properties which distinguish it from conventional powders are listed below.
______________________________________ Spray Conventional Dried With Powders With Carbowax 6000 Paraffin Wax______________________________________Hall Flow Rate 20.00 27.00 sec/50gBulk Density, g/cc 3.80 4.10Green StrengthAfter Compacting 1350.00 520.00at 20 ksi, psi______________________________________
While there has been shown and described what are at present considered the preferred embodiments of the invention, it will be obvious to those skilled in the art that various changes and modifications may be made therein without departing from the scope of the invention as defined by the appended claims. | A process for producing a refractory carbide grade powder having improved particle size distribution and pressing characteristics. The process comprises forming an aqueous slurry of a standard refractory metal carbide powder and the desired matrix, attritor milling for 1 to 10 hours, removing the milled slurry from the mill, forming an aqueous slurry having a desired solid concentration, adding a water-soluble relatively long chain polyglycol as a pressing aid and spray drying the slurry to form spherical particles suitable for pressing and sintering. During sintering less grain growth of the refractory metal carbide grade powders occurs than with conventional grade powders sintered under essentially the same temperature conditions. | 2 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to apparatus for separating a food product from a tray, and more particularly separation from a tray having apertures defining a supporting lattice to which the food product is adhered.
2. Description of Related Art
Certain food products tend to adhere to the surfaces supporting them during food processing. As explained in more detail in my U.S. Pat. No. 4,645,404, separation of the food product from supporting trays is difficult where the food product is in thin strip form, as is the case with the long strips of meat jerky for human or animal consumption.
In preparing jerky, a meat containing mixture is extruded to form thin elongated strips which are arranged on a tray having apertures defining a supporting lattice. The apertures permit air circulation during drying of the product, but the nature of jerky material is such that the strips stick to the ribs or lattice of the tray during drying. The problem is made worse because the strips of meat tend to sag into the apertures as the meat dries.
The long strips of jerky must be separated intact, without breaking, so that they can be cut into predetermined short lengths for packaging. Any broken pieces cannot readily be packaged and must be discarded.
The apparatus of my U.S. Pat. No. 4,645,404 provided reasonably satisfactory separation of the strips of meat jerky from the tray lattice. However, the apparatus involved a two step procedure to effect separation, and a significant number of long strips were still broken into commercially unusable short pieces. In that apparatus a pair of conveyor belts were arranged in spaced apart end-to-end relation to define a gap across which the food product tray was carried. Preliminary separation of the jerky strips lying on top of the tray lattice was accomplished by one or more separating rollers located below the tray. Radially directed fingers of the tray were arranged to project upwardly through the tray apertures and into engagement with the food product. At least two backup rollers were located above the tray opposite each separating roller. These engaged both the food product and the tray, allowing the food product between the rollers to be moved up from the tray by the roller fingers, but keeping the tray from also moving upwardly.
Some portions of the jerky strips still stuck to the tray at various points along their lengths. Final separation was achieved by transferring the trays onto a third conveyor belt disposed at right angles to the first pair of conveyors. In making the transfer, each tray was inverted so that the already loosened jerky strips hung down in loose loops. A stripper plate above the third belt was arranged to lie within the space between the tray and the sagging strips as they moved along the belt. The partically separated strips were then pulled away from the tray by the plate and transported to a collection station. Some of the strips still adhered sufficiently tenaciously that this pulling action resulted in their breakage.
SUMMARY OF THE INVENTION
According to the present invention, all food product separation occurs in a substantially continuous process on the same conveyor belt that supports the food product trays.
The trays are inverted on the conveyor belt, and the belt is moved past a first row of roller bands located above the belt and a row of supports located below the belt. The supports are rigid and transversely spaced apart for slidable engagement with the under side of the belt. The belt is sufficiently flexible that it sags between the supports in a catenary-like configuration.
The roller bands are located between the supports, and radially directed fingers of the roller bands project downwardly through apertures in the tray and press the food product into the spaces between the food product and the sagged portions of the belt. Thus, the food product can be pushed downwardly by the roller belt fingers onto the conveyor belt despite the fact that the same belt is providing support for the tray.
The tray is preferably made of a resiliently deformable material so that it is flexed between the roller bands and supports to facilitate food product separation.
Portions of the food product overlying the first row of supports are not easily reached by the fingers of the first row of roller bands. Accordingly, a second row of roller bands and supports are located behind or beyond the first row of roller bands and supports, in staggered or laterally offset relation to the first row so as to operate on the portions of the food strips that were not acted upon by the first row of roller bands and supports.
Tray separation from the conveyor belt is accomplished by a transfer plate spaced slightly above the conveyor belt to intercept and move each tray upwardly where it can be engaged by conveyor rollers which move it up a ramp to a tray collection station.
The apparatus of the present invention thus eliminates two step strip separation, accomplishing all separation by roller belt fingers projecting downwardly through the trays for strip separation onto the same conveyor belt which provides support for the trays.
Other objects and features of the invention will become apparent from consideration of the following description taken in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagrammatic perspective view of the present apparatus, and particularly the conveyor belt and overlying roller bands;
FIG. 2 is a top plan view of a tray supporting a plurality of jerky strips;
FIG. 3 is an enlarged view of the section indicated by the numeral 3 in FIG. 2;
FIG. 4 is an enlarged view taken along the line 4--4 of FIG. 3;
FIG. 5 is a top plan view of the present apparatus;
FIG. 6 is a view taken along the line 6--6 of FIG. 5;
FIG. 7 is a diagrammatic side elevational view of the drive means for the roller bands and conveyors of the apparatus;
FIG. 8 is an enlarged view taken along the line 8--8 of FIG. 5;
FIG. 9 is an enlarged view taken along the line 9--9 of FIG. 5;
FIG. 10 is an enlarged view taken along the line 10--10 of FIG. 8;
FIG. 11 is a View taken along the line 11--11 of FIG. 5;
FIG. 12 is a view taken along the line 12--12 of FIG. 5;
FIG. 13 is a diagrammatic side elevational view of the discharge end of the apparatus, illustrating an embodiment utilizing a strip collector belt;
FIG. 14 is a diagrammatic side elevational view of the feed end of the apparatus, illustrating an embodiment employing a conveyor belt to transport inverted trays to the main conveyor belt;
FIG. 15 is a diagrammatic side elevational view similar to FIG. 14 but showing an alternate tray inverting chute.
FIG. 16 is a fragmantary top plane view of an alternate empty-tray engaging roller cosntruction and;
FIG. 17 is a side elevational view taken along line 17--17 of FIG. 16.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The present apparatus relates to the separation of strips of dried meat products from tray support surfaces to which the products are adhered. One such product is a mixture, by weight, of 75% meat by-products, 15% beef, 1% wheat flour, 1% cane molasses, 2% dextrose, 2% salt, 2% water, and 2% spices and preservatives. The mixture is extruded into meat strips 10 approximately 11/4 inch wide, 0.165 inch thick, and 48 inches long, following which the strips are dried, and then cut into lengths of about 41/4 inches for packaging.
FIGS. 2, 3 and 4 illustrate a tray 12 onto which the meat strips 10 are extruded. The tray 12 is typically made of resiliently deformable plastic about 6 inches wide and 48 inches long. Four strips 10 are supported on each tray, as seen in FIG. 4. Each tray 12 includes a plurality of apertures 14 arranged to define a supporting lattice 16 comprised of crosswise and lengthwise ribs. Each aperture 14 is about 3/8 inches wide and 3/4 inches long, making a total of about 544 apertures per tray.
After the strips 10 are extruded onto the surface of the trays, the trays 12 are stacked on racks and placed in a drying oven (not shown) in which air circulates through the apertures 14, drying the meat strips 10 and forming a jerky product. During drying the strips 10 tend to bake onto and stick to the tray lattice 16, the strips also tending to sag into the apertures 14, as seen in FIG. 3. The purpose of the present apparatus is to remove the strips 10 from the trays without breaking the 48 inch long strips into unusable shorter pieces. The separated long strips can then be cut into the desired lengths of about 41/4 inches for packaging. As will be seen, the present apparatus accomplishes such separation through the unique interaction of separating roller bands and support structure located on opposite sides of the tray conveyor belt.
As best seen in FIGS. 1 and 5-7, the present apparatus includes a rigid frame, most of which is omitted for brevity, having a pair of longitudinally extending, transversely spaced apart I-beams or sides 18.
A continuous conveyor belt 24 is trained around rollers carried by a pair of belt shafts 20 and 22 which are rotatable in suitable bearings mounted to the front and rear extremities of the frame sides 18. Another roller, carried by an idler shaft 25 extending between the sides 18, presses upwardly against the conveyor belt 24 to eliminate slack and provide proper tensioning.
The belt 24 is preferably made of a wear resistant, flexible plastic material such as vinyl that can be tensioned longitudinally, but which droops or sags transversely in areas where it is unsupported. As will be seen, this feature is useful in the separating operation to be described.
The belt 24 is supported adjacent the front of the apparatus by a row of four longitudinally oriented, transversely spaced apart pipes or supports 26. The forward and rearward extremity of each support 26 is downwardly curved, as best seen in FIG. 6, to promote smooth engagement and disengagement with the underside of the upper run of the conveyor belt 24. The supports 26 are fixed against vertical movement by attachment to a pair of brackets 28 whose ends are fixed to the frame sides 18.
A second row of longitudinally oriented, transversely spaced apart pipes or supports 30 are located behind or beyond the supports 26. There are five such supports 30, all of which are downwardly curved at their forward and rearward extremities to facilitate sliding engagement with the underside of the upper run of the conveyor belt 24. The middle one of the supports 30 is approximately the same length as each of the forward supports 26, while the other four supports 30 extend from approximately the mid portion of the frame to its rearward extremity. In a manner similar to the mounting of the supports 26, the supports 30 are fixed against vertical movement by transverse brackets 32, two of which are seen in FIG. 6, which are attached at their ends to the frame sides 18.
It is important to note that the supports 30 are transversely offset relative to the supports 26. As will be seen, the flexible belt 24 is designed to hang or sag in a catenary-like configuration between adjacent supports 26, as seen in FIG. 8. As the belt 24 passes beyond the supports 26, the areas of such sagging changes so that the catenary-like sags of the flexible belt are longitudinally aligned with the first row of supports 26, as seen in FIG. 9.
The conveyor belt 24 supports each tray 12 and conveys it in the direction or conveyor path indicated by the arrow in FIG. 6. Each tray is placed across or transversely of the belt, and in an inverted position. The food product or strips 34 located on the underside of the tray thus engage the upper surface of the upper run of the conveyor belt 24, with the long axis of each strip 34 perpendicular to the conveyor path.
As the trays 12 move with the belt 24, separator means are arranged to project downwardly through the tray apertures 14 to engage with the strips 34 and gently separate them from the tray 12 and onto the upper surface of the belt 24.
The separator means comprise a row of five separator or roller bands 36 transversely spaced across and above the conveyor belt 24 adjacent the front end of the apparatus frame. The two outside roller bands 36 are narrower than the three central bands, but each band is characterized by a plurality of projections, protrusions, or fingers 38 made of flexible plastic material or soft rubber. Each finger 38 has a transverse cross-sectional area smaller than that of one of the apertures 14 so that the fingers can pass downwardly through the apertures into contact with the strips 10. As will be seen, the vertical position of the bands 36 can be adjusted so that engagement between the fingers 38 and the strips 10 is firm enough to separate the strips from the tray lattice 16 but not forceful enough to unduly deform and break the strips. This separating action is seen in FIGS. 8 through 10.
The base fabric or material of which the bands 36 is made is commercially available in wide, continuous belts. These are cut into narrow bands to provide the bands 36 with the integral fingers 38. Although the bands 36 could be adhered or otherwise secured to the periphery of large rollers carried on transverse shafts extending above the conveyor belt 24, the bands 36 are preferably adhered in transversely spaced apart relation to one one another on a wide separator belt 37 which extends across and above the belt 24. The belt 37 is supported so that each individual roller band 36 is upwardly inclined at its leading extremity, enabling a tray 12 to easily pass below the front of the roller band. The fingers 38 thereafter come into progressively closer relationship with the strips, and then firmly engage them along a rearward, horizontally disposed extremity of the band 36.
The sagging of the belt 24 between the supports 26 is clearly evident in FIG. 8, as is the projection of the fingers 38 through the tray apertures and into engagement with the strips 10. The sagging or yieldability of the flexible belt 24 between the supports 26 provides a space into which the strips 10 can be moved to separate them from the tray lattice portions between the supports 26. The size of the space is somewhat exaggerated for clarity. In some instances a pre-existing space is not necessary so long as the belt 24 is made sufficiently yieldable that it will move away from the tray with the separated food strips to accommodate their presence on the belt. Although not clearly seen in the drawings, the action of the fingers 38 on the tray also bends or flexes the portions of the tray 12 between the supports 26. This flexing induces relative movement between the adhered food product and the tray, and further facilitates separation of the strips 10 from the tray lattice 16.
FIG. 10 illustrates in detail the action of the fingers 38 in separating the strips 10 from the tray lattice 16 and into the spaces defined by the sagging portions of the conveyor belt 24. However, the portions of the strips 10 located between the roller bands 36 are not reached or engaged by the fingers 38 of the bands, and consequently separation of the strips 10 in these areas is not achieved.
Accordingly, a second row of four roller bands 40 is mounted on a continuous separator belt 41 like the front separator belt 37. The bands 40 are identical in construction and orientation to the bands 36, but are arranged behind the bands 36 and in transversely offset or staggered relation, that is, out of longitudinal alignment with the bands 36 and in longitudinal alignment with the supports 26 between the bands 36. With this arrangement the fingers 42 engage those portions of the food strips 10 not previously acted upon and separated by the fingers 38 of the first roller bands 36. The action of the fingers 42 on the strips 10 is best seen in FIG. 9.
The separated strips 10 pressed onto the conveyor belt 24 by the separating fingers 38 and 42 are carried by the conveyor belt 24 to its discharge end. At that point the belt 24 reverses direction around a belt shaft 22, as seen in FIG. 13. The strips can be collected in a bin (not shown), or a strip collection belt 44 can be located below the belt shaft 22 to catch the strips as they fall off the belt 24. The collection belt 44 preferably includes transverse ridges or ribs forming individual recesses for the strips 10. The collected strips are carried by the collection belt 44 to a station (not shown) where they are cut into shorter lengths and packaged.
The empty trays 12 leaving the rollers belts 40 are engaged adjacent their ends by a pair of rollers 46. These rollers have a continuous band of material adhered to their periphery like the material of the bands 36 and 40, and with the same type of flexible fingers. The rollers 46 engage the tray ends and force it into a horizontal plane, which is necessary for trays which have become warped through continued usage. In a horizontal plane the tray is properly positioned for interception by the pointed end 48 of a tray raising plate 50.
Plate 50 extends across the belt 24 and is secured at its opposite sides to the frame sides 18. As the tray moves toward it the end 48 passes beneath the tray 12 and above the sagging strips 10 and belt 24, as seen in FIG. 11.
The tray portion between the rollers 46 is flexed downwardly to help in completing the separation of the strips 10 from the tray lattice 16.
A pair of rollers 52 identical to the rollers 46 are located beyond and transversely inwardly of the rollers 46 to engage each tray 12 as it leaves the rollers 46, as seen in FIG. 12. The trays raised by plate 50 from the conveyor belt are first driven up the inclined surface of the plate 50 by the rollers 46, and then further driven downwardly by the rollers 52 until the end ones of the trays 12 drop into a pair of collection hangers 54 mounted to the rearward end of the plate 50. From this point the trays can be taken up for reuse in the strip processing operation.
Although the trays 12 can be manually inverted and placed on the belt 24 at the forward or feed end, as seen in FIG. 6, this operation is preferably automated by using a tray feed belt 56, as seen in FIG. 14. Trays coming from the drying oven (not shown) are normally in the upright position seen in FIG. 14, and the belt 56 is operated to bring the upright trays to a point adjacent an end shaft 58 where the direction of travel of the belt 56 reverses. The trays fall off the belt 56 and engage a vertical front plate 60 attached at its ends to the frame sides 18. The plate 60 holds the upper side of the tray against movement with the belt 24 so that the lower side of the tray 12 can be engaged by the belt 24 and carried away from the plate 60. This inverts the tray 12 and locates the food product on the underside of the tray.
The showing in FIG. 7 is exemplary of the means by which the various belts and rollers of the apparatus are driven and adjusted for operation.
The drive means comprises a suitable electric motor 62 which is mounted on the apparatus frame and operated to rotate a sprocketed drive shaft 64. This drives a chain engagable with a pair of sprocketed shafts 66 and 68.
Rotation of the shaft 66 is transmitted by a chain 70 for rotation of a sprocket mounted to the rear conveyor belt shaft 22. The belt roller on the shaft 22 acts upon the conveyor belt 24 to move it along the conveyor path previously described.
Rotation of the other sprocketed shaft 68 adjacent the motor 62 operates a drive chain 72 which rotates a sprocketed shaft 74 which drives the separating belt 41. A chain 76 trained about the sprocket of the shaft 74 also rotates a sprocketed shaft 78 which drives the separating belt 37.
Another chain 80 engages a sprocket of the shaft 68 and drives a sprocketed shaft 82 which is rotatable to drive a shaft 82 carrying the pair of rollers 46. The shaft 86 mounting the rearward pair of rollers 52 is driven by a chain 84 extending between the sprockets of the shafts 82 and 86.
The means for adjusting belt tensions and relative positions of the apparatus components is best seen in FIGS. 7, 13 and 14. The horizontal portion of the lower run of the separator belt 37 is urged downwardly by a pair of transverse rollers mounted to a pair of forwardly located adjustment shafts 88. As seen in FIG. 7, the vertical position of the shafts 88 can be adjusted by tightening or loosening nuts 92 which bear against an upward extension of the frame sides 18 and which operate upon vertical studs to raise and lower the bearing blocks which rotatably carry the shafts 88.
A similar arrangement of nuts 94 acting upon blocks mounting a pair of transverse adjustment shafts 96 raises and lowers the shafts 96 to adjust the vertical position of associated transverse rollers acting upon the horizontal portion of the lower run of the rearward separator belt 41.
The foregoing arrangement enables the degree of separating force exerted by the respective roller band fingers 38 and 42 to be adjusted for firm food strip separation, but without strip breakage.
An adjustment shaft 90 mounts an idler roller engaged upon the rearward portion of the separator belt 37 where it changes direction. The longitudinal position of the idler roller can be adjusted by tightening or loosening a nut 100, which adjusts the tension in the belt 37. Similarly, a nut 102 can be tightened or loosened to adjust the longitudinal position of a shaft 98 which mounts the idler roller engaged upon the separator belt 41, thereby adjusting the tension in the belt 41.
In operation, each tray 12 carrying food product strips 10 is placed in inverted position upon the conveyor belt 24, either manually or by the belt conveyor means of FIG. 14. The trays are carried by the conveyor belt 24 to the first row of roller bands 36, where the separating action illustrated in FIG. 8 occurs. The food product strips 10 are displaced downwardly from the tray 12 by the fingers 38 and into the space which exists by virtue of the cantenary sag of the belt 24 between each pair of adjacent supports 30. As previously indicated, displacement of the strips is not necessarily into existing sag spaces, but may be into spaces formed by downward yielding of the belt 24.
The portions of the food strips 10 not reached by the action of the roller fingers 38 are next acted upon by the fingers 42 of the roller bands 40 as the trays pass along the conveyor path, resulting in the separating action illustrated in FIG. 9.
Finally, the separated food strips are carried onto the strip collection belt 44, while the trays are moved up the inclined plate 50 onto the collection brackets 54 by the successive action of the rollers 46 and 52, as seen in FIG. 13.
The separating action developed by the roller bands 36, followed by the roller bands 40, and finally by the rollers 46, has been found to separate the strips 10 from the trays 12 with insignificant or no strip breakage. Moreover, utilization of the flexible conveyor belt 24, which sags or yields transversely between its underlying supports, makes possible separation of the strips in an essentially single operation, that is, with all separation occurring onto the same conveyor belt which supports and conveys the trays through the apparatus.
Referring now to FIG. 15, there is shown an alternate arrangement for feeding and inverting for the trays 12 onto the conveyor belt 24. Such means includes a vertical chute 110 having an open top 112 through which loaded trays 12 may be fed. The lower end of chute 110 is of reduced aide area and defines a tray discharge opening 114. The front of the discharge opening 114 is defined by a rearwardly and downwardly inclined wall 115 of chute 112. It will be apparent that as lowermost tray 12 enters the lower portion of chute 110, the inclined wall 115 will cause the tray to tilt into a generally, vertically extending position and forward movement of the upper run of the conveyor belt 24 (to the left of FIG. 15) will cause the tray to flip into an inverted position, with the meat strips 10 facing downwardly against the upper surface of the conveyor belt 24.
Referring now to FIGS. 16 and 17, there is shown a modified arrangement of the empty tray-engaging rollers designated 46 and 52 in FIG. 13. In the embodiment of FIG. 16, an extra set of rollers 120 are interposed between rollers 46 and 52 to assist in preventing the empty trays fro being twisted as they pass from plate 50 onto the upper run of conveyor belt 24.
Various modifications and changes may be made with regard to the foregoing detailed description without departing from the spirit of the invention. | An apparatus for separating a food product from a tray having apertures defining a supporting lattice to which the food product is adhered. A conveyor belt carries the tray in an inverted position with the food product on the bottom and engaging the upper surface of the belt. The undersurface of the belt is slidably supported by a first row of fixed, transversely spaced apart supports. A first row of roller bands with radially directed fingers is located above the belt with the roller bands midway between the supports. The fingers project through the tray apertures and move the product away from the tray and toward the conveyor belt. The conveyor belt sags between the supports, providing room for the product to move for separation from the tray. | 1 |
FIELD OF THE INVENTION
This invention relates to polymer blends and, more particularly, to a blend of thermoplastic polymers which form a single phase solid solution of excellent optical clarity and good flexural properties.
BACKGROUND OF THE INVENTION
Thermoplastic polymers useful for injection molding and extrusion to form molded articles and films often are deficient in one or more properties. Efforts to modify the properties of a polymer that is otherwise suitable, for example, by blending it with another polymer usually produce an opaque or cloudy blend which is not acceptable when the molded article or film must be clear and transparent. For example, U.S. Pat. No. 4,141,927 to White et al. discloses blends of polyetherimides and of polyesters based primarily on terephthalic acid and isophthalic acid. The patent discloses blends which formed multiple phase solid state solutions in the composition range from about 25 to 90 weight percent polyester. Such compositions are understood to be opaque and cloudy. Blends of polyarylates with polyetherimide are disclosed in the U.S. Pat. No. 4,250,279 to Robeson et al., and U.S. Pat. No. 4,908,419 to Holub et al. Three components blends of polyetherimide, polyester and a third polymer are also disclosed in U.S. Pat. No. 4,687,819 to Quinn et al. and U.S. Pat. No. 4,908,418 to Holub. None of these patents suggests a polymer composition having the combination of desired flexural properties, clarity and transparency.
There is a continuing need for thermoplastic polymer compositions that have high flexural moduli, high flexural strength and high heat deflection temperatures and that can be injection molded or extruded to form articles of excellent clarity and transparency.
BRIEF SUMMARY OF THE INVENTION
The composition of the invention is a visually clear blend of thermoplastic polymers comprising (A) a polyetherimide which is described in more detail hereinafter and (B) a polyester of a dicarboxylic acid component comprising 2,6-naphthalene dicarboxylic acid and a glycol component comprising at least one aliphatic or cycloaliphatic glycol selected from the group consisting of ethylene glycol, 1,3-trimethylene glycol, 1,4-butanediol, 1,5-pentanediol, 1,6-hexanediol, 1,7-heptanediol, neopentyl glycol, 1,4-cyclohexanedimethanol and diethylene glycol.
The invention also includes molded articles and films formed of the novel polymer blend. In addition, the invention includes a method for improving the physical properties of a polymer composition comprising a polyester of 2,6-naphthalene dicarboxylic acid that comprises melt blending or solution blending with the polyester a polyetherimide of the type described herein to form a single phase solid solution which is clear and transparent and of higher flexural modulus than the polyester.
BRIEF DESCRIPTION OF THE DRAWINGS
The sole FIGURE of the drawings is a plot of polymer compositional ranges for certain clear and cloudy polymer blends.
DETAILED DESCRIPTION OF THE INVENTION
As used herein, the term “polyester” means a polyester of a single dicarboxylic acid and a single glycol or a co-polyester of one or more dicarboxylic acids and one or more glycols. The term “dicarboxylic acid component” means the acid or mixture of acids (or their equivalent esters, anhydrides or halides) which react with a glycol or glycols to form a polyester. Similarly, the term “glycol component” means the glycol or glycols which react with such acid or acids (or their equivalent esters, anhydrides or halides) to form a polyester.
The novel polyetherimide/polyester blends of the invention comprise about 1% to 99% of a polyetherimide of the formula:
where n represents a whole number in excess of 1, for example 10 to 10,000 or more. The radical —O—R—O— is in the 3- or 4- and 3-′ or 4′-positions.
The radical —R— is a member of the class consisting of:
where m is 0 or 1 and Q is
and x is a whole number from 1 to 5, inclusive.
The radical —R′— is a divalent organic radical selected from the class consisting
(1) aromatic hydrocarbon radicals having from 6 to 20 carbon atoms and halogenated derivatives thereof;
(2) alkylene radicals and cycloalkylene radicals having from 2 to 20 carbon atoms; and
(3) radicals of the formula:
where R″ is:
and y is a whole number from 1 to 5, inclusive.
Such polyetherimides can be formed, for example, by the reaction of an aromatic bis(ether anhydride) of the formula:
with a diamino compound of the formula:
H 2 N—R′—NH 2
Included among the methods of making the polyetherimide are those disclosed in U.S. Pat. Nos. 3,847,867; 3,847,869; 3,850,885; 3,852,242; 3,855,178; 3,887,588; 4,017,511; and 4,024,110. These disclosures are incorporated herein by reference.
The novel polyester/polyetherimide blends of the invention also comprise about 99% to 1% of a polyester of 2,6-naphthalenedicarboxylic acid and of one or a mixture of two or more of the following aliphatic and cycloaliphatic glycols:
ethylene glycol
1,3-trimethylene glycol
1,4-butanediol
1,5-pentanediol
1,6-hexanediol
1,7-heptanediol
neopentyl glycol
1,4-cyclohexanedimethanol (cis and trans isomers and mixtures thereof)
diethylene glycol
In addition, the polyester or copolyester may be modified by other acids or a mixture of acids including, but not limited to:
terephthalic acid
isophthalic acid
phthalic acid
4,4′-stilbenedicarboxylic acid
oxalic acid
malonic acid
succinic acid
glutaric acid
adipic acid
pimelic acid
suberic acid
azelaic acid
sebacic acid
1,12-dodecanedioic acid
dimethylmalonic acid
cis-1,4-cyclohexanedicarboxylic acid
trans-1,4-cyclohexanedicarboxylic acid
The glycols or mixture of glycols may also be modified by other glycols or a mixture of glycols including, but not limited to:
1,8-octanediol
1,9-nonanediol
1,10-decanediol
1,12-dodecanediol
2,2,4,4-tetramethyl-1,3-cyclobutanediol
The amount of modifying acid or glycol (preferably less than 10 mole percent) which may be incorporated in the polyester while still achieving a clear, single phase blend depends on the particular acids and glycols which are used. Although it is not intended for this invention to be limited by any particular theory, the polyester and copolyester compositions which will produce single phase, clear materials can generally be determined by the method of Coleman, et al. [M. M. Coleman, C. J. Serman, D. E. Bhagwagar, P. C. Painter, Polymer, 31, 1187 (1990).] for prediction of polymer-polymer miscibility. Polyesters of 1,6-naphthalene dicarboxylic acid having solubility parameters between about 10.85 (cal·cm −3 ) 0.5 and about 15.65 (cal·cm −3 ) 0.5 as calculated by the method of Coleman et al. in general form single phase, clear blends.
Polyetherimides of the invention which are preferred are those in which:
R′ is an aromatic hydrocarbon radical having from 6 to 10 carbon atoms, or an alkylene or cycloalkylene radical having from 2 to 10 carbon atoms; or where
m, x and y are as defined above.
Polyetherimides of the invention which are even more preferred are those in which:
Polyetherimides of the invention which are even more preferred are those in which
Preferred blends of polyetherimides and polyesters of the invention are those in which the glycol component is ethylene glycol or 1,4-cyclohexanedimethanol or a mixture of ethylene glycol and 1,4-cyclohexanedimethanol.
In another aspect of the invention, a blend wherein the dicarboxylic acid component of said polyester comprises 2,6-naphthalene dicarboxylic and terephthalic acid and the glycol component of said polyester comprises ethylene glycol and 1,4-cyclohexanedimethanol is preferred.
In yet another aspect of the invention, a blend wherein said polyester has an acid component which comprises 100 to 10 mole percent 2,6-naphthalenedicarboxylic acid and 0 to 90 mole percent of terephthalic acid, isophthalic acid, or a mixture of terephthalic and isophthalic acid is preferred.
In yet another aspect of the invention, a blend wherein said polyester has an acid component which comprises 50 to 10 mole percent 2,6-naphthalenedicarboxylic acid and 50 to 90 mole percent terephthalic acid, or a mixture of terephthalic acid and isophthalic acid is preferred.
In yet another aspect of the invention, a blend wherein the dicarboxylic acid component of said polyester consists essentially of 2,6-naphthalenedicarboxylic acid and terephthalic acid and the glycol component of said polyester consists essentially of ethylene glycol and 1,4-cyclohexanedimethanol, and wherein the amount of 2,6-dinaphthalene dicarboxylic acid in said dicarboxylic acid component is at least about 32 mole percent and the amount of 1,4-cyclohexanedimethanol in said glycol component is no more than about 65 mole percent, is preferred.
A most preferred embodiment of the composition of the invention comprises (A) about 10 to 50 weight percent of a polyetherimide and (B) about 90 to 50 weight percent of the polyester. Preferred polyesters are polyesters of 2,6-naphthalenedicarboxylic acid and ethylene glycol or copolyesters of 2,6-naphthalenedicarboxylic acid and ethylene glycol modified with terephthalic and/or isophthalic acid and with butanediol and/or 1,4-cyclohexanedimethanol.
The blends of the invention can be compounded in the melt, for example, by using a single screw or twin screw extruder. They may also be prepared by solution blending. Additional colorants, lubricants, release agents, impact modifiers, and the like can also be incorporated into the formulation during melt blending or solution blending.
The examples which follow further illustrate compositions and the method of the invention and provide comparisons with other polymer blends.
This invention can be further illustrated by the following examples of preferred embodiments thereof, although it will be understood that these examples are included merely for purposes of illustration and are not intended to limit the scope of the invention unless otherwise specifically indicated. The starting materials are commercially available unless otherwise indicated.
EXAMPLES
Example 1
Polyesters and copolyester of Table 1 below were blended in equal parts by weight with a polyetherimide (PEI). The polyesters were prepared by reacting the acids, 2,6-naphthalenedicarboxylic acid (NA) or terephthalic acid (TA), or mixtures thereof, with ethylene glycol (EG) or 1,4-cyclohexanedimethanol (CG), or mixtures thereof. The polyetherimide was Ultem 1000™ polyetherimide, which is commercially available from General Electric Company. This polyetherimide is essentially the reaction product of 2,2-bis[4(3,4-dicarboxyphenoxy)phenyl] propane dianhydride:
and meta-phenylenediamine.
The 50/50 by weight polyester/polyetherimide blends were prepared in a solution of 75/25 by volume methylene chloride/hexafluoroisopropanol and precipitated by dropping into methanol, with stirring. The precipitate was isolated by decanting and dried under vacuum at ≈60° C. for three days. The blends were tested by differential scanning calorimetry in order to determine the glass transition temperature (T g ), crystallization temperature (T c ), and melting temperature (T m ). Particular note was taken as to whether each blend exhibited one or two glass transition temperatures, intermediate between the glass transition temperatures of the polyester and polyetherimide. The blends were also melt pressed into thin films at ≈280° C. The films were inspected visually for clarity.
The results of differential scanning calorimetry and film clarity observations shown in Table 1 demonstrate the particular copolyester composition ranges over which a solid single phase blend with good clarity may be obtained. All of the pressed films exhibited a light brown color similar to that of the pure polyetherimide. Based on the observations of T g s and film clarity, a map of the composition range over which a visually clear blend is obtained is illustrated in the drawings.
TABLE 1
Mole % in Acid
Mole % in Glycol
Number
Film
Sample
NA
TA
EG
CG
of Tgs
Clarity
A1
0
100
100
0
Two
Cloudy
B1
0
100
42
58
Two
Cloudy
C1
0
100
28
72
Two
Cloudy
D1
0
100
0
100
Two
Cloudy
E1
100
0
100
0
One
Clear
F1
68
32
0
100
One
nd
G1
100
0
35
65
One
Clear
H1
66
34
35
65
One
Clear
I1
66
34
68
32
One
Clear
J1
32
68
36
64
One
Clear
K1
34
66
67
33
One
Clear
L1
5
95
0
100
Two
Cloudy
M1
10
90
0
100
Two
Cloudy
N1
20
80
0
100
Two
Cloudy
O1
51
49
100
0
One
Clear
P1
16
84
100
0
One
Clear
Q1
16
84
29
71
Two
Cloudy
nd: not determined
The blends of polyetherimide with polyesters of terephthalic acid and ethylene glycol or 1,4-cyclohexanedimethanol, or mixtures thereof, formed two phase solid solutions and thus resulted in cloudy films (i.e. samples A1, B1, C1, D1), in accordance with the teachings of White et al. in U.S. Pat. No. 4,141,927. The blends with polyesters of terephthalic acid with ethylene glycol or 1,4-cyclohexanedimethanol, or mixtures thereof, which were modified by 20 mole percent or less of 2,6-naphthalenedicarboxylic acid (i.e. samples L1, M1, N1) also resulted in two phase solid solutions and cloudy films. In contrast, the blends of polyesters based on 2,6-naphthalenedicarboxylic acid with ethylene glycol and 1,4-cyclohexanedimethanol, or mixtures thereof, (i.e. samples E1, G1) surprisingly formed single phase solid solutions and clear films. The results also demonstrate that visually clear blends may still be obtained if a polyester based on 2,6-naphthalenedicarboxylic acid with ethylene glycol and 1,4-cyclohexanedimethanol, or a mixture thereof, is modified with certain amounts of terephthalic acid. This is demonstrated by samples H1, I1, J1, K1, O1 and P1. Furthermore, the results demonstrate that the amount of modifying terephthalic acid which may be used while still obtaining a visually clear blend is dependent on the particular glycol or mixture of glycols which is used. For example, the polyesters of both samples P1 and Q1 are composed of 16% 2,6-naphthalendicarboxylic acid and 84% terephthalic acid. However, sample P1 is a clear blend while sample Q1 is a cloudy blend. The difference is due to the particular glycols which are used in these samples, namely, 100 mole percent ethylene glycol in the clear blend P1 and 100 mole percent 1,4-cyclohexanedimethanol in the cloudy blend Q1.
Example 2
Blends of polyesters and the same polyetherimide described in Example 1 were compounded in the melt and injection molded. The polyesters compounded were as follows: poly(ethylene 2,6-naphthalenedicarboxylate); poly(ethylene terephthalate); poly(ethylene-cocyclohexane-1,4-dimethylene terephthalate) with 42 mole % ethylene and 58 mole % cyclohexane-1,4-dimethylene in the glycol; and poly(ethylene-co-cyclohexane-1,4-dimethylene terephthalate) with 28 mole % ethylene and 72 mole % cyclohexane-1,4-dimethylene in the glycol.
The polyester compositions along with the blend compositions and observed clarity are reported in Table 2. All of the blends exhibited a light brown color similar to that of the pure polyetherimide.
The diffuse transmittance of injection molded articles formed from several of the blends, which is a measure of the visual clarity of the articles, was determined by the procedure of ASTM D1003. The results of these measurements are included in Table 2.
TABLE 2
Polyester Composition
Mole % in
Mole % in
Weight %
% Diffuse
Acid
Glycol
PEI
Visual
Transmit-
Sample
NA
TA
EG
CG
in Blend
Clarity
tance
A2
0
100
100
0
0
Clear
B2
″
″
″
″
10
Cloudy
C2
″
″
″
″
20
Opaque
D2
″
″
″
″
30
Opaque
19
E2
0
100
42
58
0
Clear
80
F2
″
″
″
″
10
Opaque
G2
″
″
″
″
20
Opaque
13
H2
″
″
″
″
30
Cloudy
17
I2
0
100
28
72
0
Clear
81
J2
″
″
″
″
10
Opaque
K2
″
″
″
″
20
Opaque
11
L2
″
″
″
″
30
Opaque
5
M2
100
0
100
0
0
Clear
N2
″
″
″
″
10
Clear
51
O2
″
″
″
″
20
Clear
51
P2
″
″
″
″
30
Clear
46
Samples B2, C2, D2, F2, G2, H2, J2, K2, L2 were opaque or cloudy because they formed two phase solid solutions, as taught by White and Matthews in U.S. Pat. No. 4,141,927. However, samples N2, 02, and P2 (which are compositions of this invention) were surprisingly clear. In addition, the molded articles formed from these compositions exhibited a high percentage of diffuse light transmittance.
Example 3
Blends of poly(ethylene 2,6-naphthalenedicarboxylate) with the same polyetherimide described in Example 1 were prepared by first compounding on a co-rotating twin screw extruder and the injection molding into parts for mechanical testing. All of the blends exhibited excellent transparency and a light brown color similar to that of the pure polyetherimide. The blend compositions, processing conditions, and mechanical properties are given in Table 3. The diffuse transmittance of the articles formed from blends of the invention, measured according to ASTM D1003, are also included in Table 3.
TABLE 3
Sample
A3
B3
C3
D3
PEI Weight %
0
10
20
40
Compounding Temp. (° C.)
295
295
295
295
Molding Temp. (° C.)
300
305
305
305
% Diffuse Transmittance***
51
41
42
Appearance
Clear
Clear
Clear
Clear
Izod Impact Strength (ft · lb/
in)****
Notched 23° C.
0.6
0.6
0.6
Notched −40° C.
0.7
0.6
0.5
0.5
Unnotched 23° C.
20.1
21.9
17.0
26.4
Unnotched −40° C.
10.2
8.5
11.8
14.5
Flexural Strength (psi)*
14410
15600
16510
18520
Flexural Modulus (kpsi)*
347
370
377
411
Heat Deflection Temperature
(° C.)**
at 66 psi
109
115
125
141
at 264 psi
88
98
110
125
*measured according tc ASTM D790
**measured according to ASTM D648
***measured according to ASTM D1003
****measured according to ASTM D256
Some of the advantages of these blends are demonstrated by these results. The flexural strength, flexural modulus, and heat deflection temperatures increase with the addition of the polyetherimide to the polyester. In addition, the blends can be processed at a much lower temperature than that which is required when processing the pure polyetherimide, and the molded articles exhibit high diffusive transmittance. Because of these properties of the novel polymeric blends, they can be molded at reasonably low temperatures to form articles which are resistant to deformation at elevated temperatures. For example, molded articles of the novel polymeric blends can be used as containers that can withstand heat such as cooking vessels or as polymeric. parts positioned near motors in golf carts, lawnmowers and the like. In all of these uses the optical clarity and the resistance to thermal deformation are valuable properties of the novel polymer blends of the invention.
The invention has been described in detail with particular reference to preferred embodiments thereof, but it will be understood that variations and modifications can be effected within the spirit and scope of the invention. | This invention relates to a visually clear blend of thermoplastic polymers comprising a polyetherimide and a polyester of (a) an acid component comprising 2,6-naphthalene dicarboxylic acid and (b) a glycol component comprising at least one glycol selected from the group consisting of ethylene glycol, 1,3-trimethylene glycol, 1,4-butanediol, 1,5-pentanediol, 1,6-hexanediol, 1,7-heptanediol, neopentyl glycol, 1,4-cyclohexanedimethanol and diethylene glycol. | 2 |
The present application is a continuation of pending application Ser. No. 07/109,770 filed on 10/16/87 which in turn is a continuation-in-part of co-pending application Ser. No. 07/029,735 filed 03/24/87 for Card Holding, Carrying And Retaining System, which application is still being prosecuted concurrently with this application as Continuation application Ser. No. 07/293,690 filed 01/05/89.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an improved card holding, carrying and retaining system by which an individual can efficiently collect and mount cards such as a business card immediately upon receipt of the card during meetings, conventions, etc. and thereafter employ the mounting means to carry the card so that it will not be mutilated, misplaced or lost and thereafter upon return home or to his or her place of business immediately transfer the card to a retaining means such as a business card file box or a rotary file holder. The present invention further relates to a novel housing member for retaining the tray in which the retained cards are placed and further relates to a novel carrying member for retaining a series of card holding members for use during a business trip. The present invention also relates to business card retaining means which can be used in conjunction with conventional organizers and planners.
2. DESCRIPTION OF THE PRIOR ART
In general, card filing systems are well known in the prior art. Conventionally, a multiplicity of filing cards are placed in a filing card retaining means. Conventional filing card retaining means include a tray or a wheel in which the filing cards are place, such as those manufactured by Eldon or by Rolodex respectively. The tray card holder or rotary card holder includes one or more card holding means such as tracks, rails, cylindrical rods, etc. onto which the filing cards are movably inserted. The filing cards, in turn, having mating slots adjacent their lower edge by which the cards may be movably and removably inserted onto the tracks, rails, rods, etc of the card holding means.
When people attend a business meeting, a trade show or a convention, they frequently receive a large number of business cards from individuals with whom they may be negotiating a transaction or who they meet at a trade show or convention. Many times these individuals may be prospective customers or clients. The cards are frequently placed in a coat pocket or purse and may thereafter be wrinkled, torn, misplaced or lost. In addition, assuming the business cards are brought back to the office, they are frequently placed in a desk drawer where they are forgotten. Alternatively, if the newly acquired business cards are maintained in a safe place and are brought back to the office, the information from the cards must be transmitted to the filing card system. One alternative is to transcribe the information from the business card onto the filing card. In addition to taking extra time to do this work with each business card, information may be incorrectly transcribed, leading to greater problems and a waste of time in locating the correct information. In an alternative process, the business card may be somehow attached to the filing card such as by tape or staples. Since the business card is usually about the same height as the filing card and an allowance must be made for the slots by which the filing card is movably attached to the tracks in the card holder, the business card is often too tall for the card holder trays, thereby preventing the tray from being closed. It is therefore necessary to cut the business card so that it fits onto the filing card so that the tray can be closed while at the same time not interfering with the slots at the lower edge of the filing card. Since telephone numbers and/or addresses are frequently placed adjacent the top or bottom of the card, this information is cut off and therefore must be written onto the body of the card.
Some Rolodex type trays have a closing lid to prevent the cards from getting dirty. Others, are left exposed. In embodiments where the cards are inserted onto a carrying tray, the tray itself does not include an appropriately fitted housing member so that the cards may be stored and thereby reduce the likelihood that they will become soiled.
When a businessperson wishes to go on a business trip, it is necessary for him or her to copy down the address from the business card or alternatively remove the card from the card holding file and place it in his or her wallet or briefcase (or pocket book). If the individual is a salesperson and must make frequent calls to a large number of customers or potential customers, this becomes a significant chore. In addition, there is a significant risk that the cards may becomes lost or soiled.
Loose-leaf type business organizers and planners have become very popular. Business cards are not conveniently stored in such organizers and are merely fitted into a slot therein from which they can fall out or become creased or soiled.
Therefore, the card filing systems known in the prior art all suffer from the same defects. Business cards can be dirtied, torn, lost or mislaid when received and if they are brought back to the office intact, they must be physically modified before they can be placed onto the filing card or information must be taken from the business card and written onto the filing card. In open tray type card holders (which are the most convenient), the prior art systems provide no housing with a matched fitting to the tray to keep the cards safe and to prevent them from getting dirty or from be soiled (such as coffee being spilled on them). In addition, no prior art system provides an efficient method by which a selected number of the business cards can be removed and taken on a trip, which system at the same time assures that the business cards will be kept safely and be prearranged in a given selected order or other system.
Therefore, there is a significant need for a product which permits a business card to be immediately mounted upon receipt and thereafter safely carried so that it will not become disfigured or lost and which further permits the card to be immediately inserted onto the tracks of a card file without any further work involved.
There further exists a significant need for a system by which business cards can be efficiently mounted, collected and safely stored when received and thereafter instantly inserted into a card holder or tray upon the individual's return to the office without a need for modifying the card in any way or transcribing information from the business card onto the filing card.
There is also a significant need for a system by which cards mounted in an open tray can be protected through a protecting housing member when the cards and tray are not in use. There is also a need for a system by which a multiplicity of the protective housing members can be stacked or mounted on a wall unit, for more efficient use.
There is additionally a significant need for an organizing and carrying system to selectively carry a group of business cards on a trip in a specific safe and organized manner.
There is a further significant need for efficiently carrying business cards in a loose-leaf type business planner or organizer.
SUMMARY OF THE PRESENT INVENTION
The present invention relates to an improved system whereby a business card can be immediately placed onto a card holding means which permits the card to be immediately stored in a card carrying means which can be carried in a coat pocket or purse and further upon return to one's office permits the business card to be immediately removed from the card carrying means and placed in a desk card retaining means such as a card file or rotary file without any need for physical alteration of the business card or transcription of the information from the business card to the filing card.
The present invention additionally relates to a housing member which perfectly matches the desk card retaining means to keep the cards and desk card retaining means or tray covered when not in use to thereby assure that the cards and tray will not become dirty by means such as food or drink being spilled on them. The matching housing member further includes features such as a tray to retain cards before they are alphabetically filed in the desk card retaining means.
The present invention further relates to a matching case member which permits a multiplicity of card carrying means to be stored and carried in a preselected order. As a result, if it is desired to select a group of cards retained by the present invention card holding means and carrying them on a business trip, the user can remove the business cards and associated card holding means from the card retaining means and place them in the card carrying means. If it is desired to have a preselected group of card carrying means on the trip so that each card carrying means contains a group of cards for businesses or individuals to be called on during a given period of time or a given location, the matching case member can hold a multiplicity of card carrying members in a preselected order with the associated preselected business cards therein. In this way, a business trip can be efficiently organized with the cards for individuals or business to be called on in a given morning placed in one card carrying means and the cards for individuals or businesses to be called on in the afternoon and during future days to be placed in selected additional card carrying means.
In addition, the present invention further permits the business card to be removed from the card retaining means and placed in the card carrying means for use when the individual is going to a meeting with that person, thereby eliminating the necessity of once again transcribing the information from the card in the card retaining means onto a piece of paper to be taken by the individual to the meeting.
It has been discovered, according to the present invention, that use of a card holding means or strip means comprising at least one slot adjacent one edge for movable mating engagement with the rail or track of a card carrying means or card retaining means and a self adhesive section along one face of the card holding means which self adhesive section may be protected by a removable covering means, enables a user to quickly affix a business card to the card holding means by removal of the covering strip and pressing the back of the business card adjacent the self adhesive section. This assembly thereby permits an individual to have a means for retaining a business card in a multiplicity of locations such as a card carrying means or card retaining means.
It has further been discovered that if a card carrying means such as a case comprising at least one rod or track capable of movably and removably receiving the at least one slot of the card holding means is used in conjunction therewith, then upon affixation of the business card to the card holding means, the card holding means can be retained in the card carrying means or case by insertion of the slot or slots in the card holding means onto a respective one of the track or tracks in the case.
It has additionally been discovered, according to the present invention, that if a card retaining means such as a tray or rotary file (for example an Eldon file tray or Rolodex Rotary File) comprising at least one track or rod which movably and removably accommodates the slot or slots in the card holding means is used in conjunction therewith, then upon return to the office or other location where the card retaining means is kept, the strip means and the business card affixed thereto can be removed from the card carrying means and transferred to the card retaining means.
In addition, if it is desired to remove the business card for use in a future trip to that individual, the card can be easily removed from the card retaining means and placed in the card carrying means or case which is carried to the meeting.
It has also been discovered that if the card retaining means is an open tray configuration, a matching housing member which permits the card retaining means or tray to removably slide within the housing member provides an efficient means to keep the cards and associated tray clean. If the housing member includes a storage tray, cards can be placed in the tray and later filed in the card retaining means when time permits.
It has also been discovered that if at least one and preferably a pair of openings are placed in the rear wall of the matching housing member, the matching housing member can be mounted on a wall for ready access.
It has further been discovered that if non-slip members such as Bumpons˜ (a Trademark of 3M Corporation) are placed on the floor or base of the housing member, the housing members can be stacked one on top of the other. In addition, if such Bumpons˜ are placed on the bottom of the card retaining member, the Bumpons˜ facilitate more easy use and non-slippage of the card retaining member.
It has additionally been discovered that a matching case member including a multiplicity of preformed slots for individually retaining a multiplicity of card carrying means provides an ideal means for carrying a multiplicity of card carrying means containing a multiplicity of preselected cards in each card carrying means, to thereby efficiently organize a business trip.
It has additionally been discovered that if two card retaining means are placed side by side on a backing member which incorporates a selected series of holes to enable the backing member to be inserted in a loose-leaf type book, the card retaining means of the present invention can be used in conjunction with conventional business planners or organizers in loose-leaf form.
It is therefore an object of the present invention to provide a business card holding means such as a strip whereby the card can be permanently affixed to the strip so that it can be movably and removably retained in a card carrying case or card retaining file.
It is a further object of the present invention to provide a business card retaining system whereby the card can be immediately affixed to a card holding means or strip which permits the card to be movably and removably inserted in and carried in a card carrying means such as a card carrying case from which it can be removed and movably and removably inserted in a card retaining means such as a tray file (either open or with a closing top) or rotary file (such as a Rolodex), all without the necessity of altering the physical shape of the card or transcribing information from the card onto another piece of paper such as a filing card.
It is another object of the present invention to substantially eliminate the possibility of mutilating or losing business cards or other cards or incorrectly transcribing information from the cards onto another piece of paper.
It is an additional object of the present invention to provide a matching housing member for open card retaining means to thereby enclose the card retaining means when not in use and further provide a means for storing unfiled cards in an efficient and safe manner so that they may be later filed when time permits.
It is another object of the present invention to provide a means by which housing members may be stacked one on top of the other and/or by which housing members may be mounted on a surface such as a wall.
It is an additional object of the present invention to provide a case means for carrying a multiplicity of card carrying means in a preselected order.
It is another object of the present invention to provide an embodiment of a card retaining means which can be used in conjunction with conventional business planners or organizers in loose-leaf form.
Further novel features and other objects of the present invention will become apparent from the following detailed description, discussion and the appended claims taken in conjunction with the drawings.
DRAWING SUMMARY
Referring particularly to the drawings for the purpose of illustration only and not limitation, there is illustrated:
FIG 1 is a perspective view of the a card holding means of the present invention such as a strip member, with the self adhesive section completely covered by a covering strip.
FIG. 2 is a perspective view of the card holding means illustrated in FIG. 1, with a portion of the covering strip peeled away to disclose the self adhesive section.
FIG. 3 is a perspective view of a card holding means such as a strip member and a fragmentary view of a card affixed to the strip member.
FIG. 4 is an elevational view of two card holding means detachably affixed to each other along one lengthwise edge by a perforated central strip.
FIG. 5 a perspective view of a card carrying means such as a card carrying case used in conjunction with the card holding means illustrated in FIGS. 1 through 3 movably and removably inserted therein.
FIG. 6 is a perspective view of a card retaining means such as a card file tray, with the card holding means movably and removably inserted therein.
FIG. 7 is a longitudinal cross-sectional view taken along line 7--7 of FIG. 6.
FIG. 8 is a perspective view of a rotary card retaining means such as a Rolodex file, with the card holding means movably and removably inserted therein.
FIG. 9 is a perspective view of an alternative embodiment of an open card retaining means such as a card file tray, with the card holding means movably and removably inserted therein.,
FIG. 10 is a top plan view of the card retaining means illustrated in FIG. 9, with the card holding means and associated business cards removed
FIG. 11 is a cross-sectional view of the card retaining means illustrated in FIG. 9, taken along line 11--11 of FIG. 10, to thereby illustrate the rails on which the card holding means are retained.
FIG. 12 is a cross-sectional view of the card retaining means illustrated in FIG. 9, taken along line 12-12 of FIG. 10, to thereby illustrate a longitudinal view of one of the rails and the handle member by which the card retaining means is moved.
FIG. 13 is a perspective view of a card retaining meanings housing member including a slidable tray member therein for retaining unfiled business cards.
FIG. 14 is a longitudinal cross-sectional view of the housing member illustrated in FIG. 13, with a card retaining means and associated card holding means and business cards retained therein as well as the slidable tray for retaining unfiled business cards retained therein, to illustrate the relationship between (i) the rail means for slidably receiving the card retaining means within the housing member, (ii) the lower portion of the housing member which slidably receives the card holding tray and (iii) the clearance provided for the business cards carried in the card retaining means after it is inserted into the housing member.
FIG. 15 is a perspective view of a case means for carrying a multiplicity of card retaining means in a preselected order, illustrating two card retaining means carried therein.
FIG. 16 is an alternative embodiment of a card retaining means for use in conjunction with a business planner.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Although the apparatus and method of the present invention will now be described with reference to specific embodiments in the drawings, it should be understood that such embodiments are by way of example and merely illustrative of but a small number of the many possible specific embodiments which can represent applications of the principals of the invention. Various changes and modifications obvious to one skilled in the art to which the invention pertains are deemed to be within the spirit, scope appended claims.
Referring to FIG. 1, there is shown at 10 a card holding means such as a strip member. The card holding means comprises at least one retaining means 12 located on one edge 14 of the card holding means. In the preferred embodiment, the strip retaining means are two slots 12, as shown in FIG. 1, with each slot having a wide portion 16 located in the body 20 of the card holding means or strip member 10, and a narrow portion 18 opening into the edge 14 of strip member 10 such that the card holding means may be inserted onto a pair of tracks or rails through its narrow portion 18 and retained by its wider portion 16.
The card holding means or strip member 10 further comprises a self adhesive section 24. In the preferred embodiment, the self adhesive section 24 is a strip located adjacent an edge 26 directly opposite to the edge along which the strip retaining means 12 are located, and further located on one face 30 of the card holding means 10. The self adhesive section 24 is protected by a removable section covering means 32 which completely covers the self adhesive section 24 when the card holding means 10 is not in use, as illustrated in FIG. 1 and is peeled off (as partially shown in FIG. 2) when the card holding means is to be used. In the preferred embodiment, when the self adhesive section 24 is a strip located adjacent one edge of the card holding means 10, the removable section covering means 32 is a paper strip which is removably placed over the self adhesive section.
As shown in FIG. 3, after the section covering means 32 is peeled away, a card such as a business card 40 can be permanently attached to the card holding means 10 by aligning the card 40 onto the card holding means 10 and pressing the back of the card onto and against the uncovered self adhesive section 24 until a firm bond is secured. In the preferred embodiment as shown in FIG. 3, the bottom of the card 40 has been aligned just above the upper portion of the strip retaining means 12. It will be appreciated that the business card 40 could be aligned at any location although the embodiment shown in FIG. 3 is preferred since it provides the shortest practical combined vertical height of the business card 40 and card holding means 10. Therefore, a card 40 can be easily and permanently retained on the card holding means 10.
In the preferred embodiment, the card holding means is a rectangular strip which is approximately the same length as a conventional business card. Conventional business cards are approximately three and one-half inches long and two inches high. In the preferred embodiment, the strip is approximately three and one-half inches long and one and one-eighth inches high. The two slots extend through the faces of the strip and extend out one edge. They are spaced apart such that the distance 15 between their centers is approximately one inch. This conforms to the distance between the longitudinal centerlines of the tracks on card retaining files such as those made by Eldon or Rolodex. In the preferred embodiment, the self adhesive section is a strip located on one face of the rectangular strip.
As illustrated in FIG. 4, one convenient method of storing a multiplicity of unused card holding means 10 is to detachably affix two such card holding means 10 to each other along one lengthwise edge by a perforated central strip 11. When the card holding means 10 are to be used, they are torn apart at the location of the perforated central strip 11.
Referring to FIG. 5, there is shown one embodiment of a card carrying case 50. The card carrying means or case 50 comprises at least one rail or track 52 which can accommodate the strip retaining means 12 of the card holding means 10. In the preferred embodiment as shown in FIG. 5, a pair of rods or tracks are aligned in generally parallel relationship to each other and spaced apart so that their longitudinal centerlines are approximately the same distance apart as the distance between the centers of the strip retaining means -2 on the card holding members 10. The configuration of the remainder of the card carrying means or case 50 is optional and one of many possible embodiments is illustrated in FIG. 5. In this embodiment, the card carrying case 50 comprises a front ledge 54, a bottom 56, a rear portion 58 and a flexible cover 60 which can be opened to permit insertion of the card holding means 10 (with or without business cards attached) and thereafter closed by folding the lower edge 61 of the cover 60 immediately behind the front ledge 54, thereby protecting the card holding means 10 and attached cards 40 inside the card carrying case 50. The rods or tracks are held in place by being affixed to the front ledge and rear portion of the card carrying case. As shown in FIG. 5, the card holding means 10 can be snapped into place on the rods or tracks 52 through the narrow portion 18 and held therein by the wider portion 16 of the strip retaining means 12.
As shown in FIG. 5, the card holding means 10 can be snapped into place on the rods or tracks 52 of the card carrying case 50 and retained thereon for ready use. At such time as a card holding means 10 is needed, it can be easily snapped out of its position in the card carrying case 50 and the card 40 can be permanently affixed to the card holding means 10 as previously described. As shown in FIG. 5, the internal height of the card carrying means 50 is large enough to accommodate a conventional business card affixed to the card holding member 10. Through this method, a card 40 can be immediately affixed to a card holding member 10 and thereafter movably and removably held in the card carrying case 50.
Upon return to the office or other location where the card retaining file is kept, the business cards can be removed from the card carrying case 50 and snapped into place in the card retaining file.
One possible embodiment of the card retaining means 60 is shown in FIGS. 6 and 7. The card retaining file must comprise at least one rail or track which can accommodate the strip retaining means or slots 12 of the card holding member 10. In the preferred embodiment, the card retaining means 60 is a file which has a pair of rods or tracks 62 which are aligned in generally parallel relationship to each other and spaced apart so that their longitudinal centerlines are approximately the same distance apart as the distance between the centers of the strip retaining means 12 on the card holding means 10. One additional feature on the card retaining file is a well or temporary card placement area 64 located at the front of the file. Cards can be placed in this area and later filed alphabetically. While the card retaining means 60 is shown in FIGS. 6 and 7 as an open tray, it will be appreciated that it can be an enclosed type file comparable to the ones commercially sold by Eldon Corporation.
Another possible embodiment of the card retaining means 70 is the rotary file shown in FIG. 8. Once again, the important component for purposes of the present invention is that the rotary card retaining file 70 comprises at least one rail or track 72 which can accommodate the strip retaining means 12 of the card holding member 10. In the preferred embodiment, the rotary card retaining means 70 is a file which has a pair of tracks 72 which are aligned in generally equidistant relationship to each other along a circular path and spaced apart so that their longitudinal centerlines are approximately the same distance apart as the distance between the centers of the strip retaining means 12 on the card holding means 10.
An alternative embodiment of the card retaining means 80 is shown in FIGS. 9 through 12. FIG. 9 is a perspective view of an open card retaining means 80 such as a card file tray. Also shown in FIG. 9 is a multiplicity of separator members 100 used to divide the cards along a specific order, such as alphabetical order. FIG. 10 is a top plan view of the card retaining means 80. FIG. 11 is a cross-sectional view taken along line 11--11 of FIG. 10. FIG. 12 is a cross-sectional view taken along line 12--12 of FIG. 10. The body of the card retaining means 80 is formed of one piece construction (as by plastic injection molding) and comprises a rear wall 82, a floor 84, a front wall 86 and a handle 88. In the preferred embodiment illustrated, the front wall 86 and the rear wall 82 are generally parallel to each other and are generally perpendicular to the floor 84. The handle 88 extends from the front wall 86 and is preferably offset at an angle thereto. A well 90 is formed by and bounded by the front wall 86, the floor 84 and the rear wall 82. The card retaining means must comprise at least one rail or track which can accommodate the strip retaining means or slots 12 of the card holding member 10. In the preferred embodiment, the card retaining means 80 comprises a pair of rods or tracks 92 and 94 respectively which are aligned in generally parallel relationship to each other and spaced apart so that their longitudinal centerlines are approximately the same distance apart as the distance between the centers of the strip retaining means 12 on the card holding means 10. The pair of rods 92 and 94 are aligned in the well 90 and as illustrated in FIG. 12 extend for the entire length of the well 90 from the front wall 86 to the rear wall 82. As shown in FIG. 11, in the preferred embodiment the rods are part of the one piece construction of the front wall, floor and side wall, and extend upwardly from the floor. Rod 92 is supported on stem 96 which extends from floor 84 and rod 94 is supported on stem 98 which extends from floor 84. In each case, the rod 92 is offset from the stem 96 so that one portion of the circumference of each rod is aligned with the inwardmost portion of its supporting stem, as shown in FIG. 11. Of course, it is also possible for the rod to be centered on its supporting stem. Alternatively, the rods could be merely cylindrical tubes which are supported by the front and rear walls, comparable to the illustration of the embodiment shown in FIG. 7. The card holding means 10 and associated cards 40 (or card holding means alone) are supported on the rods 92 and 94 as previously described.
As part of the system of the presently invention, the card retaining means 80 can itself be retained within a housing member whose interior dimensions are design to accommodate the card retaining means 80 when it is filled with card holding means 10 and associated cards 40. A preferred embodiment of such a housing member 110 is illustrated in FIG. 13. The housing member 110 is comprised of an open faced chamber which includes and is bounded by a pair of generally parallel and oppositely disposed side walls 112 and 114 and a pair of generally parallel and oppositely disposed walls 116 and 118 which serve as the top and bottom walls respectively. A rear wall 120 completes the chamber which is completely open on its front surface area 122. In the preferred embodiment, all of the walls 112, 114, 116, 118 and 120 are created in a one-piece construction (such as by plastic injection molding) and essentially form a box which is open on one face. The embodiment shown in FIG. 13 is generally square, but other shapes such as rectangular with walls 112, 114, 116, and 118 being longer than wall 120 are within the spirit and scope of the present invention. The interior surface of side walls 112 and 114 further comprise a pair of rails or shelves. Interior surface 113 of side wall 112 comprises a pair of rails or shelves 124 and 126. As illustrated in FIG. 14, each rail or shelf 124 and 126 abuts rear wall 120 and extends forward to a distance adjacent but not at the front opening 122. The interior surface of side wall 114 also comprises a pair of rails or shelves 128 and 130 which are oppositely disposed to the rails or shelves 124 and 126, and are parallel to them, to thereby form two sets of rails. Lower rails 124 and 128 are oppositely disposed and parallel to each other. Upper rails 126 and -30 are oppositely disposed and parallel to each other. Rails 124 and 126 are generally parallel to each other and as illustrated in FIG. 14 are set apart by a distance slightly larger than the height of rear wall 82 of card retaining member 80. Rails 128 and 130 are generally parallel to each other and are set apart by a distance slightly larger than the height of rear wall 82 of card retaining member 80. As shown in FIG. 14, the distance between lower rails 124 and 128 and the floor 118 is set so that the card retaining means 80 filled with card holding means 10 and associated cards 40 and separator members 100 can fit within the interior space 130 of housing means 110. The card retaining means 80 is inserted into the housing means 110 such that the respective edges of the floor 84 slidably rest on a respective one of the lower rails protruding from the interior sidewalls of the housing means 110 and such that the respective edges of the rear wall 82 abuts a respective one of the lower surfaces of the upper rails protruding form the interior sidewalls of the case member, as illustrated in FIG. 14. The rails 124, 126, 128 and 130 protrude only a sufficient distance so as to provide support for the floor 84 and stabilization on the rear wall 82, and not so far into the space 132 so as to interfere with the business cards 40 or separator members 100.
In the space 134 between the floor 118 and the lower pair of rails 124 and 128, the housing member 110 further comprises a slidable tray 140 whose dimensions are designed to fit within space 134. The upper portion of the sidewalls of tray 140 abut the lower portions of lower rails 124 and 128 such that the tray 140 can slide in and out of the housing member or means 110 along its floor 118. The tray can be used to hold business cards 40 which have not yet been filed in the card retaining means 80.
As shown in FIG. 14, the card retaining means 14 is inserted such that the handle 88 protrudes from the open surface 122. It is also within the spirit and scope of the present invention to make the housing member 1-0 sufficiently deep to accommodate the handle within the space 132 such that the handle 88 does not protrude from the case member 110.
Several optional features help make the housing member 110 more accessible and easier to use. A least one opening in the rear wall 120 serves to provide a means for mounting the housing member 110 on a wall or other surface. In the illustration in FIG. 13, the rear wall 120 of housing member 110 includes a pair of openings or mounting means 121 and 123 by which the housing member can be mounted on a wall or other surface (through hooks, nails or comparable apparatus).
The housing member 110 may also include a multiplicity of stacking means 127 such as Bumpons˜ located on the lower surface 118, as illustrated in FIG. 14. In the preferred embodiment, there are four stacking means 127, with one located adjacent each corner on the lower surface of the housing member. In this way, the Bumpons˜ provide a nonslip surface by which the housing members can be stacked one on top of the other. Comparable stacking means or Bumpons˜ 129 can be located on the lower such of the card retaining means 50 (as illustrated in FIG. 14) to enable them to be more easily used on a surface, as the Bumpons˜ 129 provide a nonslip surface.
Therefore, through the case member as described, the present invention includes an entire system which comprises the card holder member, the card carrying means, the card retaining means and the housing member or means.
The housing member and its associated components can be made of plastic or any other suitable material such as pressed cardboard or styrofoam.
An additional element of the system is a matching case means which permits a multiplicity of card carrying means to be stored and carried in a preselected order. The case means 150 is illustrated in FIG. 15 and includes a conventional case comprising a rectangular shaped base 152 having a floor and four walls and defining an interior space 154 therein. The case 150 is closed by a lid 160 which can be hingeably attached to the base 150 at end one. The interior space 154 is partitioned into a multiplicity of slots 162, each of which is shaped in the same configuration as a card carrying means and is just large enough to accommodate one card carrying means 50. In the preferred embodiment, the space 154 is partitioned into two parallel rows of slots as illustrated in FIG. 15. The slots can be formed of styrofoam, rubber, or other insert material which can be individually formed and then inserted into the case means 150. Alternatively, the slots can be made of wood or comparable material and built into the case means 150. The case means 150 may include a handle 156.
As a result, if it is desired to select a group of cards retained by the present invention card holding means and carrying them on a business trip, the user can remove the business cards and associated card holding means from the card retaining means and place them in the card carrying member. If it is desired to have a preselected group of card carrying means on the trip so that each card carrying means contains a group of cards for businesses or individuals to be called on during a given period of time or a given location, the matching case means 150 can hold a multiplicity of card carrying means 50 within each of the respect slots 162 in a preselected order with the associated preselected business cards therein. In this way, a business trip can be efficiently organized with the cards for individuals or business to be called on in a given morning placed in one card carrying means 50 and the cards for individuals or businesses to be called on in the afternoon and during future days to be placed in selected additional card carrying means.
One alternative embodiment to the card carrying case 50 is to carry the business cards 40 in an alternative embodiment of the present invention which is designed to be used in conjunction with a conventional loose-leaf planner or organizer. This embodiment is illustrated in FIG. 16. The planner card carrying means 200 comprises a back sheet 202 which can be made of plastic, cardboard, or comparable suitable material, and which is generally rectangular in shape and is dimensioned to fit into a conventional loose-leaf planner or organizer. The back sheet 202 includes a multiplicity of holes 204 adjacent one longitudinal edge and aligned to fit onto the rings of the loose-leaf planner. The preferred embodiment is three holes 204 as illustrated in FIG. 16, but any embodiment with two or more holes is within the spirit and scope of the present invention. At the opposite longitudinal edge and protruding from one lateral face of the back sheet 202 is at least one but preferably a pair of card retaining sections 205 each of which includes a front ledge or face 206, a bottom 208 and a rear wall parallel to the front wall 206, which rear wall may be a portion of the backing sheet 202. Each card carrying section further comprises at least one rail or track which can accommodate the strip retaining means 12 of the card holding means 10. In the preferred embodiment as shown in FIG. 16, each section 205 has a pair of rods or tracks 210 and 212 which are aligned in generally parallel relationship to each other and spaced apart so that their longitudinal centerlines are approximately the same distance apart as the distance between the centers of the strip retaining means 12 on the card holding means 10. The rods or tracks 210 and 212 are supported by the front wall 206 and the portion of the back sheet 202 parallel to the front wall 206. In the embodiment illustrated in FIG. 16, there are two such sections 205, but it will be appreciated that any multiplicity of sections are within the spirit and scope of the present invention and are limited only by the design of the planner or organizer for which the particular embodiment is designed. In the illustration shown in FIG. 16, the two sections 205 are aligned adjacent each other, however, they can also be aligned one above the other if the width of the back sheet 202 for the particular embodiment has sufficient room to permit this design.
Of course the present invention is not intended to be restricted to any particular form or arrangement, or any specific embodiment disclosed herein, or any specific use, since the same may be modified in various particulars or relations without departing from the spirit or scope of the claimed invention hereinabove shown and described of which the apparatus and method shown is intended only for illustration and for disclosure of an operative embodiment and not to show all of the various forms of modification in which the invention might be embodied.
The invention has been described in considerable detail in order to comply with the patent laws by providing a full public disclosure of at least one of its forms. However, such detailed description is not intended in any way to limit the broad features or principles of the invention, or the scope of patent monopoly to be granted. | The present invention relates to an improved system whereby a business card can be immediately placed onto a card holding means which permits the card to be immediately stored in a card carrying means which can be carried in a coat pocket or purse and further upon return to one's office permits the business card to be immediately removed from the card carrying means and placed in a desk card retaining means such as a card file or rotary file without any need for physical alteration of the business card to transcription of the information from the business card to the filing card. In addition, the present invention further permits the business card to be removed from the desk card holder and placed in the carrying case for use when the individual is going to a meeting with that person, thereby eliminating the necessity of once again transcribing the information from the card in the desk card holder onto a piece of paper to be taken by the individual to the meeting. The present invention further relates to a novel housing member for retaining the desk card holder in which the retained cards are placed and further relates to a novel carrying member for retaining a series of card holding members for use during a business trip. The present invention also relates to business card retaining means which can be used in conjunction with conventional organizers and planners. | 1 |
CROSS REFERENCE TO RELATED APPLICATION
This application claims the priority of German Application No. 198 31 139.7 filed Jul. 11, 1998, which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
This invention relates to a device incorporated in a fiber processing machine such as a carding machine, a cleaner or the like and is of the type which has at least one operationally fixed carding segment which cooperates with the clothing of a rapidly rotating roll forming part of a fiber processing machine. The end portions of the carding segment are associated with adjusting means with which the radial distance between the roll clothing and the carding segment clothing may be varied.
In a known apparatus, as disclosed, for example, in published European Patent Application No. 0 422 838, the main carding cylinder of a carding machine is associated with a plurality of fixed carding segments, whose end portions are secured to the lateral frame of the carding machine. At each end of each carding segment a plate having an externally projecting attachment is provided which carries a securing (fixing) screw with a setting nut. By manually turning the setting nuts, the distance of the clothing of the carding segment relative to the cylinder clothing may be individually adjusted. Such a setting procedure by means of setting nuts to obtain a desired and uniform carding gap during the initial assembly of the carding machine or during a later readjustment is complicated. It is a further drawback of such an arrangement that an adjustment is possible only during standstill of the machine, resulting in an interruption of the production.
SUMMARY OF THE INVENTION
It is an object of the invention to provide an improved device of the above-outlined type from which the discussed disadvantages are eliminated and which, in particular, is structurally simple, is easy to assemble and makes possible a more accurate and more uniform adjustment and furthermore allows such adjustments, whereby a change of the carding intensity during normal operation of the carding machine may be performed.
This object and others to become apparent as the specification progresses, are accomplished by the invention, according to which, briefly stated, the fiber processing machine includes a fiber processing roll carrying a roll clothing on a circumferential surface thereof; an operationally substantially stationary carding segment carrying a segment clothing for cooperating with the roll clothing along a circumferential length portion thereof; a strip-supporting component fixedly held on a machine frame and having a supporting surface; and a segment-supporting strip extending circumferentially along the roll and being held on the supporting surface of the strip-supporting component. The segment-supporting strip has an upper surface supporting the carding segment at opposite end portions thereof and a lower surface opposite the upper surface. A radial distance between the clothing points of the segment clothing and the clothing points of the roll clothing is determined and is changeable by the shape and/or the position of the segment-supporting strip.
Thus, with the measures according to the invention it is possible to vary the carding intensity in a simple manner in response to changes of technological magnitudes, for example, the nep number and/or the fiber damage or when the fiber material to be processed changes. It is a further advantage of the invention that after a relocation of the segment-supporting strip, the uniform distance between the carding segment clothings, on the one hand, and the cylinder (roll) clothing, on the other hand, is maintained circumferentially uniform, resulting in a significant improvement in the produced sliver. Upon adjustment, the position of the convex outer face of the segment-supporting strip radially shifts. The flexibility (elasticity) of the segment-supporting strip ensures that the arcuate shape of the outer surface of the segment-supporting strip is adaptable to thus ensure, at all locations along the circumference, the uniformity of the distance between the carding segment clothings, on the one hand, and the cylinder clothing, on the other hand. It is a further advantage that the adjustment may be effected continuously, for example, during operation of the fiber processing machine. Such an adjustment may be effected automatically or by a manual, pushbutton operation and thus a time-consuming assembly work and an interruption in the production are avoided. It is of particular advantage that the convex outer surface of the segment-supporting strip on which the carding segments are positioned is, on each side of the machine, radially adjustable concentrically to the circumferential surface of the cylinder. In this manner an infinite number of supporting locations for the end regions of the carding segments may be steplessly adjusted.
By a carding segment there is meant in the present context a carrier element which is provided with a clothing and which is substantially stationary during operation. The carding segment is radially locally moved only if the carding gap is to be changed. Further, the carding segment, in accordance with a preferred embodiment of the invention, is displaced circumferentially together with the segment-supporting strip during adjustment. A desired change of the radial distance may be effected, for example, upon a change of the type of the processed fiber material, while a necessary change is effected, particularly during operation, because of an undesirably increasing nep number and/or a fiber shortening in the sliver. The apparatus according to the invention is preferably a component of a "selfadjusting" carding machine. The change in the type of fiber material may be effected as a function of stored data. A change as a function of the nep number and/or the fiber shortening is based on measured values.
The invention has the following additional advantageous features:
The radial distance between the carding segment and the carding cylinder is determined by the radial thickness of the segment-supporting strip.
The supporting surface and the underface of the segment-supporting strip are arcuate and extend parallel to one another.
The supporting surface and the underside of the segment-supporting strip are arcuate and converge as viewed in one circumferential direction to lend the segment-supporting strip an elongated, wedge-shaped configuration.
The segment-supporting strip is displaceable in the circumferential direction.
The segment-supporting strip is replaceable.
The supporting surface of the strip-supporting component is a convex face of a side plate of the carding machine.
The supporting surface of the strip-supporting component extends parallel to a convexly arcuate face of a side plate of the carding machine.
The strip-supporting component has a longitudinally extending groove in which the segment-supporting strip is partially received.
The segment-supporting strip is a wear-resistant, low-friction flexible plastic.
The radial displacement of the supporting surface of the segment-supporting strip is approximately 0.01 to 0.3 mm.
The carding segment remains stationary during circumferential displacement of the segment-supporting strip.
The carding segment and the segment-supporting strip are displaced together circumferentially.
The adjustment of the radial distance is stepless.
The clothed roll is the main carding cylinder and/or the licker-in of a carding machine or the roll of a fiber opener or cleaner.
The stationary carding segments are biased against the segment-supporting strip, for example, by a spring, a tensioning band or the like.
The clothed roll (such as a carding cylinder) cooperates with a plurality of stationary carding segments.
The carding segment has two or more carding elements.
The adjusting device includes a driving mechanism such as a motor.
The adjusting device has setting elements such as levers, a toothed rack, gears, rotary joints and the like.
The adjusting device exerts its force essentially to the middle of the segment-supporting strip.
The segment-supporting is provided with teeth at least along one part of its length for meshing with a gear of the motor drive.
The motor drive is connected with an electronic control and-regulating device, such as a microcomputer.
A measuring member is connected to the electronic control-and-regulating device for detecting the fiber length of the fibers processed by the fiber processing machine.
A measuring member detecting the nep number is connected with the electronic control-and-regulating device.
A measuring member for detecting the distance between the carding element clothing and the roll clothing is connected with the electronic control-and-regulating device.
A switching element for actuating the drive of the adjusting device is connected to the electronic control-and-regulating device.
An inputting element for the measuring values of the fiber length is connected to the electronic control-and-regulating device.
The segment-supporting strip and the strip-supporting component are wedge-shaped as viewed circumferentially and are oppositely oriented.
The carding gap may be set to be constant.
The carding gap may be set to be conically tapering.
The convex outer surface of the segment-supporting strip has a contour which has a circular, circumferential portion and an inclined portion or a depression.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic side elevational view of a carding machine incorporating the device according to the invention.
FIG. 2 is a schematic sectional side elevational view illustrating one part of a carding cylinder, cooperating with a stationary carding segment positioned by a device according to the invention.
FIG. 2a is an enlarged side elevational detail of FIG. 2.
FIG. 3a is a schematic side elevational view of one part of a carding cylinder showing two carding segments supported in a first position by a device according to the invention.
FIG. 3b is a view similar to FIG. 3a, showing the segment-positioning device in a second position in which the two carding segments are only radially shifted.
FIG. 3c is a view similar to FIG. 3a, showing the segment-positioning device in a second position in which the two carding segments are radially and circumferentially shifted.
FIG. 4a is a schematic side elevational view of a flexible bend supporting the segment-adjusting device according to the invention.
FIG. 4b is a sectional view taken along line IVb--IVb of FIG. 4a.
FIG. 5 is a schematic sectional side elevational view of a further preferred embodiment of the invention.
FIG. 6 is a schematic side elevational view of a segment-supporting device according to the invention, having a wedge-shaped segment-supporting strip and a wedge-shaped strip-supporting component.
FIG. 7 is a schematic, partially sectional side elevational view of an adjusting drive according to the invention, also illustrating a block diagram for its control.
FIGS. 8a and 8b are schematic side elevational views of yet another preferred embodiment of the invention for an oblique positioning of the carding segments, shown in two operational positions.
FIG. 9 is schematic, partially sectional side elevational view of a further embodiment of the invention for an oblique positioning of the carding segments.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 illustrates a carding machine which may be, for example, an EXACTACARD DK 803 model manufactured by Trutzschler GmbH & Co. KG, Mobnchengladbach, Germany. The carding machine has a feed roll 1 cooperating with a feed tray 2, licker-ins 3a, 3b, 3c, a main carding cylinder 4, a doffer 5, a stripping roll 6, crushing rolls 7, 8, a web-guiding element 9, a sliver trumpet 10, calender rolls 11, 12, a traveling flats assembly 13 having flat bars 14, a coiler can 15, a sliver coiler 16 and stationary carding segments 17' and 17" positioned by a segment-adjusting device according to the invention. The direction of rotation of the various rotary members is shown by curved arrows drawn therein. The carding segment 17' is positioned between the licker-in 3c and the rearward end sprocket 13a of the traveling flats assembly 13 while the carding segment 17" is situated between the doffer 5 and the frontal end sprocket 13b of the traveling flats assembly 13.
Turning to FIG. 2, on each side of the carding machine an approximately semicircular rigid side plate 18 is secured to the non-illustrated machine frame. To the external face of each side plate, in the region of its periphery, an arcuate, rigid strip-supporting component 19 is affixed which is concentric with the rotary axis M of the main carding cylinder 4. The strip-supporting component 19 has an upper, convex supporting surface 19a and an underside 19b. On the strip-supporting component 19 a flexible, segment-supporting strip 20 is positioned which is preferably made of a low-friction, wear-resistant plastic. The segment-supporting strip 20 has a convex supporting face 20a and a concave underface 20b which is positioned on the convex supporting surface face 19c in a circumferential groove 19' of the strip-supporting component 19. The segment-supporting strip 20 may be shiftable with respect to the strip-supporting component 19 in the direction of arrows A, B. The displacement of the segment-supporting strip 20 is effected by a displacing device which includes a drive such as a motor, a gearing or the like, as will be described later, in conjunction with FIG. 7. The carding segment 17' has, at opposite ends, engagement faces which lie on the convex surface of the respective segment-supporting strip 20 (only one is visible in FIG. 2). The underside of a carrier 23 forming part of the carding segment 17' carries circumferentially consecutive carding elements 24a, 24b having respective carding clothings 24a' and 24b'. An imaginary circle on which the clothing points of the carding elements 24a and 24b lie is designated at 21. The main carding cylinder 4 carries on its circumference a cylinder clothing 4a, for example, a sawtooth clothing, oriented toward the segment clothings 24a', 24b'. An imaginary circle circumscribable about the clothing points of the cylinder clothing 4a is designated at 22. The radial distance between the circles 21 and 22 is designated at a and amounts to, for example, 0.20 mm. The distance between the convex outer face 20a and the circle 22 is designated at b. The radius of the convex outer face 20a is designated at r 1 , while the radius of the circle 22 is designated at r 2 . The radii r 1 and r 2 intersect in the rotary axis M of the carding cylinder 4.
As further illustrated in FIG. 2, the elongated wedge-shaped segment-supporting strip 20 is displaceable in the direction of the arrows A, B on the groove bottom 19c whereby the carding segment 17' is displaced radially in the direction of the arrows C or D. The distance a between the carding element clothings 24a' and 24b' on the one hand and the cylinder clothing 4a on the other hand is thus adjustable in a simple and accurate manner.
In FIGS. 3a, 3b and 3c the displacement of the segment-supporting strip 20 on and with respect to the strip-supporting component 19 occurs in the direction of the arrow A. By virtue of the displacement of, for example, 50 mm, the distance b between the points of the clothings 24a' and 24b', on the one hand, and the clothing points of the cylinder clothing 4a, on the other hand, that is, the distance b between the two imaginary circles 21 and 22 is increased from b 1 (FIG. 3a), for example, 0.30 mm, to b 2 (FIGS. 3b and 3c), for example, 0.50 mm. The radius of the convex outer face of the groove bottom 19c of the strip-supporting component 19 is designated at r 3 and the radius of the concave inner surface 20b of the segment-supporting strip 20 is designated at r 4 . By virtue of the displacement of the segment-supporting strip 20 in the direction A, the carding segments 17a, 17b of FIGS. 3a, 3b, 3c are shifted in the direction of the arrow D radially with respect to the carding cylinder 4, so that the distance between the clothing of the segments and the clothing of the carding cylinder is increased from a to b. In FIG. 3a the initial position is shown where between one end of the segment5 supporting strip 20 and one end of the strip-supporting component 19 a distance c prevails. According to FIGS. 3b and 3c, after the displacement of the segment-supporting strip 20 in the direction A, between one end of the segment-supporting strip 20 and one end of the strip-supporting component 19 only a smaller distance d is still present. As shown in FIG. 3b, only the segment-supporting strip 20 is displaced in the direction A, while the carding segments 17a, 17b do not move in the circumferential direction, that is, the distance e between one end of the strip-supporting component 19 and the carding segments 17a, 17b remains the same. The carding segments are, by means of a holding and loading element, for example, a tensioning band (FIG. 5), a tension spring or the like, held fixedly with respect to the circumferential direction. The elastic holding and securing element, however, makes possible to displace the carding segments 17a, 17b in the direction D. According to FIG. 3c, the segment-supporting strip 20 and the carding segments 17a, 17b are shifted together in the direction A, that is, the distance e shown in FIG. 3b is increased to the distance f shown in FIG. 3c. The carding segments 17a, 17b are entrained to a certain extent by the segment-supporting strip 20 in the direction A. In such a case only one securing element, for example, a spring or the like is required which frictionally or form-fittingly connects the carding segments 17a, 17b with the segment-supporting strip 20.
As shown in FIG. 4a, within the groove 19', between the concave inner face 20b of the segment-supporting strip 20 and the groove bottom 19c of the strip-supporting component constituted by a flexible bend 26, a displaceable, wedge-shaped intermediate strip 25 is provided which is made of a flexible material, such as a plastic. The segment-supporting strip 20 extends parallel to the intermediate strip 25 and is made of a flexible plastic material as well. The flexible bend of the carding machine is designated at 26. FIG. 4a shows the flats zone of a fixed-flats carding machine which, in contrast to FIG. 1, has no traveling flats assembly 13. Rather, a series (more than two) of carding segments 17a-17n is provided.
As shown in FIG. 5, a tensioning band 27 made, for example, of plastic, steel or the like is provided which is secured at one end to a stationary support 29 by a tension spring 28. The other end of the tensioning band 27 is secured to another, non-illustrated support. The carding segments 17a, 17b and 17c are attached by securing elements, for example, screws 30a, 30b and 30c, to the tensioning band 27. As a result, the carding elements 17a, 17b and 17c are pressed against the segment-supporting strip 20, and upon displacement of the latter, they are held stationarily to prevent them from moving circumferentially, but to shift only in the direction of the arrow D.
FIG. 6 shows schematically the strip-supporting component 19 together with the segment-supporting strip 20 shiftable thereon. The distance between the convex outer surface 20a and the convex inner surface 20b decreases circumferentially as viewed in the direction B from gi to g 2 and the distance between the convex outer surface 19a and the rotary axis M of the carding cylinder 4 increases circumferentially as viewed in the direction B from h 1 to h 2 so that the sum of the two distances g 1 , h 1 and, respectively, g 2 , h 2 is constant at all locations along the circumference. The concave inner face 20b and the convex outer face 19a are in a gliding contact with one another. The center of curvature of the concave inner face 20b and the center of curvature of the convex outer face 19a lies externally of the axis M of the carding cylinder 4.
Turning to FIG. 7, to the segment-supporting strip 20 a carrier pin 31 is secured which is coupled with a toothed rack 32a. The latter, in turn, meshes with a gear 32b rotatable in the direction O or P. The gear 32b is driven by a driving device 33, for example, a reversible motor, whereby the segment-supporting strip 20 may be shifted in the direction of the arrows A, B.
An electronic control-and-regulating device 34, for example, a microcomputer is provided to which there are connected a measuring member 35 for an automatic detection of the nep number, a measuring member 36 for detecting the fiber length and a setting member, for example, the drive motor 33. The measuring member 35 may be, for example, a NEPCONTROL NCT model, manufactured by Trutzschler GmbH & CO. KG. The measuring values for the fiber length which, for example, may be determined by a fibograph, may be inputted by an inputting device 37 into the electronic control-and-regulating device 34. Further, a switching element 38, for example, a pushbutton or the like may be connected to the electronic control-and-regulating device 34 for actuating the motor 33. Further, a measuring member 39, for example, a FLATCONTROL FCT (manufactured by Trutzschler GmbH & CO. KG) for detecting the distance a between the points of the clothings 24a', 24b' on the one hand, and the points of the carding cylinder clothing 4a, on the other hand, may be connected to the electronic control-and-regulating device 34. The types of fiber material to be processed may be stored in a memory which, for example, is integrated into the microcomputer 34.
Turning to FIGS. 8a and 8b, the convex outer surface 20a of the segment-supporting strip 20 has a particularly shaped contour which is provided with cutouts having surface portions 20b', 20b" which extend substantially parallel to the surface of the carding cylinder 4 and surface portions 20c' and 20c" which extend at an inclination to the surface portions 20b' and 20b41 . As shown in FIG. 8a, the carding segments 17a, 17b are initially set such that the carding clearance a, that is, the distance between the carding segment clothings 24a', 24b', on the one hand, and the carding cylinder clothing 4b, on the other hand, is constant. It has been shown in practice that after a certain period of operation, the first teeth of the carding segment clothings 24a', 24b' (as viewed in a direction opposite to the rotational direction 4b of the carding cylinder 4) undergo a more substantial wear than the other teeth. Therefore, according to FIG. 8b, the segment-supporting strip 20 is shifted in the direction A, so that the region of the carding segments 17a, 17b having the worn teeth, glides upwardly on one oblique surface 20c', 20c" and thus the carding clearance with respect the carding cylinder clothing 4a assumes an angle α which is open in a direction opposite to the direction 4b. In this manner, the worn teeth will have a lesser or no penetration into the fiber material, and the lesser worn or not worn teeth of the carding segment clothings 24a' and 24b' are then utilized for the carding work.
The inclined setting of the carding segments 17a, 17b at an angle α may be effected according to the embodiment shown in FIG. 9 by providing depressions (dips) 20d', 20d" in the surface 20a of the segment-supporting strip 20.
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. | A fiber processing machine includes a fiber processing roll carrying a roll clothing on a circumferential surface thereof; an operationally substantially stationary carding segment carrying a segment clothing for cooperating with the roll clothing along a circumferential length portion thereof; a strip-supporting component fixedly held on a machine frame and having a supporting surface; and a segment-supporting strip extending circumferentially along the roll and being held on the supporting surface of the strip-supporting component. The segment-supporting strip has an upper surface supporting the carding segment at opposite end portions thereof and a lower surface opposite the upper surface. A radial distance between the clothing points of the segment clothing and the clothing points of the roll clothing is determined and is changeable by the shape and/or the position of the segment-supporting strip. | 3 |
FIELD OF THE INVENTION
[0001] The present invention relates to the field of insulation and thermal barriers, and, more particularly to a method for forming a multi-layer, nonwoven fiberglass insulating mat, and the mat formed therefrom.
BACKGROUND OF THE INVENTION
[0002] In recent years, needled nonwoven textile fabrics have become increasingly popular. Needled nonwovens are created by mechanically orienting and interlocking the fibers of a spunbond or carded web or batt. In particular, numerous needled or felted fabrics have been formed of either natural or synthetic fibers, or both; however, inorganic fibers such as glass fibers, are not normally suitable for felting or needling because glass fibers are quite brittle and do not lend themselves to being carded, needled, or felted. They are typically consolidated by either an air lay or wet lay process into a fabric having generally poor physical properties.
[0003] More recently, the desire to make thicker (1 inch or greater), lower weight basis, and lower density (less than about 5 pounds per cubic foot) insulating (thermal or acoustical) mats has created a renewed interest in needle punching of fiberglass fibers. In one process, e-glass fibers were opened, formed into a thick batt, and mechanically bonded on a needle loom in a single pass to form a mat. Unfortunately, these mats still have a density of 6 to 12 pounds per cubic foot.
[0004] Most recently, fiberglass fibers have been bonded together by resinous binders or thermoplastic adhesives to form thicker mats. Resinous binders, however, create undesirable problems with outgassing, and most contain either phenolic or melamine formaldehydes, which are environmentally and occupationally undesirable.
SUMMARY OF THE INVENTION
[0005] The present invention is directed to a new needle punching method for producing thicker, lightweight insulating mats from fiberglass fibers, and to an insulating mat so formed which addresses and overcomes the previous problems.
[0006] Thus, one aspect of the present invention is directed to a method for forming a thicker (greater than 1 inch), lower weight basis, and lower density (about 4 pounds per cubic foot) insulating mat.
[0007] As a first step in the process, a first loose batt of fiberglass fibers is needle punched to form a relatively thin, relatively dense first layer. In one embodiment, the fiberglass fibers are e-glass. A second layer is next similarly formed by needle punching a second loose batt of fiberglass fibers. An intermediate batt of similar fiberglass fibers is then fed between the first and second layers to form a relatively thicker and less dense middle layer. The first layer, intermediate batt, and second layer are lastly needled together in a single pass to form a three-layer (lower, middle, and upper) insulating mat. As a result, the outer layers (lower and upper) are more dense and provide the integrity and strength of the overall construction and good surface quality. The first and second layers are more dense since the fiberglass fibers forming the batts are needle punched with a large number of needle punches per square inch and with deeper penetration depth into more compact layers. The intermediate layer is less dense and substantially provides the overall thickness since the final needle punching step is performed with a much lower number of punches per square inch and much less penetration depth. Further, fewer punches per square inch in the final needle punching step are required to interlock the first and second layers to the intermediate layer.
[0008] In an exemplary embodiment, the densities of each of the lower and upper layers are substantially equal, but greater than the density of the middle layer.
[0009] Another aspect of the present invention is directed to a multi-layer nonwoven insulating mat formed in accordance with the method described herein.
[0010] These and other aspects of the present invention will become apparent to those skilled in the art after a reading of the following description of the preferred embodiments when considered in conjunction with the drawings. It should be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the invention as claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a prior art nonwoven insulating mat formed from a single thick batt of fiberglass fibers.
[0012] FIG. 2 is a flow diagram of the method of the present invention.
[0013] FIG. 3 illustrates one embodiment of the insulating mat formed in accordance with FIG. 2 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0014] Referring to the Figures in general, the present invention is directed to a method for producing a multi-layer nonwoven insulating mat of fiberglass fibers, and to an insulating mat so formed.
[0015] “Needle punching” refers to the process of converting batts or webs of loose fibers into a coherent fabric, referred to as a nonwoven fabric, on a needle loom. Needle punched nonwovens are created by mechanically orienting and interlocking the fibers of a batt, as those terms are known in the art. The mechanical interlocking is achieved with a large number of barbed felting needles that repeatedly punch through a loose batt.
[0016] The generic needle punch loom comprises at least one needle board that is held in place by a needle beam. Feed rollers and exit rollers are driven to move the batt of fiberglass fibers through and out of the needle loom. A bed plate and stripper plate each have a plurality of holes (not shown) that correspond to the pattern of felting needles that are mounted on the needle board. The bed plate permits the needles to pass completely thorough the batt, while the stripper plate strips the fibers from the needles as they are retracted upwardly or downwardly so that the material can pass through the loom.
[0017] The needle loom used to practice the present invention is a Model NL9/SRS, available from Fehrer of Austria. This particular needle loom has upper and lower needle boards and stripper plates; however, other needle looms capable of providing comparable mechanical interlocking of the fiberglass fibers, as described in greater detail below, may be used.
[0018] To mechanically interlock the fibers in each fiberglass batt, a drive (not shown) moves the needle boards upwardly and downwardly with the plurality of needles mounted thereon passing through the stripping and bed plates. As those skilled in the art will appreciate, the correct “felting” needles must be selected for interlocking the fibers, without damaging or breaking, the fiberglass fibers. For the method of the present invention, 15×18×25 needles are employed, but other needle geometries may also be used.
[0019] As those skilled in the art will appreciate, the primary variables affecting the effectiveness of the needling process include the depth of penetration and the concentration and pattern of the felting needles. The greater the depth of penetration, the greater the entanglement of fibers within the batt. The greater the number/concentration of punches to the batt, the more concentrated is the entanglement pattern and the more dense is the resulting batt. The degree of entanglement is dependent upon the number of needles/punches per square inch, the rate of the batt feed to the loom, the punching frequency (upwardly and downwardly speed of the needle boards), and the number of passes of the batt through the loom. These variables will be described in greater specificity in the Examples below.
[0020] The fibers used in the exemplary embodiments described herein are created from a preferred feed stock (yarns formed from continuous fibers) that is between ECG-37 and ECG-75, but ECE-225 to ECK-18 may also be used, as those categories of material are known in the art. The feed stock is first chopped into staples having lengths of about 3 inches long; however, staples between about 2 inches and 4 inches are also suitable. In one embodiment, the fibers comprising the yarn are about 9 microns in diameter, but diameters of between 5 microns and 13 microns are suitable. E-glass staple fibers are available from several vendors such as PPG, St. Gobain, and AGY. E-glass is particularly suitable because it can withstand temperatures up to about 1,200 degrees Fahrenheit. For higher temperature applications, silica glass fibers (available from BGF Industries, Inc. of Greensboro, N.C.) may be used. Silica glass fibers can withstand temperatures up to about 2,000 degrees Fahrenheit.
[0021] Turning now to FIGS. 2 and 3 , a simplified flow diagram of the process 200 and product 300 of the present invention is shown. The process begins with opening (Step 205 ). Opening is a preliminary operation in the processing of staple fibers. Opening separates the compressed masses (bales) of fiberglass staples into loose tufts. In the embodiments described herein, a Rando Opener Blender (ROB), available from Rando Company of Rochester, N.Y. is used. The open fiberglass fibers are next formed into a loose batt (Step 210 ) on a Rando Webber, also available from Rando, in preparation for the needle punching operation. A feed belt is set to run at a specified speed, whereupon loose fiberglass fibers are deposited on the belt to obtain a desired thickness and density. The loose batt so formed is between approximately 2 inches and 4 inches in thickness, depending upon the desired final thickness of the finished multi-layer mat.
[0022] The loose batt is fed through the needle loom to form a first layer 310 (Step 215 ). The batt is fed at a speed of between about 14 feet per minute and 18 feet per minute, and desirably at a speed of about 16 feet per minute. As the batt passes beneath the needle board, the needles punch the batt at between 500 punches per square inch (PPSI) and 600 PPSI. As discussed above, and as will be appreciated by those of ordinary skill in the art, there are various feed rate and punching rate combinations that will yield a suitable puncture density.
[0023] The process for forming a second layer 320 (Step 220 ) is similar to the process for forming the first layer, unless a different thickness, weight basis, etc. are desired. In each of the embodiments described herein, the puncture density of the first and second layers creates denser layers, thus enhancing the integrity and tensile strength of the these layers.
[0024] Following formation of rolls of the first and second layers, rolls of the first and second layers/mats are simultaneously fed to the needle loom as the lower and upper layers, while a loose batt of opened e-glass fibers 330 between about 4 inches and 6 inches thick is inserted between the two layers (Step 225 ). All three layers are simultaneously needled together (Step 230 ) at a speed of between about 7 feet per minute and 18 feet per minute, and desirably at a speed of about 12 feet per minute with punches 340 from needles 160 at between about 150 PPSI and 250 PPSI. The finished mat is then taken up on rolls (Step 235 ) for further processing, storage, or shipment. The final multi-layer nonwoven mat so formed may have a width of up to about 96 inches.
[0025] Depending upon the application for which the nonwoven insulating mat is intended, e.g., water heater insulation, the final thickness and weight basis of each layer may be varied when formed in accordance with the process of the present invention. The following are exemplary embodiments for multi-layer insulating mats having total thicknesses between one inch and two inches:
EXAMPLE 1
[0026] For an insulating mat with a final thickness of about one inch, the first layer begins with a loose batt of e-glass staple fibers that is about 2 inches thick. The loose batt is subjected to needle punching with a puncture density of between about 500 PPSI and 600 PPSI to produce a relatively dense layer having a thickness of about 0.125 inches, a weight basis of about 1 ounce per square foot, and a density of about 6 pounds per cubic foot. In this embodiment, the first and second, or lower and upper, layers are formed in the same manner so that they have the same thickness, weight basis, and density, although they may be formed differently for a particular application.
[0027] Rolls of the first and second layers/mats are simultaneously fed to the needle loom as the lower and upper layers, while a loose batt of opened e-glass fibers are inserted between the two layers. This loose e-glass intermediate, or middle, layer has a thickness of about 4 inches as it is inserted between the lower and upper needled layers.
[0028] All three layers are subjected to a needling puncture density of 175 PPSI at a desired penetration as each of the first and second layers were previously penetrated. In effect, then, the lower and upper layers are each needle punched twice.
[0029] Following the needle punching of the three-layer construction, the upper and lower layers each have a thickness of approximately 0.125 inches, a weight basis of about 1.0 ounces per square foot, and a density of about 6.0 pounds per cubic foot. The intermediate layer is approximately 0.75 inches thick (approximately 6 times the thickness of each of the upper and lower layers), with a weight basis of about 3.3 ounces per square foot, and a density of about 3.3 pounds per cubic foot (approximately 55 percent of the density of each of the upper and lower layers). The resulting multi-layer insulating mat then has a combined thickness of about 1 inch, an average weight basis of about 5.3 ounces per square foot, and an average density of about 4 pounds per cubic foot.
EXAMPLE 2
[0030] For an insulating mat with a final thickness of about 1.25 inches, the first layer begins with a loose batt of e-glass fibers that is about 2.5 inches thick. The loose batt is subjected to needle punching with a puncture density of between about 500 PPSI and 600 PPSI to produce a relatively dense layer having a thickness of about 0.16 inches, a weight basis of about 1.3 ounces per square foot, and a density of about 6 pounds per cubic foot. In this embodiment, the first and second, or lower and upper, layers are formed in the same manner so that they have the same thickness, weight basis, and density, although they may be formed differently for a particular application.
[0031] Rolls of the first and second layers/mats are simultaneously fed to the needle loom as the lower and upper layers, while a loose batt of opened e-glass fibers are inserted between the two layers. This loose e-glass intermediate, or middle, layer has a thickness of about 4.5 inches as it is inserted between the lower and upper needled layers.
[0032] All three layers are subjected to a needling puncture density of 175 PPSI at a desired penetration as each of the first and second layers were previously penetrated. In effect, then, the lower and upper layers are each needle punched twice.
[0033] Following the needle punching of the three-layer construction, the upper and lower layers each have a thickness of approximately 0.16 inches, a weight basis of about 1.3 ounces per square foot, and a density of about 6.0 pounds per cubic foot. The intermediate layer is approximately 0.93 inches thick (approximately 5.8 times the thickness of each of the upper and lower layers), with a weight basis of about 4.1 ounces per square foot, and a density of about 3.3 pounds per cubic foot (approximately 55 percent of the density of each of the upper and lower layers). The resulting multi-layer insulating mat then has a combined thickness of about 1.25 inches, an average weight basis of about 6.6 ounces per square foot, and an average density of about 4 pounds per cubic foot.
EXAMPLE 3
[0034] For an insulating mat with a final thickness of about one and one-half inches, the first layer begins with a loose batt that is about 2.5 inches thick. The loose batt is subjected to needle punching with a puncture density of between about 500 PPSI and 600 PPSI to produce a relatively dense layer having a thickness of about 3/16 inch, a weight basis of about 1.5 ounces per square foot, and a density of about 6 pounds per cubic foot. In this embodiment, the first and second, or lower and upper, layers are formed in the same manner so that they have the same thickness, weight basis, and density, although they may be formed differently for a particular application.
[0035] Rolls of the first and second layers/mats are simultaneously fed to the needle loom as the lower and upper layers, while a loose batt of opened e-glass fibers are inserted between the two layers. This loose e-glass intermediate, or middle, layer has a thickness of about 5 inches as it is inserted between the lower and upper needled layers.
[0036] All three layers are subjected to a needling puncture density of 175 PPSI at a desired penetration as each of the first and second layers were previously penetrated. In effect, then, the lower and upper layers are each needle punched twice.
[0037] Following the needle punching of the three-layer construction, the upper and lower layers each have a thickness of approximately 0.19 inches, a weight basis of about 1.5 ounces per square foot, and a density of about 6 pounds per cubic foot. The intermediate layer is approximately 1.12 inches thick (approximately 5.9 times the thickness of each of the upper and lower layers), with a weight basis of about 5.0 ounces per square foot, and a density of about 3.3 pounds per cubic foot (approximately 55 percent of the density of each of the upper and lower layers). The resulting multi-layer insulating mat then has a combined thickness of about 1.5 inches, an average weight basis of about 8 ounces per square foot, and an average density of about 4 pounds per cubic foot.
EXAMPLE 4
[0038] For an insulating mat with a final thickness of about two inches, the first layer begins with a loose batt that is about 3 inches thick. The loose batt is subjected to needle punching with a puncture density of between about 500 PPSI and 600 PPSI to produce a mat having a thickness of about 0.24 inches, a weight basis of about 1.9 ounces per square foot, and a density of about 6.0 pounds per cubic foot. In this embodiment, the first and second, or lower and upper, layers are formed in the same manner so that they have the same thickness, weight basis, and density, although they may be formed differently for a particular application.
[0039] Rolls of the first and second layers/mats are simultaneously fed to the needle loom as the lower and upper layers, while a loose batt of opened e-glass fibers are inserted between the two layers. This loose e-glass intermediate, or middle, layer has a thickness of about 5.5 inches as it is inserted between the lower and upper needled layers.
[0040] All three layers are subjected to a needling puncture density of 175 PPSI at a desired penetration as each of the first and second layers were previously penetrated. In effect, then, the lower and upper layers are each needle punched twice.
[0041] Following the needle punching of the three-layer construction, the upper and lower layers each have a thickness of approximately 0.24 inches, a weight basis of about 1.9 ounces per square foot, and a density of about 6.0 pounds per cubic foot. The intermediate layer is approximately 1.52 inches thick (approximately 6.3 times the thickness of each of the upper and lower layers), with a weight basis of about 6.9 ounces per square foot, and a density of about 3.4 pounds per cubic foot (approximately 56 percent of the density of each of the upper and lower layers). The resulting multi-layer insulating mat then has a combined thickness of about 2 inches, an average weight basis of about 10.7 ounces per square foot, and an average density of about 4 pounds per cubic foot.
CONCLUSIONS
[0042] The inventors have found that a relatively thick, lightweight nonwoven insulating mat of fiberglass staple fibers can be produced by needle punching in thicknesses of about 1 inch and greater when the mat is formed as a multi-layer construction. Denser lower and upper layers are first needle punched, and a relatively looser intermediate layer is laid in between the lower and upper layers, all of which are simultaneously needle punched to obtain a stronger, smoother insulating mat. The resulting multi-layer insulating mat has a lower weight basis than could heretofore be produced with conventional processes.
[0043] Although the present invention has been described with preferred embodiments, it is to be understood that modifications and variations may be utilized without departing from the spirit and scope of the invention, as those skilled in the art will readily understand. Such modifications and variations are considered to be within the purview and scope of the appended claims and their equivalents. | A method is provided for forming a relatively thick, lightweight, nonwoven insulating mat. The method includes the steps of forming a relatively thin, relatively dense first outer layer by needle punching a first batt of glass fibers and forming a relatively thin, relatively dense second outer layer by needle punching a second batt of glass fibers. A relatively thicker, relatively less dense intermediate batt of glass fibers is fed between the first and second layers. Thereafter, the first layer, intermediate batt, and second layer are needle punched together to form a multi-layer mat having a first layer, middle layer, and second layer. | 3 |
BACKGROUND OF THE INVENTION
The present invention relates to a surgical draping system for retaining sterile and clean conditions at an operation site. Surgical drapes are well known in the medical community and serve to prevent contamination of the sterilized operation site by foreign bodies, in particular micro-organisms. Two important potential sources of infection of the patient are the transfer of bacteria originating from unsterilized areas of his own body to the exposed tissue at the operation site and the airborne transfer of bacteria from other sources to the operation site such as lint or skin particles originating from the surgeon or other staff in the operating theater.
In the prior art, a wide variety of draping systems have been employed to improve sterility at the site of an operation. It is helpful to consider the features of these diverse systems to gain an appreciation of the object and subject of the present invention.
There are two main classes of surgical drapes: reusable drapes and disposable drapes. Before considering the action of drapes, it should at first be appreciated that micro-organisms can only be transmitted in a medium. They do not move freely on their own, i.e. they are transferred by fluids, aerosol droplets, lint, dust particles, skin particles or the like.
Historically cotton drapes were and still are used, as they are absorbent and soak up liquids. However, they provide no bacterial barrier. Even when replaced by polyester cotton drapes treated with liquid repellent finish, the properties are limited and are lost after a few uses. Both cotton and polyester cotton drapes are lint producers from the beginning and this production increases with each use. Latter-day fabrics for reusable drapes, such as ROTECNO (registered trade mark), which similarly present a sterile barrier to prevent infection have improved properties in a number of respects. For instance the fabric is liquid repellent, thereby still functioning as a sterile barrier when contacted by liquids, non-particle generating, and provided with a grid of crossed conductive fibers to prevent the build-up of static electricity, which when present can attract airborne particles and on discharge damage sensitive electrical equipment.
In use, such drapes are arranged around the operation site and held in position with clips which grip through the fabric onto the flesh of the patient. A single drape may be used, in which case there is an aperture in the drape which is appropriately dimensioned to allow access to the operation site. If a plurality of drapes are used, these may have a simple rectangular shape and are laid over the patient and overlap each other to form, for instance, a rectangular access area around the operation site. However, with such draping systems it is difficult to efficiently seal off the operation site from the surrounding non-sterile regions of the patient, as openings remain between the patient's skin and the drape through which micro-organisms can be freely carried. One particularly undesirable mode of patient self-infection is when fluids spilled during the operation flow under or through the drape to non-sterile regions of the patient, become contaminated and then return to the operation site, for instance by capillary action or under the application of pressure.
These fabric drapes do possess the key advantage that they are reusable, the fabric construction being suitable for typical hospital cleansing methods such as laundering followed by steam sterilization. However, over a period of time, the clipped regions of the fabric become damaged, thereby leading to further degradation of the operational conditions.
To avoid some of the shortcomings of clipping drapes, adhesive tapes can be applied to the edges of the drapes to adhere them to the patient's skin.
After laundering the reusable drapes, double-sided adhesive tape, which has a backing paper, for instance siliconized paper, is attached to the edge of the drape. The reusable drape together with the tape now one-sidely adhered to it, is then sterilized, usually steam sterilized at, for instance, 134° C. Prior to the operation, the backing paper is pulled off the adhesive tape and the drape is adhered to the patient's skin at the site of the operation.
The problem then exists of thoroughly removing the adhesive tape from the drape. Experience has shown that it is tiresome to perform this manually, and therefore correspondingly difficult to supervise that overworked staff carry out this task adequately. In any case, residual traces of adhesive remain on the drape which must be fully removed by the cleansing or laundering procedure. This presents a particular complication for the adhesive, since it must satisfy conflicting requirements. Namely, on the one hand it must be able to withstand sterilization, in particular steam sterilization at 140° C., without losing its adhesive properties, and on the other hand it should be fully removable in the cleansing process, in particular in normal hospital laundering.
Certain acrylate adhesive tapes go some way to fulfilling this task. However, during cleansing, the dissolvable glue bleaches out the color from the textile reusable drape. This results in a reusable drape which is still completely serviceable giving the appearance of being old and worn, which, in turn, frequently leads to staff disposing of the drape prematurely. Substantial unnecessary costs are thereby incurred. Also, the use of such adhesive tape represents a very substantial cost factor. It has been found in practice that the operating theater actually spends substantially more money on tape provided with this special adhesive than on the reusable drapes to which it is adhered.
As an alternative method, disposable drapes are also used; they are typically comprised of a non-woven cellulosic material. In some versions, the central part of the disposable drape is adhered to the operation site, and such drapes can be provided with an absorbent upper surface which is reinforced with plastic under the absorbent layer to act as a bacterial barrier.
Although the best of these drapes may provide an acceptable bacterial barrier, drapes of this kind are not intended to be cleaned or reused. Given the high throughput achieved in a modern operating theater, the use of such disposable drapes leads to the creation of large amounts of waste material requiring incineration with the ensuing undesirable costs and environmental consequences.
Therefore, it can be seen that a large number of approaches have been used in prior art draping arrangements and systems, each individual approach offering certain advantages but always associated with certain other disadvantages.
One general problem for all draping systems is that the number and variety of special drape designs required to meet all types of operations results in considerable costs, large storage space utilization and great administrative effort required to efficiently maintain adequate stocks of these items ready for operations.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a draping system which provides a high standard of sterility at favorable cost, is convenient to use, avoids the previous problems encountered with the use of adhesive tape and avoids the production of large amounts of waste material.
To satisfy this object, the present invention provides a surgical draping system, comprising a disposable element for adhesion at its lowest surface using first adhesive means to the operation site and a reusable drape or reusable drapes disposed about said disposable element and defining an opening providing access to the operation site through the disposable element, and is characterized in that the disposable element is itself formed as a disposable drape having a window therein and a lower impermeable layer and an upper absorbent layer, defining an absorbent surface; in that this disposable drape is provided for adhesion to said reusable drape or drapes; and in that said reusable drape or drapes leave an opening exposing at least part of the absorbent surface and the window.
In one basic and preferred variant, the disposable drape is provided on its upper surface with second adhesive means surrounding the absorbent surface for adhesion to the lower side of the reusable drape or drapes.
Alternatively, in a second variant, the disposable drape can be provided on its lower surface with second adhesive means surrounding the first adhesive means for adhesion to the upper side of the reusable drape or drapes.
This solution is partly based on the recognition that the incision foil can be used additionally to secure the reusable drape which is in any case required. This subtle solution enables virtually all the positive features present in the various prior art draping systems to be combined in a single draping system.
The absorbent upper surface of the disposable drape is provided in order to wick or soak up fluids arising from the operation, whereas the lower layer of the disposable drape advantageously constitutes a barrier to the passage of liquids and micro-organisms therethrough.
Moreover the adhesive bond to the reusable drape or drapes prevents the transfer of infection from the non-sterilized areas of the patient to the surgical wound. When removing the reusable drape or drapes, they are automatically separated from the disposable drape so that no adhesive remains on them. This arrangement also has the very substantial benefit that the adhesive no longer has to satisfy the conflicting requirements of being fully removable at the cleansing stage while possessing adhesive properties which are unaffected by both sterilization or by becoming wet during the operation. This is achieved simply because there is no longer any adhesive on the reusable drape during laundering and sterilization of the reusable drape. Additionally, costly adhesives no longer have to be used which discolor the drape.
The disposable drape is now made in relatively small sizes, being only slightly larger than the opening in the corresponding reusable drape so that the volume of waste material produced is minimized.
For practical reasons, it is also advantageous to contrive the second adhesive means in such a way that it bonds substantially more weakly to the reusable drape than the first adhesive means bonds to the patient. This ensures that on removal of the drape, after completion of the operation, the disposable drape initially remains on the patient, preventing any tendency which overworked or tired staff may have to throw away the reusable drape together with the disposable drape.
Additionally, the second adhesive means of the disposable drape is preferentially contrived in such a way that it bonds substantially more weakly to the reusable drape or drapes than to the disposable drape. This ensures that when the reusable drape is separated from the disposable drape, the second adhesive means remains on the disposable drape and also avoids that the disposable drape goes to the laundry with the reusable drape or drapes.
The window provided in the disposable drape may be formed as an aperture in the disposable drape, thereby defining an open window, or may be covered, for instance with transparent plastic, in which case it should be readily removable or rupturable, in particular incisable, to provide access to the operation site when required.
The disposable drape, which is typically supplied in a sterile pack, will advantageously possess further qualities, such as for instance that the first and second adhesive means are protected prior to their respective use by appropriate removable coverings, for instance siliconized paper coverings, and that it is provided with at least substantially oppositely disposed peripheral flaps which are free from adhesive means and facilitate the deployment and removal of the disposable drape, as they may be conveniently gripped, in particular by hand.
In the first variant of the current invention, a reusable drape for use in a draping system of the kind provided above may be beneficially provided with an opening matched in shape to the absorbent surface of the disposable drape for which it is intended and have a marginal region surrounding the opening in the reusable drape for adhesion to the disposable drape by adhesive means provided on the disposable drape. An analogous provision can be made in the second variant of the current invention, where, in this case, the opening is matched in shape to the first adhesive means instead of to the absorbent surface due to the marginal region of the reusable drape being adhered to the lower side of the disposable drape instead of to the lower side.
The reusable drape is beneficially made of non-wicking and/or non-absorbent material. An advantage of such liquid repellent, in particular hydrophobic, materials lies in the integrity of the sterile barrier which they provide even when covered in liquid. This liquid repellency keeps soiling of the reusable drape to a minimum and ensures that the patient remains unsoiled. Any slight spillages of fluid during the operation will in any case be taken up by the upper absorbent surface layer of the disposable drape. In particular, the reusable drape can be made of a single layer material which forms a barrier to liquids and/or micro-organisms. Diathermy and suction tubes can be attached to the reusable drape using non-penetrating ball and socket clips.
It is intended, and also feasible, to clean, especially launder, and sterilize, in particular steam-sterilize, the reusable drape and to make the reusable drape from material with non-particle generating and/or antistatic properties.
The reusable drape can be fashioned from a single piece of fabric provided with a rectangular aperture which is slightly smaller than the outer dimensions of a disposable drape with which it is designed to be used. The aperture is so dimensioned that its rim has the same shape as the inner edge of the disposable drape's second adhesive means, so that the reusable drape can be adhered onto the disposable drape. In both variants, the reusable drape does not encroach upon the region of absorbent material in order that access to the operation site is as free as possible. Moreover, the potential for soiling the reusable drape is minimized.
By standardizing the outer dimensions of the disposable element it is possible to use one type of reusable drape for different types of operation.
Another alternative scheme offering advantages of an organizational kind is to use several reusable drapes in a given draping arrangement, wherein the reusable drapes are connectable to a portion of the second adhesive means, and wherein a sufficient number and variety of shapes of these pieces are provided to establish a similarly comprehensive and effective region of protection as that provided by the above single reusable drape draping arrangement.
In a given operating theater or hospital, one may envisage a number of differently sized and/or shaped disposable drapes being held in stock for use in different operations, and it can therefore be appreciated that in the previously described case where only one reusable drape is used in a given draping arrangement, one size of reusable drape must be held in stock for every one size of disposable drape. Through the use of multiple piece drapes, there is the possibility of reducing the number of reusable drapes required by adopting a modular approach. In a simple implementation, where the peripheries of the disposable drapes are always rectangular, only two different types of reusable drapes would be required; namely corner types and edge types. Such a modular approach would therefore offer substantial organizational and inventorial benefits in the day-to-day running of the hospital and its operating theaters.
To summarize, the physically largest part of the draping system of the invention, namely the reusable drape, can be used many times, without either expensive high performance adhesive means or clipped attachment to the patient. The Hobson's choice of the prior art between either providing a good seal to prevent patient self-infection or having ease of reuse of the drape has thereby been removed.
Furthermore, as a result of the longevity of the reusable drape, it can be made of modern, relatively expensive, material, the performance of which is superior in many departments over any material cheap enough to be suitable for such a large disposable item.
The disposable part is relatively small and so the amount of waste generated by the draping system of the invention is kept to a low level. In any case, the item immediately surrounding the operation site will be the most heavily soiled, and thus it is favorable that the item covering this area be disposable and of as small a size as practicable, as is provided by the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1A and B show a disposable drape of a first embodiment, as seen from above and below, respectively,
FIGS. 2A and B show a disposable "U" drape with an opening on one side according to a second embodiment, as seen from above and below, respectively,
FIG. 3 is a cross-section of a draping arrangement according to the first embodiment using the disposable drape of FIG. 1 together with a reusable drape,
FIGS. 4A and B show a disposable drape of a third embodiment, as seen from above and below, respectively, and
FIG. 5 is a cross-section of a draping arrangement according to a third embodiment of the invention using the disposable drape of FIG. 4 together with a reusable drape.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
A disposable drape 1 according to a first embodiment of the draping arrangement is shown in FIG. 1.
Here, the disposable drape 1 is built up on a transparent rectangular plastic sheet or foil, the central area of which will form the window 2 through which the operation site is to be accessed and the periphery of which will define the periphery of the disposable drape 1. With the exception of two peripheral flap regions 7, the whole of the bottom side 1' of the plastic sheet is coated with adhesive to form the first adhesive means 3. The first adhesive means is then protected prior to use by a siliconized paper cover 3' which is to be peeled off at the appropriate time. Reference numeral 3' in fact points to a corner of the cover which is in the process of being peeled off.
A second adhesive coating is provided on the other, i.e. top, side 1" of the plastic sheet, to form the second adhesive means 4, wherein the siliconized paper cover 4' on the side facing away from the plastic sheet is likewise retained until use. A piece of absorbent material 5, having a central hole which defines the window 2 and outer dimensions which are sufficiently small to enable it to fit within the strips of double-sided adhesive tape comprising the second adhesive means 4, is provided on the top side 1" of the plastic sheet.
As briefly mentioned above, oppositely disposed regions are left free of adhesive on the periphery of the plastic sheet, thereby forming flaps 7 which are large enough to be taken hold of, in particular by hand, to aid the application and removal of the disposable drape. A thus constructed complete disposable drape may be sterilized and stored in a sterile package until use.
It will be appreciated that the adhesive layers may be provided in several ways, for instance by spraying or transfer rolling a film of adhesive onto the plastic sheet, by using double-sided adhesive tape. The exposed adhesive surface of this adhesive layer is then protectable by a peel-off cover.
Also, it is not necessary that the base sheet of the disposable drape be of a unitary plastic construction. One could for instance envisage substituting the hitherto described plastic sheet by a fibrous, for instance paper, or woven, for instance liquid repellent, sheet having a centrally arranged plastic window. Alternatively, the window 2 may be an open window 2, that is an access hole or cut-out which is always present in the disposable drape.
The disposable element can also be produced in other shapes, such as in the split-U shape in accordance with a second embodiment of the disposable drape shown in FIGS. 2A and 2B, and used for example to fit various extremities of the patient's body. The reference numerals used in FIGS. 1A and 1B have also been used in FIGS. 2A and 2B, and it will be understood that the same reference numerals designate parts having the same design and/or function so that the description in connection with FIGS. 1A and 1B also applies in the same sense to FIGS. 2A and 2B.
A reusable drape 6 is now described, which, together with a disposable drape 1, forms a draping arrangement (see FIG. 3) according to a first embodiment of the invention.
The reusable drape 6 is made out of a piece of material having an aperture which is slightly smaller than the outer dimensions of a given type of disposable drape 1 with which it is designed to be used. More specifically, the aperture is so dimensioned that its rim has the same shape as the inner edge of the disposable drape's second adhesive means (4), so that the reusable drape 6 can be adhered onto the disposable drape 1 by the second adhesive means 4. Additionally, when used in conjunction with the above described disposable drape 1 of this embodiment, the reusable drape 6 should encroach very little, or not at all, upon the region of absorbent material 5 in order that access to the operation site remains as free as possible and that the potential for soiling the reusable drape 6 during the operation is kept to a minimum.
In a modification, several reusable drapes 6 are used in conjunction with the disposable drape of for instance the first embodiment to form the draping arrangement. When these reusable drapes 6 are suitably combined, they provide similar coverage to that provided by the reusable drape 6 of the first embodiment. The advantage of incorporating a multiplicity of reusable drapes 6 in a given draping arrangement lies in that a draping system can be developed wherein one and the same shape and size of reusable drape 6 can be used to form draping arrangements for variously shaped and sized disposable drapes 1, a stock of the latter being necessary for performing different operations.
Deployment of the disposable drape (1) and reusable drape (6) of the first embodiment of the draping arrangement may be performed as follows.
The operation site is sterilized. One member of the staff removes the disposable drape from its packaging and holds it taut by its peripheral flaps 7, while another staff member removes the siliconized paper covering 3' from the first adhesive means 3. The disposable drape 1 now being positioned so that the window 2 is central over the operation site, the disposable drape 1 is then stuck down. The siliconized paper covering 4' is then removed from the second adhesive means 4. The reusable drape or drapes 6 is/are now positioned over the disposable drape 1, so that the periphery of the hole in the former lies adjacently over the inner periphery of the second adhesive means 4 of the latter, and is then stuck down. For the time being, the window 2 remains complete and thus protects the sterilized operation site from airborne contamination. Subsequently, the window 2 is cut through by the surgeon, typically with a scalpel, directly before the commencement of invasive surgery. The situation pertaining during the operation is depicted in FIG. 3.
A disposable drape 1 according to a third embodiment is shown in FIGS. 4A and 4B. As in the first and second embodiments, the disposable drape 1 is constructed starting from a transparent rectangular plastic sheet or foil. A central portion of the bottom side 1' of the plastic sheet is coated with adhesive to form the first adhesive means 3. The first adhesive means is protected prior to use by a siliconized paper cover 3' which is to be peeled off at the appropriate time. Reference numeral 3' in fact points to a corner of the cover which is in the process of being peeled off.
In contrast to the first and second embodiments, in the third embodiment the second adhesive means is provided on the bottom side 1' of the plastic sheet, i.e. on the same side as the first adhesive means 3. The second adhesive means 4 is disposed outside the periphery of the first adhesive means 3 and, as before, the respective siliconized paper cover 4' is retained until use.
As becomes clear below in the passage describing a method of deployment of the draping arrangement, it is advantageous in this embodiment if the siliconized paper cover 4' is not a single continuous piece, because if it were it would have hoop-like shape and could be inconvenient to peel off. A single break or cut 8 can be provided in the "hoop" as is shown in FIG. 4B. Alternatively more breaks could be provided, in which case the cover 4' would comprise more than one piece. The-above feature facilitates removal of the siliconized paper cover 4' when it is not removed until after the first adhesive means 3 has been stuck down on the patient.
On the upper side 1" of the plastic sheet, an absorbent surface 5 is provided, which has a central aperture defining the window 2. Since the second adhesive means is on the bottom side 1' in this embodiment, the area available for the absorbent surface 5 on the top side 1" is, all things being equal, correspondingly larger. Flaps 7 are also provided which serve the same purpose as those provided in the first embodiment. Also the various constructive modifications and alternatives concerning, for instance, the provision of the adhesive means, the base sheet and the window detailed above for the first embodiment are equally valid for the third embodiment.
Furthermore, a fourth embodiment could be envisaged having the split U-shape of the second embodiment and the second adhesive means 4 arranged on the lower side 1' in an analogous fashion to the third embodiment.
Deployment of the disposable drape 1 of the third embodiment in conjunction with a one piece surgical drape 6 is performed along broadly similar lines to the deployment described above for the first embodiment. The operation site is sterilized. One member of the staff removes the disposable drape from its packaging and holds it taut by its peripheral flaps 7, while another member of the staff removes the siliconized paper covering 3' from the first adhesive means 3. The disposable drape 1 is then taken over to the patient and positioned so that the window 2 is centered over the operation site. The disposable drape 1 is then stuck down.
At this stage the method of deployment differs somewhat from that described for the first embodiment. Namely, the edge of the aperture in the reusable drape 6 is tucked under the periphery of the disposable drape, so that the edge of the aperture in the reusable drape lies adjacent to but beneath the inner periphery of the second adhesive means 4 of the disposable drape. Only then is the siliconized paper covering 4' removed from the second adhesive-means 4 and the latter stuck to the surgical drape 6.
It is for this reason that it is advantageous when the siliconized paper covering 4' is not a single continuous piece, because if it were it would have hoop-like shape and could be inconvenient to peel off. One could, for instance provide at least one break in the "hoop", or form the cover 4' from more than one piece.
Then, as for the first embodiment, the window 2 is left complete, an access hole subsequently being cut in it only directly before the commencement of invasive surgery. The situation pertaining is shown in FIG. 5.
For the sake of completeness it is pointed out that the reusable drapes used for the purposes of the present invention can be designed in the same manner as existing reusable drapes and are available from the company Rotecno AG, Steinstrasse 35, 8045 Zurich, Switzerland. The disposable drapes can be basically similar to those available from the 3M or Kimberly-Clark companies, for example, but require the addition of the second adhesive means and the use of sizes matched to the reusable drapes so as to adapt the disposable drapes for use in the draping system of the present application.
For the sake of emphasis it is pointed out that when realizing the disposable drape as a sheet of plastic the window therein may be formed as a closed window, in which case the transparent or translucent plastic sheet does not have an opening therein but itself defines the window. In this case the surgeon then cuts the plastic away at the site of the surgical incision to obtain access to the patient. Alternatively the window can be an open window, that is to say an opening in the sheet of plastic through which the surgeon automatically has access to the site of the operation. If the disposable drape is made of another material which is not sufficiently transparent or translucent then the window provided therein can be formed by a transparent or translucent plastic sheet or can also be an open window. | A two-part surgical draping system comprising a disposable drape (1) for adhesion to an operation site, and one or more reusable drapes (6) placed over the disposable drape (1). The disposable drape (1) comprises a window (2), an upper absorbent layer (5) and a lower impermeable layer, first adhesive means (3) for adhering the lower impermeable layer to the patient, and non-adhesive preferably oppositely disposed margins (7) which serve to facilitate handling of the disposable drape (1). For attachment of the one or more reusable drapes (6) to the disposable drape (1), either the upper or the lower surface of the disposable drape is provided with second adhesive means (4) which is adherable to the lower or upper side of the reusable drape respectively. After attachment, the one or more reusable drapes (6) leave an access opening to the operation site. Moreover, the adhesive means (3,4) are preferentially protected prior to use by respective removable coverings (3',4'). | 0 |
This application is a division of application Ser. No. 801,640 filed Nov. 25, 1985, now U.S. Pat. No. 4,682,609.
BACKGROUND OF THE INVENTION
The present invention is directed to devices for measuring cervical dilation.
In the early stages of labor, the doctor monitors cervical dilation to determine how far labor has advanced. Dilation monitoring is typically performed by inserting two fingers and noting how far they can be extended laterally.
Needless to say, this type of measurement is far from repeatable. Even if a given doctor comes to recognize different degrees of dilation by feel, he cannot reliably communicate that degree of dilation to another doctor without some objective scale. To overcome this shortcoming--i.e., to provide a way to assess dilation by means of an objective scale--devices for measuring cervical dilation have been proposed, but they have not attracted widespread use. The reason seems to be that the patient finds insertion of foreign objects more objectionable than insertion of the doctor's fingers.
It is accordingly an object of the present invention to permit an objective dilation measurement without the objectionable insertion of foreign objects.
SUMMARY OF THE INVENTION
The foregoing and related objects are achieved through the use of a dilation meter that comprises a pair of pivot arms pivotably mounted to each other. On one end of each arm is a ring adapted to fit around the bases of two adjacent fingers of a doctor. On the other end of one arm is a scale on which are provided indicia indicating meter pivot angle, while an indicating element such as a pointer is on the other end of the other arm to point to indicia on the scale. The scale is positioned with respect to the rings so that it fits in the palm of the doctor's hand when the rings are on the bases, rather than on the tips, of his fingers.
Dilation is determined from the angle measurement by means of a function, keyed to the sizes (lengths and thicknesses) of the doctor's fingers, that converts pivot angle to dilation. The doctor makes an initial determination of the size range for his fingers to determine which of several such conversion functions to use. The function may be provided on a separate table, or multiple functions may be provided on the device itself, and the functions are based on placement of the rings at the bases of the doctor's fingers rather than at their tips. In this way, an objective, repeatable dilation determination can be made without the need to have the meter touch the patient.
BRIEF DESCRIPTION OF THE DRAWINGS
These and further features and advantages are described in connection with the accompanying drawings, in which:
FIG. 1 is a front elevational view of the dilation meter of the present invention shown in position on the doctor's fingers;
FIG. 2 is an exploded view of the meter of FIG. 1;
FIG. 3 is an isometric view of a container for dilation meters of the type shown in FIG. 1;
FIG. 4 is a cross-sectional view of a part of the container of FIG. 3;
FIG. 5 is a detailed view of the table provided on the container of FIG. 3;
FIG. 6 is a perspective view of an alternate embodiment of the meter of the present invention;
FIG. 7 is an isometric view of an alternate embodiment of the container;
FIG. 8 is an isometric view of another alternate embodiment of the meter of the present invention.
FIG. 9 is an isometric view of another alternate embodiment of the meter of the present invention.
FIG. 10 is a front elevational view of another alternate embodiment of the meter of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows a dilation meter 10 of the present invention in place on a doctor's hand 12. It includes two pivot arms 14 and 16 mounted together for pivoting about a pivot axis 18. At the distal ends of the arms 14 and 16 are mounted two rings 20 and 22, respectively. Rings 20 and 22 are adjustable in diameter and enclose the bases of the two adjacent fingers 24 and 26 that the doctor uses to perform the dilation measurement. At the proximal end of one pivot arm 14 is a scale 28 on which indicia are inscribed at different angular positions. At the proximal end of the other pivot arm 16 is an indicating element in the form of an elongated extension with a window 30 through which the doctor can see an indicium and thereby note the pivot angle--typically in arbitrary units--when his fingers are at their maximum lateral extension in the cervix. All parts of the meter are made of a plastic that will not be adversely affected by irradiation or other ordinary sterilization procedures.
As FIG. 2 shows, arm 14 is snap fit to arm 16. A resilient flanged boss 34 provided on arm 14 at its pivot axis extends through a registering aperture 36 at the pivot axis of arm 16 and thereby holds the two arms together.
Since the dilation for a given meter angle depends on the size of the doctor's fingers, the box 38 (FIGS. 3 and 4) in which the meters are delivered is provided with a calibration device. Perforations on the side of the box 38 define a tab 39 whose removal reveals an opening 40 in which a slide 42 is slidably mounted by any appropriate means such as track-defining internal rails 44 and 46 secured by spacers 48 and 50 to one wall 52 of the box 38. Complementary edges 54 and 56 on the wall and the slide define the opening 40, so the size of the opening 40 varies with the position of the slide 42.
Length indicia 54 are printed on the box wall 52 adjacent the slide 42, and a pointing indicium 57 is printed on the slide 42 to point to them. The size indicia in the illustrated embodiment are different colors, say, red, blue, green, and yellow.
Before a doctor uses a meter for the first time, he fits the rings 20 and 22 on the bases of his fingers and places his fingers in the opening 40 with the slide 42 disposed in a position somewhat to the left in FIG. 3. He opens his fingers until the meter reaches a predetermined reading, sliding the slide to the right as he does so. He then observes the size indicium 54 to which the pointing indicium 56 points when the meter reaches the predetermined reading, and this is an indication of the relative size of his fingers. Best calibration is obtained when the doctor's fingers are crooked in the manner in which they are crooked when he takes a dilation measurement.
When the doctor then uses the meter 10 to take an actual dilation measurement, he notes the angle indicium on the meter and consults a table 58 on container wall 52 to find the entry under the angle reading for his color. This is the dilation measurement. FIG. 5 shows the table in detail.
In practice, the doctor may rely for his own purposes on the angle measurement alone, converting to the dilation measurement only in communicating his measurements to others.
To avoid the need to consult a table on a separate box to determine dilation, the dilation-meter scale may be arranged to provide a dilation reading directly. Such a meter 59 is depicted in FIG. 6. The scale 60 on meter 59 provides indicia in four parallel ranges 62, 64, 66, and 68. Each range corresponds to a different finger size, and the doctor makes the dilation measurement by simply observing the indicium pointed to by the indicating element, in this case, a pointer 70.
The meter 59 shown in FIG. 6 may come in a container like box 72 of FIG. 7. Removal of a tab (not shown) reveals two holes 74 and 76 representing a predetermined cervical dilation. The initial calibration for the type of meter shown in FIG. 6 is performed by placing the tips of the doctor's fingers in the two holes and observing the range in which the pointer 70 points to an indicium representing the predetermined dilation.
FIG. 8 depicts a meter in which the indicating element includes a magnifying "glass" 78, typically made of transparent plastic, that magnifies the images of the indicia so that the doctor can read them more easily.
To further simplify the dilation determination, the disposable part of the meter can be provided without an integral scale. Instead, it could be adapted to be mechanically attached to a position encoder included in an electronic scale 80 (FIG. 9). With this type of an arrangement, the doctor simply presses a button when his fingers are in holes 74 and 76. The scale 80 is thereby automatically calibrated and displays dilation on an LCD display 84.
To increase measurement resolution in a strictly mechanical embodiment of the present invention, angle-multiplying arrangements can be used. An example is illustrated in FIG. 10, which shows rings 20 and 22 on arms 14 and 16 that are pivotably secured to each other for pivoting about a pivot axis 18. Instead of being attached directly to a pointer and scale, however, the arms 14 and 16 in the FIG. 10 embodiment are pivotably secured to auxiliary, angle-multiplying arms 86 and 88, respectively, for pivoting with respect to them about pivot points 90 and 92. The auxiliary arms 86 and 88 are in turn pivotably secured to each other at pivot point 94. A scale 98 and indicating element 98 are provided on the ends of auxiliary arms 86 and 88, respectively, and it becomes apparent upon reflection that a small change in the angle between the main arms 14 and 16 results in a much larger change in the angle between the auxiliary arms 86 and 88. The FIG. 10 embodiment thus affords greater resolution in the dilation measurement.
In light of the foregoing description, it can be appreciated that the present invention can be practiced in a wide variety of embodiments. It permits a doctor to make an objective dilation measurement without touching the patient with an objectional foreign object. The present invention therefore constitutes a significant advance in the art. | A meter (10) for measuring cervical dilation during labor includes rings (20 and 22) that fit at the bases of the user's fingers (24 and 26). Pivot arms (14 and 16) mount the rings (20 and 22) at one end and a scale and indicator (30) at the other end. Scale indicia indicate the separation of the rings. Ring separation can be translated into the separation of the finger tips and thus into cervical dilation. | 0 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates to a drain cover assembly interlock having a releasable plug for obstructing a discharge port upon removal of a drain cover.
[0003] 2. Description of Related Art
[0004] Properly designed pool and spa drain covers provide several safety functions; namely, they prevent or mitigate evisceration, hair entanglement, finger and toe entrapment and body suction entrapment. If the drain cover is missing from the drain, body entrapment and evisceration are prevalent hazards which are particularly devastating to children. These hazards arise because of the drain suction from the now exposed discharge port positioned behind the drain cover.
[0005] The suction associated with evisceration and body and limb entrapment may be eliminated by “interlocking” the drain cover, i.e., when the covers are removed all flow and suction are interrupted.
SUMMARY OF THE INVENTION
[0006] Accordingly, it is one object of this invention to provide a drain cover assembly that interrupts suction from the discharge port upon removal of the drain cover.
[0007] It is another object of this invention to provide a drain cover assembly that discharges a plug into the discharge port upon removal of the drain cover.
[0008] It is another object of this invention to provide a drain cover assembly that retains a plug, such as a ball, within a retainer that responsively releases the ball into the path of the discharge port upon removal of the drain cover.
[0009] It is another object of this invention to provide an interlocked drain cover assembly that includes components that will not entangle a bather's or swimmer's hair.
[0010] These and other objects of this invention are addressed by a drain cover that responsively releases a suitably-sized plug, such as an elastomeric ball preferably having a diameter somewhat larger than the drain discharge port, into the vicinity of the drain when the drain cover is removed. This ball becomes entrained in the discharge flow and, because of its size, lodges itself in the entrance to the drain discharge port which is somewhat smaller in diameter than the ball. This “check valve” action isolates a swimmer from the suction proclivities of the drainage pump.
[0011] Several devices are described for securing the ball when the drain cover is in situ; such devices release the ball when the cover is removed. The freely movable nature of the unrestrained ball is a unique attribute of the present invention. The unrestrained ball will be urged into contact with the discharge outlet by water flow, gravity and/or other means. To function efficiently, two additional properties should be realized: hair entanglement with the interlock mechanism should be minimized or eliminated; and the flow rate should not be compromised significantly.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] These and other objects and features of this invention will be better understood from the following descriptions taken in conjunction with the drawings wherein:
[0013] [0013]FIG. 1 is a side cross-sectional view of a drain cover assembly in situ, according to one preferred embodiment of this invention;
[0014] [0014]FIG. 2 is a side cross-sectional view of the drain cover assembly shown in FIG. 1, in a ball plug deployed position;
[0015] [0015]FIG. 3 is a side cross-sectional view of a drain cover assembly in situ, according to one preferred embodiment of this invention;
[0016] [0016]FIG. 4 is a side cross-sectional view of the drain cover assembly shown in FIG. 3, in a ball plug deployed position;
[0017] [0017]FIG. 5 is a side cross-sectional view of a drain cover assembly in situ, according to one preferred embodiment of this invention;
[0018] [0018]FIG. 6 is a side cross-sectional view of the drain cover assembly shown in FIG. 5, in a ball plug deployed position;
[0019] [0019]FIG. 7 is a side cross-sectional view of a drain cover assembly in situ, according to one preferred embodiment of this invention;
[0020] [0020]FIG. 8 is a perspective view of a ball plug retainer according to one preferred embodiment of this invention;
[0021] [0021]FIG. 9 is a side cross-sectional view of the drain cover assembly shown in FIG. 7, in a ball plug deployed position;
[0022] [0022]FIG. 10 is a side cross-sectional view of a drain cover assembly in situ, according to one preferred embodiment of this invention;
[0023] [0023]FIG. 11 is a perspective view of a ball plug retainer according to one preferred embodiment of this invention;
[0024] [0024]FIG. 12 is a side cross-sectional view of the drain cover assembly shown in FIG. 10, in a ball plug deployed position;
[0025] [0025]FIG. 13 is a side cross-sectional view of a drain cover assembly in situ, according to one preferred embodiment of this invention;
[0026] [0026]FIG. 14 is a perspective view of a ball plug retainer according to one preferred embodiment of this invention; and
[0027] [0027]FIG. 15 is a side cross-sectional view of the drain cover assembly shown in FIG. 13, in a ball plug deployed position.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0028] FIGS. 1 - 15 show various embodiments of drain cover assembly 10 . Drain cover assembly 10 according to this invention is preferably used in connection with swimming pools, spas, whirlpool baths and other vessels that require drains drawing water, particularly where bathers and/or swimmers may come into contact with such drains. Applicant has used the term “pool” surface to describe the surface or surfaces adjacent drain cover assembly 10 , however such term is intended to also describe whirlpools, bathtubs, spas and any other similar surface having a recessed discharge drain 15 with a discharge port 20 out of a drain cavity 25 .
[0029] According to a preferred embodiment of this invention, drain cover assembly 10 includes drain cover 30 configured for attachment with respect to discharge drain 15 and plug 50 retained by at least a portion of drain cover 30 , such as retainer 70 . Plug 50 is responsively discharged from drain cover 30 upon removal of drain cover 30 from discharge drain 15 . Plug 50 is then responsively positioned, by flow of the water, over discharge port 20 thereby blocking fluid flow into discharge port 20 . Various specific embodiments of this invention are described in more detail below.
[0030] According to a preferred embodiment of this invention, and as shown in the drawings, plug 50 comprises a ball, more specifically an elastomeric ball preferably having a diameter larger than a diameter of discharge port 20 . Plug 50 or ball 50 may be elastomeric, polymeric or any other structure, preferably having flexible, deformable and/or conforming characteristics. However, additional shapes, configurations and materials are contemplated for use as plug 50 including polyhedrons, discs, cones and any other suitable shape having suitable properties to block fluid flow into discharge port 20 . However, the term “ball” will be used throughout the remaining specification for the purposes of consistency.
[0031] In addition, ball 50 preferably has a specific gravity greater than unity so that the ball does not float and is thereby, when released, more easily urged into contact with the discharge port 20 . Ball 50 may comprise a material having a lower specific gravity however a tether or other device may be necessary to maintain ball 50 within close proximity to discharge port 20 .
[0032] The following headings and related descriptions describe various preferred embodiments of the present invention. Other variations are contemplated that accomplish the same purpose of releasing a plug into the vicinity of a discharge port upon removal of a drain cover.
[0033] FIGS. 1 - 15 show that discharge drains 15 may be configured with two discharge ports 20 and 20 ′. Usually one discharge port is open, shown as element 20 , and one is plugged, shown as element 20 ′. The preferred embodiments of this invention work equally well when discharge port 20 is plugged and discharge port 20 ′ is open. Further, the preferred embodiments of this invention work equally well when both discharge port 20 and discharge port 20 ′ are open; but then require that drain cover assembly 10 include two cup and ball assemblies.
External Ball Retention
[0034] [0034]FIGS. 1 and 2 show one preferred embodiment of this invention wherein retainer 70 of drain cover assembly 10 includes a generally spherical segment, such as cup 75 for restraining ball 50 . As shown in FIG. 1, cup 75 is positioned outside of drain cover 30 relative to drain cavity 25 and restrains ball 50 against the surface of the pool floor. By positioning cup 75 outside of drain cavity 25 , the flow rate of the drain system is not reduced by retainer 70 . In addition, hair entrapment or entanglement is eliminated or minimized by positioning cup 75 flush with the bottom surface of the pool.
[0035] Cup 75 preferably protects the ball from UV radiation, particularly an elastomeric ball. Cup 75 may include one or more holes 77 to permit viewable confirmation of the presence of ball 50 in retainer 70 . Conventional wisdom in the aquatics industry suggests that small holes will not entangle hair. Cup 75 may be constructed of stainless steel or other material that will not degrade in the pool environment.
[0036] According to this embodiment of the invention, and as shown from FIG. 1 to FIG. 2, removal of drain cover 30 releases ball 50 which will quickly be entrained into the water discharge flow pattern. This will bring ball 50 up against the discharge port 20 in drain 15 as shown in FIG. 2. Because the ball diameter is preferably larger than the inside diameter of discharge port 20 , ball 50 will remain fixed to discharge port 20 thereby stopping all fluid flow therethrough. As a result, when drain cover 30 is removed from the drain, either intentionally or accidently, ball 50 will obstruct discharge port 20 thereby maintaining a safe condition in the vicinity of the drain.
[0037] The safe flow rate established for drain cover 30 using the protocol in ASME/ANSI A112.19.8M-1987 is unaffected by the interlock drain cover assembly 10 described herein and shown in FIGS. 1 and 2. Two cup and ball interlocks may be used if two discharge ports 20 , 20 ′ are active in drain cavity of the main drain.
[0038] According to a preferred embodiment of this invention, ball 50 should have a specific gravity greater than unity. This prevents flotation of ball 50 and thus ensures that ball 50 is urged into drain cavity 25 by gravity and water flow and remains in the vicinity of discharge port 20 .
Internal Ball Retention
[0039] According to a preferred embodiment of this invention shown in FIGS. 3 and 4, retainer 70 includes tube 80 associated with or integrated with drain cover 30 . Tube 80 preferably extends downwardly into drain cavity 25 bound by drain cover 30 . Ball 50 is preferably positioned within tube 80 which surrounds and/or encloses ball 50 until drain cover 30 is removed or disassociated from the vicinity of discharge port 20 .
[0040] As shown in FIG. 3, tube 80 preferably extends from drain cover 30 downwardly until flush with a bottom surface of drain cavity 25 against which ball 50 is retained. Tube 80 is preferably tightly fitted against the side wall within drain cavity 25 , in part to minimize flow rate disruptions through discharge port 20 .
[0041] As described above, ball 50 is preferably elastomeric and is captured within tube 50 . The diameter of ball 50 is preferably somewhat larger than the diameter of discharge port 20 . Ball 50 preferably has a specific gravity greater than unity if it is solid. In general, ball 50 , solid or not, should sink in water, in part, to maintain a close proximity to discharge port 20 in the event that drain cover 30 is removed. Two balls 50 may be used in tube 80 when two discharge ports 20 , 20 ′ are active. If tube 80 is closed at the top, ball 50 will be protected from UV attack.
[0042] As shown in FIG. 4, when drain cover 30 is removed, ball 50 is released into the discharge flow. Ball 50 will be pulled against discharge port 20 by the water flow through discharge port 20 and will accordingly block all fluid flow into and through discharge port 20 by the vacuum generated therein.
[0043] Human hair cannot be entangled around tube 80 because tube 80 preferably remains flush against the side and bottom of drain cover 30 during normal operation with drain cover 30 in situ.
Internal Ball Retention—Tube on Discharge Port
[0044] According to a preferred embodiment of this invention shown in FIGS. 5 and 6, drain cover assembly 10 includes retainer 70 having tube 80 associated with or integrated with drain cover 30 and extending downwardly into drain cavity 25 bound by drain cover 30 . Like the embodiment described for FIGS. 3 and 4, tube 80 preferably surrounds ball 50 until drain cover 30 is removed from discharge port 20 . However, according to this preferred embodiment and as best shown in FIG. 5, tube 80 extends from drain cover 30 into proximity with and above discharge port 20 instead of flush with a lower surface of drain cavity 25 .
[0045] In addition, a lower edge of tube 80 includes an angled edge to prevent hair entanglement. The bottom end of tube 80 is preferably cut on an angle to prevent hair from hanging up or becoming entangled on the bottom end of tube 80 . The bottom plane of tube 80 should include an angle α with the horizontal plane such that α≧tan −1 μ, where μ is the friction coefficient between the tube material and human hair. α is preferably less than 45° to retain ball 50 in tube 80 when drain cover 30 is in situ.
[0046] As described above, ball 50 is preferably elastomeric and is captured within tube 80 while resting on the protrusion of port 20 as shown in FIG. 5. The diameter of ball 50 is preferably somewhat larger than the inside diameter of discharge port 20 . Ball 50 preferably has a specific gravity greater than unity if it is solid. In general, ball 50 should sink in water, in part, to maintain a close proximity to discharge port 20 in the event that drain cover 30 is removed. Two balls 50 may be used in tube 80 when two discharge ports are active, specifically in deep main drains where there may be enough tube 80 height to capture two elastomeric balls. A cap at the top end of tube 80 may be used to protect ball 50 from UV attack.
[0047] As shown in FIG. 6, when drain cover 30 is removed, ball 50 is released into the flow pattern of fluid through drain cavity 25 and into drain port 20 . Ball 50 will quickly seal itself against discharge port 20 when its diameter is somewhat larger than that of drain port 20 in drain cavity 25 . Fluid flow is thereby terminated and no suction-related hazards are present at drain cavity 25 .
Internal Ball Retention—Stem and Hoop
[0048] FIGS. 7 - 15 show drain cover assembly 10 wherein retainer 70 includes stem 90 extending downwardly from drain cover 30 and hoop 95 (FIGS. 7 - 9 ); capped tube 100 (FIGS. 10 - 12 ); or cup 105 (FIGS. 13 - 15 ) positioned at a distal end of stem 90 .
[0049] FIGS. 7 - 9 show a preferred embodiment of this invention having hoop 95 attached to a distal end of stem 90 . Hoop 95 preferably includes an open lower edge generally flush with a bottom surface of drain cavity 25 formed behind drain cover 30 .
[0050] Stem 90 and hoop 95 , such as shown in FIG. 8, are preferably corrosion-resistant metal, or other suitable material, and are preferably fastened to drain cover 30 so that stem 90 hugs the side wall of drain cavity 25 . Stem 90 is preferably of a sufficient length and shape to position hoop 95 against the bottom of drain cavity 25 . Hair cannot become entangled with retainer 70 of this embodiment because both stem 90 and hoop 95 preferably remain flush against the drain structure 15 defining drain cavity 25 .
[0051] Ball 50 , preferably elastomeric and somewhat heavier than water so it sinks, is retained in hoop 95 while drain cover 30 remains in situ. When drain cover 30 is removed, the previously captured ball 50 is released into the discharge flow of the drain cavity 25 and is brought against the mouth of discharge port 20 by the water flow through discharge port 20 . Because ball 50 has a larger diameter than that of discharge port 20 , ball 50 will seal discharge port 20 against further discharge flow. All suction hazards are thereby removed by this action at drain cavity 25 .
[0052] FIGS. 10 - 12 show drain cover assembly 10 having retainer 70 that includes stem 90 extending downwardly from drain cover 30 and a tube 100 capped on top but open at the bottom attached to a distal end of stem 90 . The open bottom end of tube 100 is in generally flush contact with the bottom surface of drain cavity 25 .
[0053] Ball 50 , preferably elastomeric and somewhat heavier than water so that it sinks, is retained in capped tube 100 while drain cover 30 remains in situ, such as shown in FIG. 10. When drain cover 30 is removed, the previously captured ball 50 is released into the discharge flow of drain cavity 25 and is brought against the mouth of discharge port 20 by the water flow through discharge port 20 , such as shown in FIG. 12. Because ball 50 has a larger diameter than that of discharge port 20 , bail 50 will seal discharge port 20 against further discharge flow. All suction hazards are thereby removed at drain cavity 25 by this action.
[0054] FIGS. 13 - 15 show drain cover assembly 10 having retainer 70 that includes stem 90 extending downwardly from drain cover 30 and cup 105 attached to a distal end of stem 90 . The open bottom end of cup 105 is in generally flush contact with the bottom surface of drain cavity 25 .
[0055] Ball 50 , preferably elastomeric and somewhat heavier than water so it sinks, is retained in cup 105 while drain cover 30 remains in situ, as shown in FIG. 13. When drain cover 30 is removed, the previously captured ball 50 is released into the discharge flow of drain cavity 25 and is brought against the mouth of discharge port 20 by the water flow through discharge port 20 , as shown in FIG. 15. Because ball 50 has a larger diameter than that of discharge port 20 , ball 50 will seal discharge port 20 against further discharge flow. All suction hazards are thereby removed at drain cavity 25 by this action.
[0056] The embodiments of this invention as described and shown in FIGS. 7 - 15 , should include ball 50 that is heavier than water so it should sink. If solid, ball 50 should have a specific gravity greater than unity. A UV resistant ball 50 is desired to survive the pool environment.
[0057] The bottom area of drain cavity 25 should be large enough to accommodate the preceding embodiments without compromising the flow rate of the discharge system.
[0058] While in the foregoing specification this invention has been described in relation to certain preferred embodiments thereof, and many details have been set forth for purpose of illustration, it will be apparent to those skilled in the art that the invention is susceptible to additional embodiments and that certain of the details described herein can be varied considerably without departing from the basic principles of the invention. | Missing drain covers used in connection with swimming pools, spas and/or other applications expose humans and animals to discharge ports in the drains that can develop near vacuums which eviscerate, entrap the body and entangle hair. A drain cover is disclosed that releases an elastomeric plug in the neighborhood of the drain upon removal of the drain cover. The plug becomes entrained in the discharge flow and eventually plugs up the smaller diameter discharge port eliminating vacuum hazards by checking all discharge flow and pressure. | 4 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a lace provided with a tubular lace body.
2. Description of the Related Art
Conventionally, as to a lace which needs to be pass through a hole for fixation, a lace, where its core is made of a linear material having elasticity such as a rubber, the outer periphery of the core is covered with fiber, and the fiber portion has knobby portions for hooking into holes of a lace-up shoes, thereby being fixed without lacing, is well-known.
The knobby portions are braided so as to hook the hole after passing through the hole of the lace-up shoes, and can freely vary its diameter depending on the tension put on the lace. Therefore, the lace has a configuration, where a plurality of knobby portions, of which ends are fixed by the rubber of the core, and the core which is inelastic (flexible) and not fixed, are braided and placed. When a tension is put on the core of rubber, the rubber portion extends and the distance between the ends extends, so that the core of the knobby portion becomes flat, and the diameter becomes smaller.
Moreover, when the tension is not put on the lace, the rubber portion becomes normal length, and the distance between the ends also becomes normal, so that the shape of the knobby portion is restored to be original, and the diameter becomes greater.
Thus, it is possible to control variation of the diameter of the knobby portion by the tension put on the lace, so that the shoe lace which does not loosen without lacing can be made as described above.
For example, the Japanese Patent No. 3493002 discloses such lace provided with knobby portions.
3. Related Art Documents
Patent Document 1: Japanese Patent No. 3493002
However, in the above technology, the both ends of the inelastic knobby portion are fixed to the rubber core, so that the rubber portion cannot extends under high tension. The reason is that the knobby portion is braided by the inelastic fiber and the rubber portion is fixed by the inelastic.
Moreover, the rubber portion corresponding to the core of the knobby portion repeats extension and shrinks in response to the high tension.
SUMMARY OF THE INVENTION
Therefore, there are a portion that is subjected to heavy stretching force and a portion that is subjected to no stretching force, and when large strain is accumulated at the boundary between the portions subjected to different stretching forces and the strain reaches the limit, the lace ruptures. In order to solve the above problem, we provide a lace provided with tubular lace body of elastic material, comprising knobby portions repeatedly placed at intervals, of which diameter vary depending on tension on the knobby portion in an axial direction.
According to the present invention mainly having the above configuration, the lace having an economical advantage, which is not easily torn and does not get loose without lacing, can be provided.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagram showing a portion of a lace of a first embodiment.
FIG. 2 is a diagram showing that the lace of the first embodiment is under tension in an axial direction.
FIG. 3 is a diagram showing that the lace of the first embodiment is used for a shoe lace.
FIG. 4 is a diagram showing that the lace of the first embodiment is used for a lace for trousers.
FIG. 5 is a flowchart of fixing process by using the lace of the first embodiment.
FIG. 6 is a perspective view of an entire lace of a second embodiment.
FIG. 7 is a cross-section view of a lace of a third embodiment.
FIG. 8 is a cross-section view of a lace of a fourth embodiment.
FIG. 9 is a cross-section view of a lace of a fifth embodiment.
FIG. 10 is an enlarged view of a braided portion of a lace body of a sixth embodiment.
FIG. 11 is a side view of both sides of the lace of the present invention.
FIG. 12 is a cross-sectional view when the lace of the present invention is configured to be a rubber tube.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Embodiments of the present invention will be described hereinafter. Relationship between Claims and Embodiments is as follows. The first embodiment will mainly describe Claim 1 . The second embodiment will mainly describe Claim 2 . The third embodiment will mainly describe Claim 3 . The fourth embodiment will mainly describe Claim 4 . The fifth embodiment will mainly describe Claim 5 . The sixth embodiment will mainly describe Claim 6 . The present invention is not to be limited to the above embodiments and able to be embodied in various forms without departing from the scope thereof.
First Embodiment
Outline of First Embodiment
FIG. 1 is a diagram showing a portion of a lace of a first embodiment. As shown in FIG. 1 , the lace of the first embodiment is a lace provided with tubular lace body of elastic material, comprising a knobby portion repeatedly placed at intervals, of which diameter varies depending on tension on the knobby portion in an axial direction. This configuration enables to provide a lace which is not easily torn under high tension which is repeatedly put on the lace body.
Note that the design of the lace of FIG. 1 continues only in horizontal direction in the elevation view, and FIG. 11 is a side view of both sides of the lace of the present invention.
Configuration of First Embodiment
As shown in FIG. 1 , a ‘lace’ 0100 of a first embodiment is a lace provided with tubular lace body comprising knobby portions repeatedly placed at intervals. Specifically, the knobby portions are configured by repeated placed ‘cores’ 0101 , and ‘ends’ 0102 . FIG. 2 is a diagram showing that the lace of the first embodiment is under tension in an axial direction. As shown in FIG. 2 , when putting the tension in the axial direction, the diameter of the knobby portion varies, such that the knobby portion shrinks. When removing the tension in the axial direction, the diameter of the knobby portion varies, such that the knobby portion expands.
The ‘knobby portion’ of the first embodiment is ‘repeatedly placed at intervals’. Therefore a plurality of knobby portions is placed on the lace body. The plurality of knobby portions may be placed only with intervals between the cores, and the interval is not necessary to be regular. Therefore, the knobby portion may be placed at regular intervals or at random, and the interval is design variation. As show in FIGS. 3 and 4 , it is possible to provide laces for various cases such as a case of lacing up shoes or a case of fastening trousers.
Moreover, as to the knobby portion, ‘diameter varies depending on tension on the knobby portion in an axial direction’. Specifically, as the tension in the axial direction increases, the diameter is reduced, and as the tension in the axial direction decreases, the diameter increases.
FIG. 5 is a flowchart of fixing process by using the lace of the first embodiment. The process includes the following steps. At the outset, in a step S 0501 , tension on the lace is put in an axial direction, such that the diameter of the knobby portion is reduced. Subsequently, in a step S 0502 , the lace under tension is made to pass through a hole. Subsequently, in a step S 0503 , it is determined whether lace length is suitable for keeping fixed state. If the length is not suitable, the step S 0502 is repeated. If it is determined that the length is suitable, processing shifts to a step S 0504 . Subsequently, in a step S 0504 , the tension put on the lace is reduced, such that the diameter of the knobby portion increases, thereby expanding the knobby portion. Thus, it is possible to keep the state of being fixed only by hooking the knobby portion on the hole without lacing.
Note that the ‘knobby portion’ of the present invention is a portion having diameter greater than that of a non-knobby portion with no tension in the axial direction. Therefore, the knobby portion is a part of the lace body, and configured by the after-mentioned elastic material similar to the lace body.
The terms ‘configured by the elastic material’ means that the lace is configured by a material having a property of elasticity. Examples of the elastic material include natural rubber and synthetic rubber. The lace may be configured to be rubber tube as shown in FIG. 12 by singularly using such material, or may be configured by combination of such materials and inelastic materials such as polyester, nylon, acryl or polyurethane. Therefore, according to this configuration where the entire lace body made of elastic material, the entire lace body can extend and shrink under tension in the axial direction, so that distortion is not easily caused on the respective portions of the lace, thereby providing the lace which is not easily torn under high tension which is repeatedly put on the lace body.
Effects of First Embodiment
According to the lace of the first embodiment having the above configuration, the lace can preserve the knobby portion under high tension, and can be repeatedly used, thereby solving the problem of the conventional technology.
Second Embodiment
Outline of Second Embodiment
FIG. 6 is a perspective view of an entire lace of a second embodiment. As show in FIG. 6 , the lace of the second embodiment is basically similar to that of the first embodiment, and the elastic material is braided by rubber and less-elastic normal material. This configuration enables extension and shrink in the axial direction without heavy load for the lace.
Functional Configuration of Second Embodiment
The configuration of the lace of the second embodiment is basically similar to that of the first embodiment as described with reference to FIG. 1 . Hereinafter, description of difference in configuration of the elastic material is mainly provided.
The ‘rubber-like material’ is a material having elasticity and a thread-like shape, and can well expand under tension in the axial direction. Note that the term ‘rubber-like material’ does not exclude a rubber material, and therefore, includes any type of rubber such as natural rubber and synthetic rubber. The configuration braided by the rubber-like material enables sufficient extension with small tension in the axial direction.
The ‘less-elastic normal material’ is fiber material with less elasticity in comparison with the rubber-like material. Therefore, the term ‘less-elastic’ is a technical term and means ‘poor in elasticity’ and does not mean ‘not elastic’. Examples of the less-elastic normal material include the polyester, nylon, acryl, and polyurethane. The configuration braided by such normal fiber materials with high line density enables to provide the lace with durability to tear. Moreover, using the normal material, it is possible to form various shape of knobby portions, which are hard to be formed in using only the rubber-like material.
The rubber-like material and the normal material configure the elastic material of the first embodiment by braiding them with each other. The term ‘braiding’ means general method for braiding the rubber-like material and the normal material in straight lines crossing each other diagonally. This configuration makes it possible to utilize both advantages of the rubber-like material and the normal material. Specifically, the rubber-like material is provided with durability to shrink and tear under strong tension in the axial direction by being braided with the normal material with high durability, and the normal material is provided with elasticity in the axial direction without heavy load by being braided with the rubber-like material.
Moreover, in the braiding, timing of crossing the materials and amounts of the materials to be used may be appropriately determined. Therefore, the ratio of the rubber-like material and the normal material may be equal, or may be 1:5 or 1:7 where the normal material is more used than the rubber-like material. Here, in order to secure the elasticity sufficient for performance of the lace of the first embodiment, for example, the suitable ratio between the rubber-like material and the normal material is approximately 1:7.
Hereinafter, a description of forming the knobby portion placed on the lace body of the first embodiment made by braiding the elastic material is provided. As described above, the knobby portion is necessary to be formed, such that the diameter thereof varies depending on tension on the knobby portion in an axial direction, and this function is necessary to be secured even in the braided configuration. Specifically, it is possible to make partial pitch variation in the braiding, for example, a portion of the lace may be loosely braided in comparison with other portions. This makes it possible to make deflection on the knobby portion, such that the knobby portion is more extendable, and to configure the lace body by the rubber-like material and normal material without patch of separately braided materials at the core and the end of the knobby portion.
Effects of Second Embodiment
According to the lace using the normal material of the second embodiment, in addition to the first embodiment, it is possible to provide laces of various designs, and to provide the lace not only with durability to tear. Moreover, the normal material reduces friction drag with the hole, and provides the lace with smoothness in moving.
Third Embodiment
Outline of Third Embodiment
FIG. 7 is a cross-section view of a lace of a third embodiment. As show in FIG. 7 , the lace of the third embodiment is basically similar to that of the first embodiment, and further comprises a ‘centrally-placed lace’ 0705 that is centrally placed in a ‘tube’ 0703 configured by tubular structure of the lace body, consists of less-elastic material, configures a core of the knobby portion, and is balled up at a ‘portion corresponding to knobby portion’ 0704 so as to follow a variation of distance between ends of the knobby portion in response to the variation of the diameter of the knobby portion. According to this configuration, it is possible to reduce difficulty in restoring the original state of the knobby portion due to repeated use of the lace.
Configuration of Third Embodiment
The configuration of the lace of the third embodiment is basically similar to that of the first embodiment as described with reference to FIG. 1 . Hereinafter, description of difference in configuration of the centrally-placed lace is mainly provided.
The ‘centrally-placed lace’ has a function of following a variation of distance between ends of the knobby portion in response to the variation of the diameter of the knobby portion, and is balled up at the portion corresponding to the knobby portion, thereby configuring the core of the knobby portion. The ‘variation of distance between ends of the knobby portion in response to the variation of the diameter of the knobby portion’ means that the variation of the diameter of the knobby portion is caused by the tension in the axial direction put the lace body, and the distance between ends of the knobby portion varies in response to the variation of the diameter. The ‘function of following’ the variation is, for example, when the distance between ends of the knobby portion is reduced, the after-mentioned balled-up portion of the centrally-placed lace further shrinks, and when the distance between ends of the knobby portion increases, the balled-up portion of the centrally-placed lace extends.
Here, the balled-up portion of the centrally-placed lace is made at the portion corresponding to the knobby portion. According to this configuration, the elastic material configuring the lace body forms the knobby portion along the portion corresponding to the knobby portion of the centrally-placed lace, so that the portion corresponding to the knobby portion works as the core for forming the knobby portion. Moreover, by internally placing the centrally-placed lace as the core, the knobby portion can preserve the firmness to endure the repeated use. Note that it is necessary to prevent position gap at the portion corresponding to the knobby portion in order to function the centrally-placed lace as the core of the knobby portion. In order to secure the function as the core of the knobby portion, it is required that the centrally-placed lace connects the respective portions corresponding to the knobby portion and has the thread-like form where it is fixed at the ends of the lace.
Note that since the centrally-placed lace is not necessary to extend or shrink the lace, the centrally-placed lace may be configured by inelastic material, not by elastic material. Therefore, even when putting the tension in the axial direction on the lace body and extending it, the centrally-placed lace does not extend like the rubber-like material. The centrally-placed lace has slightly longer than the lace body, and the ‘balled-up portion’ has, for example, a spirally-twisted form. According to this configuration, it is possible to reduce difficulty in restoring the original state of the knobby portion when the balled-up portion gets entangled in repeated use of the lace.
Effects of Third Embodiment
According to the lace having the configuration of the third embodiment, in addition to the first embodiment, it is possible to reduce difficulty in restoring the original state of the knobby portion of the lace body due to repeated use of the lace.
Fourth Embodiment
Outline of Fourth Embodiment
FIG. 8 is a view showing an outline of a lace of a fourth embodiment. As show in FIG. 8 , the lace of the fourth embodiment is basically similar to that of the first embodiment, and the diameter W1 of the ‘core of the knobby portion’ 0801 of the lace body is 1.5 times or more of the diameter W2 of the ‘end of the knobby portion’ 0802 of the lace body without tension in the axial direction. According to this feature in the shape of the knobby portion, the lace easily hooks on the hole, and can smoothly move upon adjusting its length.
Configuration of Fourth Embodiment
The configuration of the lace of the fourth embodiment is basically similar to that of the first embodiment as described with reference to FIG. 1 . Hereinafter, description of difference in diameter of the knobby portion is mainly provided.
The state ‘without tension in the axial direction’ is a state that tension on the lace does not exist. Under this state, for example as shown in FIG. 3 , the core of the knobby portion has the diameter greater than the ends of the knobby portion, and functions as a fixture by being hooked on the hole. Therefore, for the function of the knobby portion, the diameter of the core of the knobby portion is required to be greater than that of the hole.
Meanwhile, when the diameter of the core of the knobby portion becomes excessively greater, the balance in the shape of the entire lace is lost, thereby spoiling the appearance of the lace. Moreover, it is necessary to put excessive tension in the axial direction on the lace to reduce the diameter of the core of the knobby portion and level the diameter of the entire lace. It is assumed that the lace is daily used as the fixture by men and women of all ages, it is preferable that the diameter of the core of the knobby portion varies with the minimum tension in the axial direction, such that elders and children who are less powerful can use the lace. Therefore, it is preferable that the knobby portion easily hooks on the hole, and the diameter of the entire lace is easily leveled.
In this regard, by using the lace of the present invention, where the diameter of the core of the knobby portion on the lace body was 7 mm, and the diameters of the ends were 4 mm, it was possible to reduce the diameter of the core of the knobby portion and to level the lace body without putting heavy tension in the axial direction.
Effects of Fourth Embodiment
According to the lace having the configuration of the fourth embodiment, in addition to the first embodiment, the lace easily hooks on the hole, and can smoothly move upon adjusting its length.
Fifth Embodiment
Outline of Fifth Embodiment
FIG. 9 is a view showing an outline of a lace of a fifth embodiment. As show in FIG. 9 , the lace of the fifth embodiment is basically similar to that of the first embodiment, and the diameter W3 of the ‘core of the knobby portion’ 0901 of the lace body is 1.3 times or less of the diameter W4 of the ‘end of the knobby portion’ 0902 of the lace body under tension in the axial direction. According to this feature in the shape of the knobby portion, the lace can smoothly passes through the hole.
Configuration of Fifth Embodiment
The configuration of the lace of the fifth embodiment is basically similar to that of the first embodiment as described with reference to FIG. 1 . Hereinafter, description of difference in diameter of the knobby portion under tension is mainly provided.
The state ‘under tension in the axial direction’ is a state that tension is put on the lace. In this state, for example as shown in FIG. 2 , the diameter of the core of the knobby portion becomes smaller than that of the state without tension in the axial direction, and the lace can pass thorough the hole without hooking. Therefore, for the function of the knobby portion, the diameter of the core of the knobby portion is required to be sufficiently small for passing through the hole under tension in the axial direction. It is ultimately preferable that the ‘diameter sufficient small for passing through the hole under tension in the axial direction’ is the same as that of the ends of the knobby portion. However, in the lace of the present invention, the elastic material is used for the lace body, and the lace has the tubular shape. Therefore, there is a room inside the tube, and if the diameter of the core of the knobby portion is slightly greater than that of the ends, the knobby portion extends to the room inside the tube upon passing through the hole, hereby passing the hole having the same diameter as that of the ends.
In this regard, by using the lace of the present invention, where the diameter of the core of the knobby portion on the lace body was 7 mm, and the diameters of the ends were 4 mm, it was possible to make the lace pass through the hole having 4 mm diameter by putting the tension in the axial direction on the lace even in the state that the diameter of the core of the knobby portion was approximately 5 mm.
Effects of Fifth Embodiment
According to the lace having the configuration of the fifth embodiment, in addition to the first embodiment, the lace can smoothly passes through the hole.
Sixth Embodiment
Outline of Sixth Embodiment
FIG. 10 is an enlarged view of a braided portion of a lace body of a sixth embodiment. As show in FIG. 9 , the lace of the sixth embodiment is basically similar to that of the first embodiment, and the lace body is braided at 45 degrees angle to the axial direction. According to this feature, the lace can smoothly passes through the hole.
Configuration of Sixth Embodiment
The configuration of the lace of the sixth embodiment is basically similar to that of the first embodiment as described with reference to FIG. 1 . Hereinafter, description of difference in braiding angle of the lace body is mainly provided.
As shown in FIG. 10 , the terms ‘the lace body is braided at 45 degrees angle to the axial direction’ mean a state where the rubber-like material and the normal material are braided at approximately 45 degrees angle. As described above, it is preferable that the lace body can pass through the hole without hooking, and degree of the hooking can vary depending not only on the diameter of the knobby portion but also on surface shape of the knobby portion. Specifically, as the surface shape of the knobby portion gets smooth, the lace body can easily pass through the hole. Here, as the braiding angle gets wide, the braiding gets loose, thereby the lace easily hooks on the hole. Meanwhile, as the angle gets narrow, the diameter of the lace body is reduced, the diameter of the knobby portion relatively becomes greater, and it becomes difficult to make the diameter of the knobby portion small and to make the lace pass through the hole unless heavy tension in the axial direction is put on the lace.
In this regard, by using the lace of the present invention, where the lace body is braided by the rubber-like material and the normal material at approximately 45 degrees angle to the axial direction, it is possible to make the lace smoothly pass through the hole without causing the above problem.
Effects of Sixth Embodiment
According to the lace having the configuration of the fifth embodiment, in addition to the first embodiment, the lace can smoothly passes through the hole.
DESCRIPTION OF REFERENCE NUMERALS
0100 Lace
0101 Core of knobby portion
0102 End of knobby portion
0103 End
0200 Lace
0201 Core of knobby portion
0202 End of knobby portion
0701 Core of knobby portion
0702 End of knobby portion
0703 Tubular portion
0704 Portion corresponding to knobby portion
0705 Centrally-placed lace
1201 Core of knobby portion
1202 End of knobby portion | In the conventional lace with knobby portions having elastic rubber core, there is difference in degree of stretch between both ends and core of the knobby portion. Therefore, there are a portion that is subjected to heavy stretching force and a portion that is subjected to no stretching force, and when large strain is accumulated at the boundary between the portions subjected to different stretching forces and the strain reaches the limit, the lace ruptures. In order to solve the above problem, we provide a lace provided with tubular lace body of elastic material, comprising knobby portions repeatedly placed at intervals, of which diameter vary depending on tension on the knobby portion in an axial direction. | 3 |
[0001] The present application claims priority under 35 U.S.C. §119 to Korean Patent Application No. 10-2008-0137599 (filed on Dec. 30, 2008), which is hereby incorporated by reference in its entirety.
BACKGROUND
[0002] A packaging technique for a semiconductor integrated device is continuously developed with demands for miniaturization and high capacity. In recent years, various techniques for stack package satisfying miniaturization, high capacity, and packaging efficiency are developed. In the semiconductor industry, the term “stack” refers to a technique for piling up at least two semiconductor chips or packages. This technique ensures implementation of products having memory capacity larger than memory capacity which can be implemented in a process for integrating a semiconductor in a memory device and an increase in use efficiency of a packaging area.
[0003] In accordance with the manufacturing technique, a stack package is classified into a method of stacking individual semiconductor chips and then packages the stacked semiconductor chips at a time and a method of stacking individually packaged semiconductor chips. In general, the stack package is electrically connected through metal wires or a through silicon via.
[0004] A stack package using metal wires has at least two semiconductor chips stacked on a substrate through an adhesive, and the respective chips and the substrate are electrically connected to each other through the metal wire. However, in the stack package using the metal wires, electrical signals are exchanged through the metal wire, which leads to a low operation speed, requires a large number of wires, and consequently causes deterioration in the electrical characteristics of the chips. Further, to form the metal wires, an additional area is required on the substrate, which causes an increase in the package size. In addition, a gap needs to be provided for wire-bonding to the bonding pads of the respective chips, which results in an increase in the total height of the package.
[0005] To overcome these problems in the stack package using the metal wires, a stack package structure using a through electrode is proposed for preventing deterioration in the electrical characteristics of the stack package and reduction in size.
[0006] FIG. 1 is a sectional view illustrating a stack package using a through electrode.
[0007] As illustrated in FIG. 1 , in the stack package using through electrodes, first semiconductor chip 10 is disposed at a bottom surface thereof and then second semiconductor chip 20 having through electrode 21 formed therein is stacked on and/or over first semiconductor chip 10 . In this case, a metal wire of first semiconductor chip 10 and through electrode 21 of second semiconductor chip 20 are bonded to each other by bumps 41 and bonding agent 43 . Third semiconductor chip 30 having through electrode 31 formed therein is stacked on and/or over second semiconductor chip 20 . Through electrode 31 of third semiconductor chip 30 is electrically connected to through electrode 21 of second semiconductor chip 20 or the metal wire by bumps 41 or bonding agent 43 . In this way, in the stack package using the through electrodes, electrical connection is made through the through electrodes. Therefore, electrical deterioration can be prevented, such that the operation speed of the semiconductor chips can be enhanced and miniaturization can be achieved.
[0008] The through electrode refers to a via of tens or hundreds rim. Accordingly, to form a through electrode of such size, it takes a lot of time and costs to the extent of several or tens times as much as a general semiconductor process. Moreover, yield is considerably low due to defects occurring when the through electrode is formed, defects when the devices are connected to each other through the bumps, and the like. Three or more devices are consumed due to one defect occurring during packaging, which causes an increase in the process costs of the products.
SUMMARY
[0009] Embodiments relates to a semiconductor package apparatus and a method of manufacturing the same that integrates a plurality of semiconductor devices without through electrode.
[0010] Embodiments relate to a semiconductor package apparatus and a method of manufacturing the same that does not require a through electrode needs to be formed, thereby preventing the occurrence of defects caused by the through electrode.
[0011] Embodiments relate to a semiconductor package apparatus and a method of manufacturing the same that simplifies the structure of the semiconductor chip, reduces the overall process time enhances overall production yield.
[0012] In accordance with embodiments, a semiconductor package apparatus can include at least one of the following: a first semiconductor chip bonded to a substrate with a metal wire turning upward, a second semiconductor chip conductively bonded to the first semiconductor chip in a vertical direction such that a metal wire of the second semiconductor chip and the metal wire of the first semiconductor chip have facing points, and a third semiconductor chip conductively bonded to the first semiconductor chip in a vertical direction so as to be disposed horizontally with respect to the second semiconductor chip such that a metal wire of the third semiconductor chip and the metal wire of the first semiconductor chip have facing points.
[0013] In accordance with embodiments, a method of manufacturing a semiconductor package apparatus can include at least one of the following: bonding a first semiconductor chip to a substrate with a metal wire turning upward, conductively bonding a second semiconductor chip to the first semiconductor chip in a vertical direction such that a metal wire of the second semiconductor chip and the metal wire of the first semiconductor chip having facing points, and then conductively bonding a third semiconductor chip to the first semiconductor chip in the vertical direction so as to be disposed horizontally with respect to the second semiconductor chip such that a metal wire of the third semiconductor chip and the metal wire of the first semiconductor chip having facing points.
[0014] In accordance with embodiments, a semiconductor package apparatus can include at least one of the following: a first semiconductor chip having bonded to a substrate; a first wire formed in the first semiconductor chip; a second semiconductor chip conductively bonded to the first semiconductor chip; a second wire formed in the second semiconductor chip, wherein the second metal wire of the second semiconductor chip is bonded to the first metal wire of the first semiconductor chip; a third semiconductor chip conductively bonded to the first semiconductor chip; and a third wire formed in the third semiconductor chip, wherein the third metal wire of the second semiconductor chip is bonded to the first metal wire of the first semiconductor chip.
[0015] In accordance with embodiments, a semiconductor package apparatus can include at least one of the following: a substrate; a first semiconductor chip bonded to the substrate, the first semiconductor chip having a first metal wire formed therein; a second semiconductor chip conductively bonded to the first semiconductor chip, the second semiconductor chip having a second metal wire formed therein; and a third semiconductor chip conductively bonded to the first semiconductor chip such that the third semiconductor chip is disposed laterally relative to the second semiconductor chip, the third semiconductor chip having a third metal wire formed therein, the second semiconductor chip being conductively bonded to the first semiconductor chip at an interface between the first metal wiring and the second metal wiring and the third semiconductor chip being conductively bonded to the first semiconductor chip at an interface between the first metal wiring and the third metal wiring.
[0016] In accordance with embodiments, a semiconductor package apparatus can include at least one of the following: a substrate; a first semiconductor chip having a plurality of first metal wires formed therein, the first semiconductor chip being bonded to the substrate at a first surface of the first semiconductor chip such that a second surface of the first semiconductor chip is exposed; a second semiconductor chip having a plurality of second metal wires formed therein that are spatially aligned and corresponds to a first set of the first metal wires, the second semiconductor chip being conductively bonded to the first semiconductor chip at the exposed second surface of the first semiconductor chip and at an interface between the second metal wires and the first metal wires; and a third semiconductor chip having a plurality of third metal wires formed therein that are spatially aligned and corresponds to a second set of the first metal wires, the third semiconductor chip being conductively bonded to the first semiconductor chip at the exposed second surface of the first semiconductor chip on the same plane as the second semiconductor chip and at an interface between the third metal wires and the first metal wires.
DRAWINGS
[0017] FIG. 1 illustrates a stack package using through electrodes.
[0018] Example FIGS. 2A to 7 illustrate a method of manufacturing a semiconductor package and a bonding structure of semiconductor chips, in accordance with embodiments.
DESCRIPTION
[0019] Hereinafter, embodiments will be described in detail with reference to the accompanying drawings which form a part hereof.
[0020] Example FIGS. 2A to 2C are views illustrating a method of manufacturing a semiconductor package apparatus in accordance with embodiments.
[0021] First, the structure of a semiconductor package apparatus in accordance with embodiments will be described with reference to example FIG. 2C .
[0022] As illustrated in example FIG. 2C , the semiconductor package apparatus includes first semiconductor chip 120 having at least a first metal wire formed therein. First semiconductor chip 120 is bonded to substrate 110 at a first surface thereof such that a second surface thereof is exposed.
[0023] Second semiconductor chip 130 has at least a second metal wire formed therein. Second semiconductor chip 130 is conductively bonded to first semiconductor chip 120 at the exposed second surface of first semiconductor chip 120 . Particularly, second semiconductor chip 130 is conductively bonded to first semiconductor chip 120 at interface 201 between the second metal wire of second semiconductor chip 130 and the first metal wire of first semiconductor chip 120 .
[0024] Third semiconductor chip 140 has at least a third metal wire formed therein. Third semiconductor chip 140 is conductively bonded to first semiconductor chip 120 at the exposed second surface of first semiconductor chip 120 . Particularly, third semiconductor chip 130 is conductively bonded to first semiconductor chip 120 at interface 201 between the third metal wire of third semiconductor chip 140 and the first metal wire of first semiconductor chip 120 . Accordingly, second semiconductor chip 130 and third semiconductor chip 140 are conductively bonded to first semiconductor chip 120 such that they are disposed laterally adjacent to each other.
[0025] Details of a process for manufacturing a semiconductor package apparatus configured as above will be described.
[0026] As illustrated in example FIG. 2A , first semiconductor chip 120 is bonded to substrate 110 in a vertical direction. First semiconductor chip 120 is bonded to substrate 110 at a first surface of first semiconductor chip 120 such that a second surface of first semiconductor chip 120 is exposed. Particularly, first semiconductor chip 120 is disposed such that the first metal wire formed therein is exposed. Substrate 110 and first semiconductor chip 120 may be bonded to each other using, e.g., resin or epoxy.
[0027] As illustrated in example FIG. 2B , second semiconductor chip 130 is conductively bonded to first semiconductor chip 120 in a vertical direction. Second semiconductor chip 130 is conductively bonded to first semiconductor chip 120 at the exposed second surface of first semiconductor chip 120 . Second semiconductor chip 130 is disposed such that the second metal wire formed therein corresponds spatially to the first metal wire of first semiconductor chip 120 . Second semiconductor chip 130 is conductively bonded to first semiconductor chip 120 at interface 201 between the second metal wire of second semiconductor chip 130 and the first metal wire of first semiconductor chip 120 . The bonding method between first semiconductor chip 120 and second semiconductor chip 130 may be implemented in various ways, and will be described below with reference to example FIGS. 3 to 7 .
[0028] As illustrated in example FIG. 2C , third semiconductor chip 140 is conductively bonded to first semiconductor chip 120 in a vertical direction such that it is disposed laterally with respect to second semiconductor chip 130 and vertically with respect to first semiconductor chip 120 . Third semiconductor chip 140 is conductively bonded to first semiconductor chip 120 at the exposed second surface of first semiconductor chip 120 . Third semiconductor chip 140 is disposed such that the third metal wire formed therein corresponds spatially to the first metal wire of first semiconductor chip 120 . Third semiconductor chip 140 is conductively bonded to first semiconductor chip 120 at interface 201 between the third metal wire of third semiconductor chip 140 and the first metal wire of first semiconductor chip 120 . The bonding method between first semiconductor chip 120 and third semiconductor chip 140 may be implemented in various ways, and will be described below with reference to example FIGS. 3 to 7 .
[0029] As described above, with the method of manufacturing a semiconductor package apparatus in accordance with embodiments, first semiconductor chip 120 is first bonded to substrate 110 . Accordingly, even if second semiconductor chip 130 and third semiconductor chip 140 are different in thickness, a semiconductor package apparatus can be manufactured by vertical and horizontal adhesion.
[0030] In accordance with embodiments, since second semiconductor chip 130 and third semiconductor chip 140 , i.e., other than first semiconductor chip 120 as a reference, are present in a form of flip chips, second semiconductor chip 130 and third semiconductor chip 140 can be electrically connected directly to first semiconductor chip 120 at the same exposed surface of first semiconductor chip 120 . Therefore, no formation of one or more through electrodes is required.
[0031] Therefore, in accordance with embodiments, since no through electrode needs to be formed, defects that may occur when a through electrode is formed can be prevented, the structure of the semiconductor chip can be simplified, and a process time can be reduced, which ensures enhanced in yield.
[0032] Example FIGS. 3 to 7 are sectional views illustrating the bonding structure of semiconductor chips in accordance with embodiments.
[0033] Example FIG. 3 is a sectional view illustrating the bonding structure of semiconductor chips in accordance with embodiments.
[0034] As illustrated in example FIG. 3 , first semiconductor chip 311 , second semiconductor chip 312 , third semiconductor chip 312 , conductive film 313 and a metal ball 314 are provided. The metal wires of two of the semiconductor chips can be conductively bonded to each other using conductive film 313 and metal ball 314 . Metal ball 314 may be composed of Au.
[0035] Example FIG. 4 is a sectional view of the bonding structure of semiconductor chips in accordance with embodiments.
[0036] As illustrated in example FIG. 4 , first semiconductor chip 321 , second semiconductor chip 322 , third semiconductor chip 322 , conductive film 323 , metal bumps 324 and anisotropic conductive film (ACF) 325 are provided. The metal wires of two of the semiconductor chips using conductive film 323 , metal bumps 324 and ACF 325 are conductively bonded together. Metal bumps 324 can be composed of Au bump.
[0037] Example FIG. 5 is a sectional view illustrating a bonding structure of semiconductor chips in accordance with embodiments.
[0038] As illustrated in example FIG. 4 , first semiconductor chip 331 , second semiconductor chip 332 or third semiconductor chip 332 , conductive film 333 , metal bump 334 , and photopolymerizable resin 335 are provided. The metal wires of two of the semiconductor chips can be conductively bonded to each other using conductive film 333 , metal bump 334 , and photopolymerizable resin 335 . Metal bump 334 can be composed of Au and photopolymerizable resin 335 can be composed of an ultraviolet (UV) curable resin.
[0039] Example FIG. 6 is a sectional view illustrating a bonding structure of semiconductor chips in accordance with embodiments.
[0040] As illustrated in example FIG. 6 , first semiconductor chip 341 , second semiconductor chip 342 or third semiconductor chip 342 , conductive film 343 , and conductive particles 344 are provided. The metal wires of two of the semiconductor chips can be conductively bonded to each other using conductive film 343 and conductive particle 344 .
[0041] Example FIG. 7 is a sectional view illustrating a bonding structure of semiconductor chips in accordance with embodiments.
[0042] As illustrated in example FIG. 7 , first semiconductor chip 351 , second semiconductor chip 352 or third semiconductor chip 352 , conductive film 353 , conductive particles 354 and photopolymerizable resin 355 are provided. The metal wires of two of the semiconductor chips can be conductively bonded to each other using conductive film 353 , conductive particles 354 , and photopolymerizable resin 355 . Photopolymerizable resin 355 can be composed of a UV curable resin.
[0043] Although embodiments have been described herein, it should be understood that numerous other modifications and embodiments can be devised by those skilled in the art that will fall within the spirit and scope of the principles of this disclosure. More particularly, various variations and modifications are possible in the component parts and/or arrangements of the subject combination arrangement within the scope of the disclosure, the drawings and the appended claims. In addition to variations and modifications in the component parts and/or arrangements, alternative uses will also be apparent to those skilled in the art. | A semiconductor package apparatus includes a first semiconductor chip bonded onto a substrate of which metal wire turning upward; and a second semiconductor chip conductively bonded onto the first semiconductor chip in a vertical direction such that a metal wire of the second semiconductor chip and the metal wire of the first semiconductor chip have facing points. The semiconductor package apparatus includes a third semiconductor chip conductively bonded onto the first semiconductor chip in the vertical direction to be disposed horizontally with the second semiconductor chip such that a metal wire of the third semiconductor chip and the metal wire of the first semiconductor chip have facing points. | 7 |
BACKGROUND OF THE INVENTION
The present invention relates to medical equipment and more particularly to surgical apparatus for suturing organs and tissues with metal staples. The proposed apparatus can find application in oncology for suturing the walls of the pharynx in laryngectomy in case of cancer as well as for suturing organs and tissues in the chest or abdominal cavity, e.g., the tissues of lungs, the stump of the stomach, intestines, and other organs.
Known in the art is a surgical apparatus for suturing organs and tissues with metal staples this known apparatus comprises a hook-shaped frame with a clamp member rigidly connected to the other part of the frame and having on the side facing the frame opening, a flat portion on which are recesses for bending the staple legs. Mounted in the frame for perpendicular travel relative to the above clamp member is a staple head provided with a holder for staples and with a staple pusher. Said staple head and pusher are provided with corresponding drives for their travel relative to the clamp member.
The holder has through slots for accommodation of metal staples therein. Said slots accurately match the recesses provided on the clamp member of the frame. The pusher has lugs corresponding to the holder slots. With the pusher moving toward the clamp member of the frame, the pushing lugs fit into the holder slots and push staples out of them.
Inserted in the staples head is an arresting fork for preventing a tissue or an organ being sutured from slipping out of the apparatus.
When applying the surgical apparatus, a tissue or an organ to be sutured should be between the flat portion of the clamp member and the operating face of the holder opposing said flat portion.
In such a position, the tissue or organ being sutured is inserted through the open lateral mouth of the hooked frame; then the tissue or organ is fixed by the arresting fork. The surgeon actuates the drive of the staple head bringing it closer to the clamp member so that a clearance necessary for suturing is set between the flat portion of the clamp member and the operating face of the holder. Thereafter the suturing of tissues is done by actuating the pusher drive; the lugs of the pusher pass through the holder slots and push the staples thereout; on puncturing the tissues being sutured, the staple legs strike against the recesses provided on the flat portion of the clamp member and are bent, thus suturing the tissues. The tissue portion to be disposed of is cut off, the holder is withdrawn from the clamp member, and the whole apparatus is removed from the operation incision.
A disadvantage of the known apparatus is its limited maneuverability that restricts its application for suturing in areas difficult of access, or for suturing under peculiar conditions when the space is limited for manipulations necessary to prepare the apparatus for the operation. This disadvantage is due to the design of the hooked frame shaped as a hook which permits the positioning of the holder and the clamp member of said frame to tissues being sutured only through the lateral opening of the frame. Whenever such positioning is not possible at all, or involves intolerable injury to the tissues being sutured or to the environmental tissues or organs because of shortage of space required for unimpeded manipulation with the apparatus in the operation cut, the use of the apparatus is actually impossible. Thus, in laryngectomy in cases of cancer with the aid of the known apparatus, the positioning of the clamp member of the frame and the holder under the tumor being operated on is possible only from the side of the chin or the chest which are distant from the suturing site. This is fraught with awkward and complicated manipulations in a limited space between the cutoff tumor and the remaining organs and tissues of the head and neck of a patient, which, moreover, result in tissue injury.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a surgical apparatus for suturing organs and tissues with metal staples, the design of which would permit a traumatic positioning of the apparatus to tissues being sutured, as well as make it possible to suture not only organs of the chest and the abdominal cavity to which access is rather simple, but also organs and tissues which are difficult-of-access for the suturing operation; this extends the applications of this surgical apparatus.
The object of the invention is achieved in a surgical apparatus for suturing organs and tissues with metal staples, which comprises a frame with a clamp member being part of said frame and having, from the side of the frame opening, a flat portion made on which are recesses for bending the staple legs, a stapler head with a staple holder and a staple pusher fitted with corresponding drives and mounted on said frame for perpendicular travel relative to the flat portion of the clamp member, wherein, according to the invention, the clamp member is connected to the other part of the frame to facilitate the withdrawal of said clamp member so as to permit the positioning of tissues being sutured to the holder from the side of the clamp member.
It is expedient that the frame be made as a U-shaped brace with a clamp member attached to its ends, one end being hinged and the other being secured with a spring lock.
It is desirable that a spring lock be provided in the place where the clamp member is hinged to the U-shaped brace, as would hold the clamp member in a withdrawn position.
The spring lock may have a groove interacting with the end of the clamp member used to hold the clamp member in a partly withdrawn position.
The clamp member can be made as a U-shaped brace and secured on the other part of the frame, both of its ends being made disconnectable.
In this case, the clamp member can be held on the other part of the frame by means of channels provided on the ends of said member and inclined relative to the longitudinal axis of the frame as well as by means of joint pins secured on the frame to fit into these channels; moreover, the clamp member can be tightened by a spring available on the frame in a direction preventing the removal of the clamp member from said joint pins.
The proposed surgical apparatus features higher maneuverability and greater functional potentialities as compared with the known one, because it permits operations not only on organs of the chest or the abdominal cavity, but is found good for operations on other organs the access to which for suturing by known apparatuses is either difficult or practically impossible. Specifically, the proposed apparatus permits suturing of the walls of the pharynx in laryngectomy in case of cancer, the bringing of the clamp member of the frame, and the holder of the apparatus, to a suturing site being carried out laterally relative to the pharynx, which is much simpler and is not fraught with traumas to the pharynx and the remaining environmental tissues.
Unlike manual suturing of the pharynx walls employed presently in laryngectomy after cutting off the tumor being removed, the employment of the proposed apparatus helps to sharply reduce infection in the operation cut and in the pharynx by the content of the tumor being removed --as an initial operation involves suturing the pharynx walls, overlapping the opening of the portion being removed with the aid of a special clip, and subsequent cutting off of the tumor between the apparatus and a clip --improves the conditions for the regeneration of tissues, whose suturing is as a rule, effected after radiation therapy, and reduces appreciably the time required for suturing the pharynx and reduces post-operation effects.
The provision of the apparatus with a detachable clamp member according to the invention helps improve the maneuverability of the apparatus while its being brought to a suturing site in a tight and difficult-of-access cavity, because it permits initially placing of the detached clamp member under an organ being sutured and then attaching to said member to the other part of the apparatus, which is much bigger than the clamp member.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will become more apparent from the description of exemplary embodiments and drawings, wherein:
FIG. 1 shows schematically a surgical apparatus for suturing organs and tissues with metal staples, according to the invention, with portions broken away and sectional;
FIG. 2 is a section on line II--II in FIG. 1;
FIG. 3 is an enlarged section on line III--III in FIG. 2;
FIG. 4 is a fragmentary elevation of the frame with a clamp member, according to the invention;
FIG. 5 is another embodiment of the frame with a clamp member, according to the invention;
FIG. 6 is a section on line VI--VI in FIG. 4;
FIG. 7 is a section on line VII--VII in FIG. 4;
FIG. 8 shows a detail taken, on arrow A in FIG. 4;
FIG. 9 is a section on line IX--IX in FIG. 5.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The surgical apparatus for suturing tissues with staples comprises a frame 1 (FIG. 1) provided with a clamp member 2 having an opening bracketed by a pair of parts, and , from the side of the opening of the frame 1, a flat portion 3 made on which are recesses R for bending the staple legs; see FIG. 2. Attached to the frame 1 is a staple head 4, and a holder 5 and a pusher 6 are inserted into head 4. The holder 5 has through slots 7 for the accommodation of staples therein and the pusher 6 has lugs 8 intended for pushing staples from said holder 5. The craters of the member 2, the slots 7 of the holder 5, and the lugs 8 of the pusher 6 are arranged to correspond to each other.
Coupled with the frame 1 is a stem 9 provided with a groove 10 arranged perpendicular to the flat portion 3 of the clamp member 2 of the frame 1. The staple head 4 has a rod 11, while the pusher 6 has a rod 12 (FIG. 2) provided in the groove 10 of the stem 9 of the frame 1. The rod 11 is made to have an exterior thread 13 at its end in order to accept a nut 14, and is provided with a threaded hole 15 inserted into which is a screw 16. The nut 14 is a drive of the staple head 4 and has a circular groove 17 for interacting with the stem 9 of the frame 1. The screw 16 is a drive for the pusher 6 and has a circular groove 18 (FIGS. 2 and 3) at one of its ends, coupled with which is a fork at the end of the rod 12 of the pusher 6 (FIG. 2), while the other end has a hole 19 with grooves 20 (FIG. 1) inserted into which is a detachable handle 21 of the drive of the pusher 6 with lugs 22 for interaction with the grooves 20. Connected rigidly with the stem 9 of the frame 1 is a handle 23 for holding the apparatus. The staple head 4 has lateral grooves 24 which interact, as said head 4 moves relative to the clamp member 2, with the lateral sides of the frame 1. The rod 11 of the staple head 4 is made to have lugs 25 for interacting with the corresponding grooves of the stem 9 of the frame 1.
The drawings of the invention show two exemplary embodiments of the frame 1 (FIGS. 4 and 5). In both embodiments, the frame 1 is made closed, but, in principle, it can be made not closed too, as, e.g., in the form of a hook. What is important is that the clamp member 2 (FIG. 4) or 26 (FIG. 5) should be linked with the other portion of the frame. Further, member 2 should have the capability of being withdrawn from the other frame portion so as to permit the holder 5 an access to tissues from the side of the clamp member 26 or 2 (FIG. 4).
In the first embodiment, shown in FIG. 4, the frame 1 is made as a U-shaped brace 27 secured to whose ends is a clamp member 2 in the form of a pivotal plate. One end 28 of the clamp member 2 is connected to the brace 27 by means of a hinge 29 (FIGS. 4 and 6), while the other end 30 (FIG. 4) is connected to the same brace by means of a lock 31 which grips a pin 32 (FIGS. 4 and 7) on the clamp member 2. Said lock 31 (FIG. 4) is arranged on a rocking bar 33 coupled with the brace 27 of the frame 1 by means of an axle 34, and is pressed against the pin 32 by a spring 35 secured on the rocking bar 33 and fixed in that position by means of a turnable cam 36 provided with a lever 37. The lever 37 has a lug 38 (FIG. 8) adapted to act on the rocking bar 33 (FIG. 4) when the lever 37 turns toward the frame 1, this is necessary for disengaging the lock 31 from the pin 32 of the clamp member 2. The axle 34 and the cam 36 are secured on the brace 27 with the aid of a detachable plate 39 (FIGS. 1 and 7).
Depending on the anatomic and topographic position of an organ being sutured and on an access to it, the clamp member 2 is expediently placed in a different initial position with respect to the brace 27 (FIG. 4) of the frame 1.
In the initial position, when the apparatus is brought to a portion being sutured, the clamp member 2 is withdrawn and set in a position 40, being an extension of the lateral side of the brace 27 of the frame 1. In such withdrawn position 40, the clamp member 2 is locked by a spring lock 41 secured by one of its ends onto the lateral side of the brace 27. The lock 41 is made with a groove 42 which interacts with the end 28 of the clamp member 2 and locks it in a position 43 at an angle 25°-40° to its working position. Thanks to the fact that the clamp member 2 is able to be set in the partly withdrawn position 43, convenient use is made for the apparatus to suture organs and tissues of the chest and the abdominal cavity being in the depth of an operating wound. When the clamp member 2 is set in its working position, the pin 32 acts on an inclined surface 44 of the lock 31.
In the second embodiment, the clamp member 26 (FIG. 5) of the frame 1 is made as a detachable part whose ends are releasably to the other part of the frame 1. The clamp member 26 in the embodiment shown in FIG. 5 is an U-shaped brace whose lateral sides have on their ends closed type slots 45 inclined relative to the longitudinal axle of the frame 1 for connection with pins 46 (FIGS. 5 and 9) rigidly coupled with the other part of the frame 1.
The frame 1 (FIG. 5) is equipped with a spring 47 designed to press the walls of the slots 45 to the pins 46 and ensure the easy and dependable connection of the clamp member 26 with the rest of the frame 1.
The surgical apparatus with the clamp member 2 (FIG. 4) made as a folding-back plate operates in the following way:
For setting clamp member 2 into its initial position, it is necessary to press the lever 37 of the cam 36 against the frame 1. This is accomplished by pressing on the rocking bar 33; bar 33 thus turns to disengage the lock 31 from the pin 32 of the clamp member 2; taking the end 30 of said clamp member 2 it is necessary to turn it until it stops in a position 40. In this position 40, the clamp member lies along the lateral side of the U-shaped brace 27 of the frame 1.
Then, for suturing, for instance, the walls of the pharynx, it is necessary to draw up the larynx prepared for a surgical removal as much as possible and to bring the apparatus from the side under the larynx (perpendicular to the mouth axis) so that the lateral sides of the opened frame 1 should pass under the dissected tissues near the tongue root and envelop the larynx portion being sutured from the side of the chest and the chin.
For connecting the clamp member 2 with the lock 31, it is necessary to turn the clamp member 2 around the hinge 29 until it rests against the frame 1, the lock 31 gripping, under the action of the spring 35 of the rocking bar 33, the pin 32 of said member 2. By reversely turning the lever 37 up to the stop, the cam 36 is made to fix the bar 33 and the clamp member 2 in the operating position.
By turning the nut 14 (FIG. 1) of the staple head 4, the tissues between the clamp member 2 and the holdeer 5 are pressed and a suturing clearance is set, while the rotation of the handle 21 of the screw 16 of the pusher 6 results in pushing staples out of the holder 5 and suturing.
A special clamp is put on the portion of the pharynx walls being removed for overlapping the opening of this portion and preventing the operation cut from infection, and the tissues between said clamp and the apparatus are dissected with scalpel thereafter. Once the portion of the pharynx and the larynx is removed, the holder 5 is brought away from the clamp member 2 by turning the nut 14 of the staple head 4 in an opposite direction and the apparatus is withdrawn from the operation cut.
If it is necessary to place the clamp member 2 in an intermediate position 43 (FIG. 4) for bringing it under the organ being sutured, which may be deep in the operation cut in the chest or abdominal cavity. The clamp member 2 should be turned, prior to the apparatus application, unless the end 28 of the clamp member 2 is locked by means of the groove 42 of the spring lock 41. The rest of the apparatus operations correspond to the phases considered for the case of the apparatus application for suturing the pharynx.
The apparatus with a detachable clamp member 26 (FIG. 5) operates in the following way.
By pressing on the clamp member 26 in the direction of a spring 47, the slots 45 are brought out of engagement with the pins 46 and the clamp member 26 is disconnected from the other part of the frame 1. Then said clamp member 26 is brought to a suturing site.
To arrange the tissues being sutured between the clamp member 26 and the holder, said clamp member 26 should be connected with the other part of the frame 1 by inserting pins 46 into closed-type sloped slots 45.
In doing so, one of the lateral sides of the brace of the clamp member 26 should be arranged between the spring 47 and the pin 46 and both of the sides of the brace should be pressed against the other part of the frame 1. Upon releasing the clamp member 26, the spring 47 biases the member 26 onto the pins 46 of the frame 1. Thereafter the operation according to the second variant does not differ from the operation of the apparatus fitted with the clamp member 2 (FIG. 4) made as the folding back plate. | A surgical apparatus for suturing organs and tissues with metal staples, comprising a frame provided with an opening and a clamp member having, on a side facing the frame opening, a flat portion provided with recesses for bending staples, a staple head with a staple holder and a staple pusher, both mounted on the frame for perpendicular travel relative to the clamp member, as well as drives for the staple head and pusher. The clamp member is releasable connected to part of the frame, which permits tissues being sutured being brought to the holder from the flat portion side of said clamp member. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is related to U.S. application Ser. No. 10/938,412, filed on Sep. 10, 2004.
BACKGROUND
[0002] This description relates to enterprise application performance monitors.
[0003] Applications of an enterprise (“enterprise applications”) are typically implemented as multi-tier applications distributed over numerous computing systems. An example of a multi-tier application is a three-tier application having a data tier, a middle tier, and a client tier. The data tier can be comprised of one or more databases, which together contain the data relevant to the application. The middle tier acts as an intermediary between data in the data tier and the application's clients, managing interactions between application clients and application data. The middle tier controls and processes business logic, including how clients access data, how the application processes data, and how content is presented to clients. The client tier provides the application's user interface (e.g., a browser-based graphical user interface for a thin client application program or a thick client application program). Users communicate with the enterprise application through the user interface. The client tier interacts with the middle tier to make requests and to retrieve data from the data tier. The client tier then displays to the user the data retrieved from the middle tier. Conventionally, performance of an enterprise application is measured on an end-to-end round-trip basis from the start of a request by a user (e.g., as indicated by a depressing of a key or a button) to the time when the user can use the data supplied in response to the request.
SUMMARY
[0004] In general, in one aspect, the invention provides methods and apparatus, including computer program products, implementing techniques for receiving a first information related to a first transaction associated with a first user session with a multi-tier enterprise application, the first information including performance data that is representative of how well components in at least two tiers of the enterprise application perform in executing the first transaction; and determining based on the first information whether the first transaction is associated with a prioritized aspect of the enterprise application, and if so, taking an action based on the determining.
[0005] Implementations of the invention may include one or more of the following features.
[0006] The techniques for receiving a first information include techniques for receiving information related to a plurality of transactions, the received information including the first information. The plurality of transactions may be associated with the first user session. The received information may include performance data that is representative of how well components in at least two tiers of the enterprise application perform in executing respective ones of the plurality of transactions. The first transaction may correspond to an instance of a user request for data stored on one or more components in a data tier of the enterprise application. The first information may include performance data that is defined using a time-based metric.
[0007] The techniques for determining whether the first transaction is associated with a prioritized aspect of the enterprise application may include examining the first information to determine whether the first information includes an indicator that the first transaction corresponds to an instance of a user request for an aspect of the enterprise application that is associated with one of the following: a business critical function, a secondary function, or a tertiary function. The first transaction may correspond to an instance of a user request for an aspect of the enterprise application, and the techniques for determining whether the first transaction is associated with a prioritized aspect of the enterprise application may include examining the first information to identify a prioritization level that is associated with the user requested aspect. The prioritization level may include at least two discrete prioritization levels.
[0008] The enterprise application may be a web-based enterprise application and the first transaction may correspond to an instance of a user request for a web page that includes one or more objects formed by data stored on one or more components in a data tier of the enterprise application.
[0009] The techniques for determining whether the first transaction is associated with a prioritized aspect of the web-based enterprise application may include techniques for determining whether the first transaction is associated with a user request for a business critical function web page, a secondary function web page, or a tertiary function web page. The techniques for taking an action may include identifying a target performance value for the first transaction; and comparing the performance value included in the first information with the identified target performance value to determine whether the components in the at least two tiers of the enterprise application performed satisfactorily in executing the first transaction. The techniques for taking an action may include identifying a target performance value for each monitored element of the enterprise application that is involved in the first transaction; and for each monitored element, comparing its performance value included in the first information with its target performance value to determine whether the monitored element performed satisfactorily during the first transaction.
[0010] The techniques may further include providing in a graphical user interface, a visual indicator of a performance of the enterprise application in executing a plurality of transactions associated with one or more user sessions with the enterprise application, each of the plurality of transactions being associated with a prioritized aspect of the enterprise application, the first transaction being one of the plurality of transactions. The visual indicator may include one or more of the following: a pie chart, a bar version of a histogram, and a histogram. The visual indicator may provide a visual representation of a degree at which the performance of the enterprise application satisfies a customer experience while interacting with the enterprise application. The visual indicator may provide a visual cue to an enterprise application provider of a presence of a performance-related issue in the enterprise application that has a negative effect on the performance of the enterprise application. The visual indicator may further provide a visual cue to the enterprise application provider of an extent to which the performance-related issue in the enterprise application has a negative effect on the performance.
[0011] The techniques may further include providing in a graphical user interface, a visual indicator of a performance of one or more monitored elements of the enterprise application during an execution of a transaction associated with a user session with the enterprise application. The one or more monitored elements may include one or more of the following: a web page of the enterprise application, and a data service producer of the enterprise application. Each of the one or more monitored elements may be associated with a customer impact identifier. The customer impact identifier may include one of the following: a business critical function identifier, a secondary function identifier, and a tertiary function identifier.
[0012] In general, in another aspect, the invention features a system that includes an application performance monitoring tool operable to receive a first information related to a first transaction associated with a first user session with a multi-tier enterprise application, the first information including performance data that is representative of how well components in at least two tiers of the enterprise application perform in executing the first transaction; and determine based on the first information whether the first transaction is associated with a prioritized aspect of the enterprise application, and if so, take an action based on the determination.
[0013] Implementations of the invention may include one or more of the following features.
[0014] The application performance monitoring tool may receive the first information from a monitoring database that stores information related to transactions associated with user sessions with the enterprise application, the user sessions including the first user session. The monitoring database may store performance data that is representative of how well components in at least two tiers of the enterprise application perform in executing respective ones of the plurality of transactions. The first transaction may correspond to an instance of a user request for data stored on one or more components in a data tier of the enterprise application. The first information may include performance data that is defined using a time-based metric.
[0015] The application performance monitoring tool may be operable to determine whether the first transaction is associated with a prioritized aspect of the enterprise application by examining the first information to determine whether the first information includes an indicator that the first transaction corresponds to an instance of a user request for an aspect of the enterprise application that is associated with one of the following: a business critical function, a secondary function, or a tertiary function. The first transaction may correspond to an instance of a user request for an aspect of the enterprise application. The application performance monitoring tool may be operable to determine whether the first transaction is associated with a prioritized aspect of the enterprise application by examining the first information to identify a prioritization level that is associated with the user requested aspect. The prioritization level may include at least two discrete prioritization levels.
[0016] The application performance monitoring tool may be further operable to identify a target performance value for the first transaction; and compare the performance value included in the first information with the identified target performance value to determine whether the components in the at least two tiers of the enterprise application performed satisfactorily in executing the first transaction. The application performance monitoring tool may be further operable to identify a target performance value for each monitored element of the enterprise application that is involved in the first transaction; and for each monitored element, compare its performance value included in the first information with its target performance value to determine whether the monitored element performed satisfactorily during the first transaction.
[0017] The application performance monitoring tool may be further operable to provide in a graphical user interface, a visual indicator of a performance of the enterprise application in executing a plurality of transactions associated with one or more user sessions with the enterprise application, each of the plurality of transactions being associated with a prioritized aspect of the enterprise application, the first transaction being one of the plurality of transactions.
[0018] The application performance monitoring tool may be further operable to provide in a graphical user interface, a visual indicator of a performance of one or more monitored elements of the enterprise application during an execution of a transaction associated with a user session with the enterprise application.
[0019] The system may further include a correlation engine operable to capture, measure, and analyze error data and informational logs generated by the application performance monitoring tool.
[0020] The system may further include a customer service level monitor operable to communicate summary real-time application performance information for one or more enterprise applications for different time periods.
[0021] The system may further include a systems infrastructure dashboard that enables an end-to-end systems health view for each of the tiers of the enterprise application.
[0022] The system may further include a customer experience dashboard that summarizes metrics across one or more of the following data sources: real-time and historical; actual and synthetic traffic; page, producer and operational performance data; internally and externally sourced performance data; internal tools to support internal customers and external products to support external customers.
[0023] The system may further include an administrative console operable to enable a user to administer additions, modifications and deletions of monitoring tool supporting data, and corresponding associations and mappings information, the monitoring tool supporting data including URI data, producer data, node data, and realm data, and the mappings information including functions, page to function mappings, page to group mappings, page to producer mappings, and producer to group mappings.
[0024] The system may further include an alert notification engine configured with a set of robust configurable rules, and operable to apply the set of rules against data collected by an application performance monitoring tool, to detect abnormalities, trends, and/or short and long term performance issues, and generate an alert based on the application of the set of rules.
[0025] The system may further include an outlier data analysis tool operable to examine outlier data against a plurality of variables to determine whether there is a common cause or a number of common causes of the outlier data, and take an action based on the determination.
[0026] The system may further include a third party application monitoring tool operable to measure and monitor the performance of third party applications that are incorporated into the various product suites and used by customers; and measure and monitor key product pages and transactions from outside of an enterprise network so as to gather information on complete web page performance and total roundtrip performance time between a customer client computer and the enterprise network.
[0027] In general, in another aspect, the invention features a method that includes providing a structure that imposes checkpoints during design, development, testing and transition, and live production stages of an enterprise application lifecycle, such that performance of the enterprise application is based on metrics associated with customer impact.
[0028] Implementations of the invention may include one or more of the following features.
[0029] The method may further include identifying one or more elements of the enterprise application as elements to be monitored from a customer impact perspective; and for each identified element, associating the element with a customer impact identifier. Each identified element may be associated with one of the following customer impact identifiers: a business critical function identifier, a secondary function identifier, and a tertiary function identifier. The method may further include performing a benchmark process to determine a target performance value for each element of the enterprise application to be monitored from a customer impact perspective. The benchmark process may be performed at periodic intervals, and the target performance value for each element of the enterprise application to be monitored may be updated at the periodic intervals. The method of performing the benchmark process for each element to be monitored includes determining a first value representative of a predefined percentile of measured performance values for each of the plurality of days of the periodic interval; identifying a median of the first values; and setting the target performance value for the element based on the identified median of the first values. The predefined percentile may be a 92 nd percentile.
[0030] The details of one or more examples are set forth in the accompanying drawings and the description below. Further features, aspects, and advantages of the invention will become apparent from the description, the drawings, and the claims.
DESCRIPTION OF DRAWINGS
[0031] FIGS. 1 and 2 each show a data access system.
[0032] FIG. 3 shows a flowchart of a process for determining a customer service level of an enterprise application.
[0033] FIGS. 4-25 each show a screenshot generated by an application performance monitoring tool.
[0034] FIG. 26 shows components of a performance methodology.
[0035] FIG. 27 shows a performance matrix.
DETAILED DESCRIPTION
[0036] This description provides an example of a suite of tools that may be developed and deployed by an enterprise to monitor the performance of one or more enterprise applications. This suite of tools can be implemented by leveraging new technologies, such as rich Internet applications, to provide a robust and high-quality user experience. Although the example enterprise applications provided in this description relate to web-based products, the techniques are also applicable to non-web-based products, such as thin/thick client enterprise applications business critical function elements. Of the 24 business critical function elements of the NetBenefits product, in the most-recent 5 minute interval, 22 (i.e., the dark green portion of the pie chart) have response times that meet or exceed the target performance value, 1 (i.e., the gray portion of the pie chart) business critical function element has not been requested, and 1 (i.e., the yellow portion of the pie chart) business critical function element has a measured performance that is acceptable (the threshold for what is “acceptable” may be configured by the enterprise as a percentage of the target performance value, e.g., within 85% of the target performance value). In some examples, a portion of the pie chart may be colored red indicative of a measured performance value of the business critical function element that is unacceptable (e.g., fails to be within 85% of the target performance value). Although the color convention of the illustrated pie chart is green/gray/yellow/red, other color conventions or visual indices can be used. Further, the number of wedges of the pie chart can vary based on the product's current performance, e.g., the eWorkplace product pie chart 410 has two wedges totaling 35 business critical function elements.
[0037] When a user (e.g., an employee of the enterprise) clicks on a “Products” link 404 provided on a navigation bar 402 of the Business Unit Homepage 400 , a menu of products is provided. The user may select a “NetBenefits” link from the menu of products to obtain more detailed information about the performance of the monitored elements of the NetBenefits product that are web pages. In the example screenshot of FIG. 5 , one portion of a NetBenefits dashboard 500 is provided in a “Business Critical Functions (BCFs)” window 502 and another portion of the NetBenefits dashboard 500 is provided in a “Secondary Function Pages” window 504 . A slider located on the right-hand portion of each window 502 , 504 enables the user to view different portions of the NetBenefits dashboard 500 . In the displayed portion, detailed information about seven (e.g., “Homepage,” “Your Pension Summary,” “-Estimate a Payment,” “-Benefit Estimate #1,” “-Exchanges Landing Page,” “-Exchanges Confirmation,” and “Summary: Investments Tab”) BCF web pages of the NetBenefits product are provided. The information for the “Homepage” includes the number of views of the Homepage (e.g., 599,981), its current CSL (e.g., 96%), the average CSL for the past 24-hours (e.g., 96%), the average CSL over an 8-day period (e.g., 96%), a bar version of a histogram that visually depicts today's health of the NetBenefits Homepage based on predefined bins, and performance values (e.g., current average, current minimum, current maximum, today's average, and 8-day average). In some implementations, the percentage value in the “Current” CSL column is color coded to visually depict changes from interval to interval. Suppose, for example, that the 5-minute interval of the NetBenefits Homepage preceding the current 5-minute interval had a CSL of 94%. The current CSL of 96% may be color coded in green to show an improvement in performance. Suppose, in another example, that the 5-minute interval of the NetBenefits Your Pension Summary page preceding the current 5-minute interval had a CSL of 992%. The current CSL of 87% may be color coded in yellow or red to show a decline in performance.
[0038] For an even more detailed breakdown of the performance of the NetBenefits Homepage, the user may click on a page name, e.g., the “Homepage” link 506 to navigate to a Page Summary page 600 depicted in FIG. 6 . The Page Summary page 600 provides a number of graphs (e.g., CSL/Volume 602 , CSL/Performance 604 , Average Performance 606 , and Performance Histogram 608 ) that visually depict performance data associated with the Homepage, for example, for each 5-minute interval during a 60-minute period. If desired, the user can click on the magnifying glass icon displayed in the upper-right hand corner of each of the windows containing the graphs 602 , 604 , 606 , and 608 to obtain a larger display of the graph information. The Page Summary page 600 provides for high user interaction with the information by enabling the user to modify parameters (e.g., range: 60 min, 24 hr, 8 day, site: ALL, MMK, MRO, DAL, data time by date and time) and to update the graph that is presented in the Page Summary page 600 . The Detailed Performance Histogram 608 shows the CSL values for an individual page or producer that is a monitored element using five color coded buckets as follows:
[0000]
Description
Calculation
Color
Bucket 1
Less than or equal
x <= CSL
Green
to the CSL
Bucket 2
Exceeding the CSL
CSL < x <=
Light
but less than or
(CSL + T1)
Green
equal to CSL + First
Threshold
Bucket 3
Exceeding the First
(CSL + T1) < x <=
Yellow
Threshold but less
(CSL + T2)
than CSL + Second
Threshold
Bucket 4
Exceeding the
(CSL + T2) < x <=
Orange
Second Threshold
(CSL + T3)
but less than CSL + Third
Threshold
Bucket 5
Exceeding CSL + Third
x > (CSL + T3)
Red
Threshold
[0039] The threshold values T1, T2, and T3 can vary from product-to-product and/or element-to-element. The Performance histogram 608 allows users to view detailed histogram stack bar graphs, which display the percentage of requests that meet, and the percentage that exceed, the Customer Service Level (CSL).
[0040] The Page Summary page 600 also provides selectable buttons: “By Site,” 610 “Producers,” 612 and “Detailed Histogram,” 614 that enable the user to drill down to pages which show the performance data using different metrics. For example, clicking on the “By Site” button 610 navigates the user to the example Page by Site page 700 shown in FIG. 7 , in which the performance data (e.g., CSL, Average Performance, Volume, and Page Load Histogram) is broken down by physical site (e.g., ALL, MMK, MRO, and DAL). Likewise, clicking on the “Producers” button 612 navigates the user to the example Page by Producer page 800 shown in FIG. 8 , in which the performance data (e.g., Today's volume, CSL, Performance, Current Errors, and Clones) is shown for all of the data service producer (e.g., OSCAR switches, Plan Cache Aging Check, and Plan Switches) for the NetBenefits Homepage. Clicking on the “Detailed Histogram” button 614 navigates the user to the example Detailed Performance Histogram page 900 shown in FIG. 9 , which allows a user to change the variables based on time, site, customer or product mix to help pinpoint performance issues or events based selected parameters. The example Detailed Performance Histogram page 900 also include Performance Details measured in different/additional performance metrics including standard deviation (e.g. 1 sigma, 2 sigma) and percentiles (e.g. 92 nd percentile, 95 th percentile, and 99 th percentile).
[0041] When a user (e.g., an employee of the enterprise) clicks on a “Producers” link 406 provided on a navigation bar 402 of the Business Unit Homepage 400 , a menu of data service producers is provided. The user may select a “NB Common” link from the menu of data service producers to obtain more detailed information about the performance of the monitored elements of the NetBenefits product that are data service producers. In the example screenshot of FIG. 10 , a NB Common dashboard 1000 is provided in which a list of data service producers associated with the NetBenefits product is shown. This page displays volume, target, CSL, performance, error and close information for each producer. Suppose, for example, that the user clicks on producer name, e.g., OSCAR switches. This action causes the user to navigate to a OSCAR switches Producer Summary page 1100 depicted in FIG. 11 . The Producer Summary page 1100 provides a number of graphs (e.g., CSL/Volume 1102 , Average Performance 1104 , Total Errors 1106 , and Performance Histogram 1108 ) that visually depict performance data associated with the OSCAR switches data service producer, for example, for each 5-minute interval during a 60-minute period. The Producer Summary page 1100 also provides selectable buttons: “By Site,” 1110 and “By Slice,” 1112 that enable the user to drill down to pages which show the performance data using different metrics. For example, clicking on the “By Site” button 1110 navigates the user to the example Producer by Site page 1200 shown in FIG. 12 , in which the performance data (e.g., CSL, Average Performance, Volume, and Total Errors) is broken down by physical site (e.g., ALL, MMK, MRO, and DAL). Likewise, clicking on the “By Slice” button 1112 navigates the user to the example Producer by Slice page 1300 shown in FIG. 13 , in which the average performance of the OSCAR switch over a 60-minute interval is shown. The display of this graph can be changed to a number of other metrics (e.g., Volume, CSL, Minimum Performance, Maximum Performance) by selecting one of the options displayed in the menu 1302 .
[0042] By measuring and monitoring the performance of an enterprise application at varying levels of granularity (e.g., at a data provider level, at a data service producer level, at a web server level, and/or at an end-to-end user level), sufficient information may be provided to the monitoring tool 142 for use in generating detailed breakdowns of the performance of the enterprise application as it relates to producers, sites, clones, etc. Such breakdowns may aid the enterprise in more clearly identifying and/or investigating a problem area (e.g., CSL for MRO is significantly lower than CSL for DAL and MMK) so that troubleshooting of that problem area may be performed efficiently and effectively, as well as to diagnose customer impact.
[0043] Although the visual indicators of performance are described and depicted in terms of pie charts, bar versions of histograms, and histograms, any appropriate visual indicator and combination of visual indicators can be used. In addition, these visual indicators can be assembled in a way to create customizable screens for different users and/or for user role types.
Additional Data Processing Components
[0044] In some implementations, the enterprise network includes a server computer 120 that runs a correlation engine 144 that captures, measures, and analyzes error data and informational logs generated by the application performance monitoring tool 142 . In one example, the correlation engine 112 receives as input (e.g., from Adlex Inc.) statistics related to traffic patterns on the Internet and uses these statistics to provide a historical context to the real-time reports generated by the application performance monitoring tool 142 . In this manner, the enterprise can differentiate between a CSL that is negatively impacted by an enterprise-related event (e.g., the failure of a data service producer) as opposed to a non-enterprise-related event (e.g., the crippling effects of a virus spread on the Internet). The correlation engine 144 may also receive as input statistics related to traffic patterns within the enterprise network (e.g., across different web applications) to identify trends over various periods of time. In this manner, the enterprise may be able to identify periods of high volume corresponding to a particular time of the month (e.g., high volume bimonthly during pay periods, high volume every April during tax season) and adjust the distribution of server computer clones to avoid overloading or reduced CSLs.
[0045] In some implementations, the enterprise network 110 includes a server computer 120 that runs a Dazzling Display CSL Monitor 146 . Referring to the screenshot of FIG. 14 , in one example, the Dazzling Display CSL Monitor 1400 is used to communicate summary real-time application performance information on large display monitors. Key information about the BCF are displayed including current volume, CSL and performance in data and graphical format including histogram, line graph, and pie chart format. In addition, an odometer visual tool 1402 is used to show the application's CSL for current, today and 8-day results.
[0046] In some implementations, the enterprise network 110 includes a server computer 120 that runs a Systems Infrastructure Dashboard 148 . The Systems Infrastructure Dashboard may be used to support the daily operations of the systems operations and support groups particularly for large seasonal events. For example, FIGS. 15 and 16 show exemplary Systems Infrastructure Dashboards 1500 , 1600 for year end events; FIGS. 17 and 18 show exemplary Systems Infrastructure Dashboards 1700 , 1800 for annual enrollments. These Systems Infrastructure Dashboards 1500 , 1600 , 1700 , 1800 allow for the end-to-end systems health view for the web layer, middle-tier layer and back-end layer by use of key metrics that are calculated, accumulated and display for each of these layers.
[0047] In some implementations, the enterprise network 110 includes a server computer 120 that runs a Customer Experience Dashboard 150 . This may be used to support the operations of the business operations support function and to better attain the health of the customer (both external and internal) facing applications and systems. This Customer Experience Dashboard summarizes metrics across different kinds of data sources: real-time and historical; actual and synthetic traffic; page, producer and operational performance data; internally and externally sourced performance data; internal tools (to support internal customers, e.g., call center and back office) and external products (to support external customers). Internally sourced performance data refers to data collected with the infrastructure whereas externally sourced performance data refers to data collected outside the infrastructure and is sometimes provided by a third party source. Together these data sources provide a holistic view of customer experience to enable a decision maker affiliated with the enterprise to make necessary business-related decisions, prepare related quality analysis reports and understand customer impact and experience. Measurements may include incident information, crisis data, utilization patterns, cross-channel usage, service level metrics and customer impact assessment. In addition, the Customer Experience Dashboard serves as a central communication tool as it is a single portal to key operational data such as incident information (see FIGS. 19 , 20 , 21 , and 22 ).
[0048] In some implementations, the enterprise network 110 includes a server computer 120 that runs an Admin Console 152 . Referring to FIGS. 23 , 24 , and 25 , the Admin Console is used to streamline the administration of the underlying APM data. It helps in the administering additions, modifications and deletions of APM supporting data (e.g., URIs, Producers, Nodes, Realms) and their corresponding associations and mappings information (e.g., functions, page to function mappings, page to group mappings, page to producer mappings, and producer to group mappings). It also includes functionality to make batch updates to page Customer Service Levels (CSLs). In effect, this tool allows for the reduction in the administration workload of APM developers, improvement in response time for customers on application administration, and reduction of errors in administration.
[0049] In some implementations, the enterprise network 110 includes a server computer 120 that runs an alert notification engine 154 . The alert notification engine 154 may be configured with a set of robust configurable rules, which are applied (in some cases, continually) against the data collected by the application performance monitoring tool 142 , to detect abnormalities, trends, and/or short and long term performance issues. The set of rules may include various trigger thresholds and alarming levels, and may identify one or more groups that are to be notified of a performance issue that may require attention. In one example, when a current CSL for homepage of NetBenefits product falls below 83%, the alert notification engine 146 automatically sends a notification message to an application-level monitoring team (e.g., a monitoring team specific to the NetBenefits product) as well as an enterprise-level monitoring team (e.g., a monitoring team that oversees the health of all or a large subset of the enterprise's deployed web applications). These notification messages are sent as soon as the alert notification engine detects a satisfaction of a rule within the set. In this manner, the application-level and/or enterprise-level monitoring teams are notified of the performance issue in real-time and may take steps to address the issue before it escalates any further.
[0050] In some implementations, the enterprise network 110 includes a server computer 120 that runs an outlier data analysis tool 156 that analyzes data samples (captured by the application performance monitoring tool 142 ) that fall significantly outside the norm. These data samples, also referred to as “outlier data,” represent customers that have received very poor performance. Generally, the outlier data analysis tool 156 examines outlier data against a number of different variables to determine whether there is a common cause (e.g., location of user, time of day, system site, system identifier, customer identifier, etc.) or a number of common causes of the outlier data, which may then be corrected or otherwise attended to.
[0051] In some implementations, the enterprise network 110 includes a server computer 120 that runs one or more third party application performance monitoring tools 158 . These tools 158 incorporate data from external data sources to measure and monitor for two key purposes. First, to measure and monitor the performance of third party applications that are incorporated into the various product suites and used by customers particularly for those key pages considered as BCF and Secondary pages. These third party applications are often not able to be measured once the user's transaction is outside of the infrastructure. Secondly, to measure and monitor key product pages and transactions from outside of the infrastructure so as to gather information on complete web page performance (as opposed to only the longest item on the page) as well as the total roundtrip performance time outside of the infrastructure through the network and to the customer computer. Generally, these tools 158 monitor the availability, performance, and activity on the third party web applications, developed by third party web vendors, that run outside of the enterprise network 110 . Although described as being separate and distinct from the application performance monitoring tool 142 , there are instances in which the functionality of a third party application performance monitoring tool 158 is integrated into the application performance monitoring tool 142 .
Performance Methodology
[0052] The application performance monitoring tool 142 is strongly rooted in a rich performance methodology that was developed to support the tools and provides the underlying related processes and metrics. This performance methodology, known as FPM (Fidelity eBusiness Performance Methodology), provides a repeatable model for triaging each supported product or system and identifying its core monitored elements, e.g., BCF, Secondary and tertiary as well as its related data service producers. These prioritized monitored elements (e.g., BCFs) are used not only for performance monitoring by the monitoring tool 142 , but are also the common identifiers in many related operational processes such as service and support and availability reporting.
[0053] To be effective, a product's performance needs to not only be actively monitored but also has to be considered during the entire web page and related data producer lifecycle including design, development, testing and transition to its live production state (see FIG. 26 ). FPM provides the structure for that consideration by imposing checkpoints as well as the important focus on end customer targets as categorized in the Performance Matrix ( FIG. 27 ), as opposed to previously used internal system operating standards and definitions. This Performance Matrix contains several categories of customer targets based on customer page type expectations and was developed by a comprehensive comparative external benchmark analysis.
[0054] One of the integral processes of FPM that the monitoring tool 142 leverages is the Quarterly 92nd Percentile Benchmark analysis. At the end of each 90-day calendar quarter, a query is completed for each web page where the 92nd percentile of each day's data is obtained. The 92nd percentile was originally selected based on analysis that it provided a sufficient amount of the performance data set in comparison with alternative 95th or 90th percentiles. Next, the values are sorted in data order and the median value is extracted from the data set. This value is then set in the monitoring tool 142 during the first week following the end of a quarter as the new historical benchmark to which new page performance is measured against for the monitors. Benchmarks are updated so that fluctuations in monitoring tool 142 are based on changes on known and recent performance and account for changes in new code, infrastructure, etc. Separately, as part of the quarterly benchmark process, a comparison of the new quarter's data is made to previous quarters. Changes in the data is noted and flagged particularly for more material changes of +/−15%. If there was a change between the current quarter and the previous quarter such that the current quarter decreased by less than or equal to 15%, it represents an improvement (marked as green). Conversely, if there was a change between the current quarter and the previous quarter such that the current quarter increased by 15% or more percent, then it represents a performance degradation (marked as red). Generally, pages that degraded will require follow-up system analysis to investigate the cause and results may sometimes trigger a development work item. Additional detailed rules also exist that help business and system owners manage and decipher anomalies and changes in the performance of these elements (similar rules exist for producer thresholds as well as external sourced data), as well as impact to customer experience.
[0055] The described techniques can be implemented in digital electronic circuitry, or in computer hardware, firmware, software, or in combinations of them. The techniques can be implemented as a computer program product, i.e., a computer program tangibly embodied in an information carrier, e.g., in a machine-readable storage device or in a propagated signal, for execution by, or to control the operation of, data processing apparatus, e.g., a programmable processor, a computer, or multiple computers. A computer program can be written in any form of programming language, including compiled or interpreted languages, and it can be deployed in any form, including as a stand-alone program or as a module, component, subroutine, or other unit suitable for use in a computing environment. A computer program can be deployed to be executed on one computer or on multiple computers at one site or distributed across multiple sites and interconnected by a communication network.
[0056] Method steps of the techniques described herein can be performed by one or more programmable processors executing a computer program to perform functions of the invention by operating on input data and generating output. Method steps can also be performed by, and apparatus of the invention can be implemented as, special purpose logic circuitry, e.g., an FPGA (field programmable gate array) or an ASIC (application-specific integrated circuit). Modules can refer to portions of the computer program and/or the processor/special circuitry that implements that functionality.
[0057] Processors suitable for the execution of a computer program include, by way of example, both general and special purpose microprocessors, and any one or more processors of any kind of digital computer. Generally, a processor will receive instructions and data from a read-only memory or a random access memory or both. The essential elements of a computer are a processor for executing instructions and one or more memory devices for storing instructions and data. Generally, a computer will also include, or be operatively coupled to receive data from or transfer data to, or both, one or more mass storage devices for storing data, e.g., magnetic, magneto-optical disks, or optical disks. Information carriers suitable for embodying computer program instructions and data include all forms of non-volatile memory, including by way of example semiconductor memory devices, e.g., EPROM, EEPROM, and flash memory devices; magnetic disks, e.g., internal hard disks or removable disks; magneto-optical disks; and CD-ROM and DVD-ROM disks. The processor and the memory can be supplemented by, or incorporated in special purpose logic circuitry.
[0058] To provide for interaction with a customer or application provider operator (generically referred to as a user), the techniques described herein can be implemented on a computer having a display device, e.g., a CRT (cathode ray tube) or LCD (liquid crystal display) monitor, for displaying information to the user and a keyboard and a pointing device, e.g., a mouse or a trackball, by which the user can provide input to the computer (e.g., interact with a user interface element, for example, by clicking a button on such a pointing device). Other kinds of devices can be used to provide for interaction with a user as well; for example, feedback provided to the user can be any form of sensory feedback, e.g., visual feedback, auditory feedback, or tactile feedback; and input from the user can be received in any form, including acoustic, speech, or tactile input.
[0059] The techniques described herein can be implemented in a distributed computing system that includes a back-end component, e.g., as a data server, and/or a middleware component, e.g., an application server, and/or a front-end component, e.g., a client computer having a graphical user interface and/or a web browser through which a user can interact with an implementation of the invention, or any combination of such back-end, middleware, or front-end components. The components of the system can be interconnected by any form or medium of digital data communication, e.g., a communication network. Examples of communication networks include a local area network (“LAN”) and a wide area network (“WAN”), e.g., the Internet, and include both wired and wireless networks.
[0060] The computing system can include clients and servers. A client and server are generally remote from each other and typically interact over a communication network. The relationship of client and server arises by virtue of computer programs running on the respective computers and having a client-server relationship to each other.
[0061] Other embodiments are within the scope of the following claims. For example, the described techniques can be performed in a different order and still achieve desirable results. Although the description discusses the context of web pages of a web application, other systems which enable user interaction through a communication network may also benefit from the features discussed. | Methods, systems, and apparatus, including computer program products, implementing techniques for receiving a first information related to a first transaction associated with a first user session with a multi-tier enterprise application, the first information including performance data that is representative of how well components in at least two tiers of the enterprise application perform in executing the first transaction; and determining based on the first information whether the first transaction is associated with a prioritized aspect of the enterprise application, and if so, taking an action based on the determining. | 6 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to and the benefit of U.S. Provisional Patent Application No. 61/852,080 filed Mar. 15, 2013 and titled “APPARATUS AND METHOD FOR PROVIDING A RESISTIVE SHUNT WITHIN A LIGHT STRING” the contents of which are incorporated by reference herein in their entirety.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable.
BACKGROUND OF THE INVENTION
[0003] 1. Field of the Invention
[0004] The invention is for a system and method for providing a resistive shunt that provides for connecting two terminals within a light socket of a light string when the bulb is removed. Essentially, a resistive element is included as part of or comprises the socket bridge itself such that when the light bulb is removed, the electrically resistive element is provided in series with the bridge so as to present the same resistance between the external socket leads as that provided by the bulb when it is inserted into the socket and operational. In this manner, the overall resistance characteristics of the light string are not changed upon the removal of one or more bulbs in the light string and power/current demand increases are avoided within the light string system upon bulb removal.
[0005] 2. Description of the Prior Art
[0006] Holiday light strings are an omnipresent facet of many holiday decoration displays. Safety is one of the primary concerns in designing these light string systems. In particular, the removal of bulbs from the sockets within which the bulb typically resides presents several practical operational problems as well as safety concerns. Numerous bridging technologies exist that provide for a closed circuit condition within the socket when bulbs are removed such that the remaining bulbs in the light string remain lit. For Example, U.S. Pat. No. 7,591,658 issued on Sep. 22, 2009 to Chen (hereinafter “Chen”) provides one such shunting system in which one of the legs of an electrically conductive torsion spring is moved into a bridging position connecting the internal socket leads when the bulb is removed from the socket. One problem with this arrangement, however, is that the torsion spring is typically made of copper or another low resistance conductor. Thus, the removal of the bulb, including its associated filament resistance, causes the current drawn by the light string to increase upon bulb removal. If numerous bulbs are removed from a string, this problem increases, potentially to the point of dangerous operation. Commercial light string systems are typically rated for a maximum current draw or power consumption, and any increases up to or over those limits may be considered a safety hazard.
[0007] Underwriters Laboratories (UL) is a safety consulting and certification company that provides safety-related certification, validation, testing and inspection services. The organization advises and trains manufacturers of commercial manufacturers on various safety-related topics. UL certification is often a requirement for commercially distributed electrical systems to be offered to the public. Many retail outlets that offer holiday light string systems, for example, require that the light strings and components offered by their manufacturers pass UL certification as a condition of being offered for sale in their retail establishment. Numerous other worldwide certification organizations exist that provide similar functions.
[0008] Maximum light string current draw or power consumption is one of the most recent safety requirements to be formulated by electrical safety, standards-setting bodies. UL 588, for example, covers seasonal and holiday decorative products, specifically “factory-assembled seasonal lighting strings with push-in, midget-screw, or miniature-screw lamp holders connected in series for across-the-line use or with candelabra- or intermediate-screw lamp holders connected in parallel for direct-connection use. . . . [and] which are portable and not permanently connected to a power source.” To achieve UL certification under this specification section, a shorting test of light sockets shunts is conducted wherein bulbs are removed one at a time until many bulbs are removed from a single string. To achieve UL certification under this standard, the current of the light string shall not increase beyond a certain percentage, typically 10%.
[0009] Thus the need exists in the industry in which a shunting mechanism is provided, within a bulb socket and external to the bulb itself, such that the resistive characteristics of the shunt mirror those of the removed bulb. This may be as simple as matching a resistance of the two. In more complicated systems, the bulb circuitry can be mirrored within the shunting mechanism itself. In any case, any number of bulbs may be removed from the light string containing such a system without appreciable increased in current or power dissipation, thereby achieving the goals of the above-mentioned standards organizations and creating a safer light string system.
BRIEF SUMMARY OF THE INVENTION
[0010] In one particularly preferred embodiment, a light string socket is provided having at least two leads through which electrical power is delivered to the socket, the socket configured to receive a bulb assembly having two bulb leads, the two bulb leads being in electrical contact with the at least two socket leads such that when the bulb assembly is seated in the socket the electrical power flows through the bulb, the socket including: a shunt within the socket, the shunt bridging the at least two electrical leads within the socket when the bulb is not seated in the socket, and a resistive element is coupled to either the shunt or the leads such that the electrical power flows through the resistive element and the shunt when the bulb is not seated in the socket, the resistive element being matched to a resistive characteristic of the bulb so that the electrical power provided to the socket is substantially similar whether the electrical power is consumed by the bulb or the resistive element.
[0011] In other aspects of this embodiment, the resistive element is one of: a carbon coating deposited on the shunt, a resistor, a microelectronic circuit module, a resistive bead, or a spring; or the shunt is mechanically coupled to one of the at least two leads; or the resistive characteristic is an electrical resistance of the bulb and a resistance of the resistive element is matched to the electrical resistance of the bulb.
[0012] In another particularly preferred embodiment of the invention, a light string socket is provided having at least two leads through which electrical power is delivered to the socket, the socket configured to receive a bulb assembly having two bulb leads, the two bulb leads being in electrical contact with the at least two socket leads such that when the bulb assembly is seated in the socket the electrical power flows through the bulb, the socket including: a shunt within the socket, the shunt bridging the at least two electrical leads within the socket when the bulb is not seated in the socket, the shunt being composed of a resistive material such that it provides a resistive element, the electrical power flowing through the resistive element when the bulb is not seated in the socket, the resistive element being matched to a resistive characteristic of the bulb so that the electrical power provided to the socket is substantially similar whether the electrical power is consumed by the bulb or the resistive element.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0013] The accompanying drawings, which are incorporated in and constitute part of this specification, illustrate embodiments of the invention and together with the description, serve to explain the principles of the invention. The embodiments illustrated herein are presently preferred, it being understood, however, that the invention is not limited to the precise arrangements and instrumentalities shown, wherein:
[0014] FIGS. 1 and 2 show a first light string socket bridging arrangement containing a fixed resistive element according to one embodiment of the present invention;
[0015] FIGS. 3A-3B show two different resistive elements on the light socket bridging elements according to various embodiments of the present invention;
[0016] FIGS. 4-7 show alternative light string socket bridging arrangements containing a fixed resistive element according to various other embodiments of the present invention; and
[0017] FIGS. 8-11 show alternative light string socket bridging mechanisms including a spring arrangement coupled with or as part of fixed resistive element according to various other embodiments of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0018] To facilitate a clear understanding of the present invention, illustrative examples are provided herein which describe certain aspects of the invention. However, it is to be appreciated that these illustrations are not meant to limit the scope of the invention, and are provided herein to illustrate certain concepts associated with the invention.
[0019] The present invention provides for the inclusion of a resistive element within the bridging mechanism that resides within a light string socket. The bridging mechanism and resistive element are an integral part of the socket and are external to the bulb. The purpose of the resistive element is to replicate, as closely as possible, the resistive characteristics of the bulb itself so that when the bulb is removed from the socket, the bridging mechanism accommodates the same load current being supplied to the socket. This enables the remainder of the light string to function under electrical conditions substantially equivalent to those experienced when the bulb is present in the socket.
[0020] It should be noted that the term bulb is used in this description to denote an electrically powered element that produces light. Although most of the disclosure is directed to incandescent bulbs found on light strings, those of skill in the art will recognize the teachings of the present invention to be applicable to any of a variety of electrically powered lights such as LEDs, phosphorescent bulbs, luminescent bulbs, and other electric bulbs. Further, is should be noted that a resistive element as used herein includes, any electrically conductive resistor, or resistive element including but not limited to: a carbon resistor, surface mount resistor, a semiconductor material, carbon nanotube structures, a matrix resistive structure, or a resistive substance, coating or contact, etc.
[0021] The overall problem with not providing a resistive element of the type disclosed herein is that the overall light string, or series connected segment thereof, experiences an increase in current flow within the light string when a bulb is missing. In a series-connected electrical circuit, the missing bulb causes each of the remaining series connected bulbs to have the same supply voltage applied across their, now lower, total resistance. This is a result of Ohm's law, which for a series of serially connected resistors, R 1 through Rn, states: I=V/(R 1 +R 2 −R 3 +R 4 + . . . +Rn), where V is the supply voltage applied across the series-connected light string and I is the resultant current flowing through the light string. So it is clear from Ohm's Law that as the total resistance of the series-connected light string (R 1 +R 2 −R 3 +R 4 + . . . +Rn) decreases with the removal of each bulb, the current drawn by the overall circuit necessarily increases under a constant supply voltage. Commensurately, the voltage across each remaining resistor (bulb) also increases. Since the power (P) consumed by the bulb is given by the equation P=IV, and the current in the entire circuit increases with each missing bulb, the total power applied to the string as well as the power consumed by each bulb increases as bulbs are removed. Theoretically, this increases with each bulb removed until unsafe conditions are reached within the light string and a built-in fuse arrangement kicks in to stop current delivery or the overall light string system simply bums out and fails.
[0022] Many decorative light strings available on the market contain a shunting mechanism that is made of a highly conductive material (e.g. copper) having a low resistance in comparison to the resistive inductance of the light bulb that has been removed from the socket. Resistivity quantifies how strongly a given material opposes the flow of electric current and is a function of the geometry of the resistor. As one reference point, a 10 gauge AWG copper wire has approximately a 102 mil diameter and a resistance of approximately 1.018 Ohms per 1000 feet at temperature of 55 degrees Fahrenheit. In contrast, a typical light string bulb has a resistance of 7 to 8 Ohms through the filament. Shunts are also included within many light bulbs to permit current carrying through the bulb if the filament bums out. The inner-bulb shunt wire contains a coating that provides a fairly high resistance until the filament fails. At that point, heat caused by current flowing through the shunt burns off the coating and reduces the inner-bulb shunt's resistance. However, even after burn off, the bulb shunt still provides 2 to 3 ohms of resistance through the shunt once the coating burns off. Both of these values are significantly in excess of the resistance offered by the highly conductive materials currently used as shunts. Thus the need exists to provide a shunting mechanism within the light socket that more closely matches the resistance provided by the bulb filament such that the removal of one or more bulbs permits the continued illumination of the reaming light string bulbs without a significant increase in the light string current and power consumption.
[0023] The attached Figures illustrate various embodiments of light string sockets in which the removal of one or more bulbs on the light string still permit the remaining bulbs on the string to stay illuminated without the risk of increased current being applied to the remaining bulbs in the string. Such conditions are not only unsafe and fail to meet the newer electrical certification specifications, but they shorten the remaining bulbs' life span and cause uneven illumination of adjacent, series-connected light string segments.
[0024] Referring to FIG. 1 , a typical cross-sectional view of a light string socket 1 is provided in which the bulb assembly has been removed. Socket 1 includes a shunting mechanism 10 that bridges two inner-socket terminals 42 and 44 so as to provide electrical connectivity between them through the shunting mechanism 10 . Socket 1 further includes insulated lead wires 72 and 74 having wire leads 62 and 64 respectively that provide power to the light bulb socket via electrical coupling of the wires leads to the two inner-socket terminals 42 and 44 respectively. Wire securing wedge 90 is provided to secure mechanical placement of the lead wires 72 and 74 within the outer housing 50 of socket 1 . Attachment post 80 provides for uniform placement of the shunting mechanism 10 within the socket 1 such that proper registration of the shunt legs 12 and 14 is made with terminals 42 and 44 respectively and proper electrical connection between them is made at contact points 13 and 15 respectively. Once fully assembled and powered, current flows (depending on direction) from lead wires 72 and 74 through wire leads 62 and 64 across terminals 42 and 44 , and through shunt 10 so as to electrically connect the two socket lead wires and wire leads.
[0025] Shunting mechanism 10 is typically made of a highly conductive material such as copper. According to one preferred embodiment of the invention, a resistive sheath 20 may be applied at one or both ends of the shunt legs 12 and 14 . This sheath may, optionally, be further coated by an outer conductive sheath 30 applied atop one or both resistive sheathes 20 at the contact points 13 and 15 where the socket makes electrical connection with the shunt legs. Any one of a number of resistive coatings may be used such as a compressed carbon compound. Depending on the carbon composition and the geometric considerations of the resistive sheath, such as sheath thickness, resistive values of approximately 15-20 Ohms are achievable that are capable of safely handing ¼ watt of power. In yet another embodiment, the outer conductive sheath 30 is composed of copper flash plating that is applied to the ends of the shunt legs at connection points 13 and 15 to improve the connection with the copper or bronze terminals 42 and 44 .
[0026] Referring to FIG. 2 , the light socket of FIG. 1 is provided containing a light bulb assembly 100 having a lighting element or light bulb 105 a lighting element holder or light bulb holder 106 and light element or bulb leads 102 and 104 . Bulb leads 102 and 104 are electrically connected to the filament and/or inner-bulb shunt within bulb 105 , neither of which is shown in FIG. 2 . Bulb leads are also arranged such that when bulb 100 is seated within socket 1 , e.g.
[0027] bulb holder flanges 107 and 108 are flat against socket housing 50 and the bulb leads 102 and 104 are in electrical contact with bulb leads 102 and 104 respectively. Also as shown in FIG. 2 , mechanical biasing element 109 makes contact with leg 12 of shut mechanism 10 so as to push that leg inward toward the interior of the socket and out of electrical connection with terminal 42 thereby moving the shunt mechanism 10 and breaking the shunt's electrical connection within the socket. Once fully seated, current flows from lead wires 72 and 74 through wire leads 62 and 64 across terminals 42 and 44 , thorough bulb leads 102 and 104 and across the light bulb filament so as to illuminate the bulb.
[0028] Referring to FIG. 3 , various arrangements of the shunt mechanism legs are provided. In FIG. 3A , a shunting mechanism 10 having a leg 14 is shown. If the composition of the leg (and/or the entire shunting mechanism) is of a material possessing a high resistivity, i.e. higher than copper, then the singularly manufactured shunting mechanism itself my become the resistive element and can be used to replace existing light socket shunting mechanisms without further assembly or processing steps. Alternatively, shunt mechanism leg 14 may be coated with a resistive element 20 may be comprised of a coating applied to the shunt leg by any of a number of plating, deposition or other adhesion processes. In turn, a conductive coating 30 (e.g. copper) may be further applied or deposited on top of the resistive element so as to provide better electrical contact with the socket terminal when the shunting mechanism is engaged. As shown in FIG. 3B , an alternate location for the resistive element 220 is also show as a bead or dot 220 that is bonded to shunt leg 14 at the location of electrical contact with the socket terminals.
[0029] The key to the present invention is to substantially match the overall resistive characteristics of the shunt mechanism 10 with that of the bulb assembly such that the electrical current and power flow over the remaining portions of the light string remain substantially constant. Ideally, the resistive characteristics of the shunt mechanism at the two points of contact with the socket terminals is matched to the resistive characteristic of the bulb assembly at the same points. In one embodiment, the electrical resistance of the bulb assembly may simply be matched to that of the shunt mechanism. At the highest level of sophistication, the light bulb assembly may be a complicated structure containing microelectronic circuitry and numerous illumination elements. In this arrangement, the resistively profile of the light bulb assembly may be represented by a complex and dynamic resistivity function. It is this function that would be matched within the resistive element of the shunt mechanism so as to maintain consistent functioning of the light string. In any case, an exact matching between the resistively characteristics of the light bulb assembly and the shunting mechanism will neither be possible nor desirable. Rather, in practice, a substantial matching function will likely be implemented according to a metric by which the light string performance is measured. In this manner, and through the plurality of shunting mechanisms used within a light string, an acceptable variation about a mean current or power fluctuation may be accomplished during typical light string operation.
[0030] FIG. 4 provides yet another embodiment of the present invention. Here, similar to FIG. 3B , resistive element 320 is provided as a bead or dot 320 that is bonded, in this embodiment, to the socket terminal 42 at the location of electrical contact 313 with the shunt mechanism leg 12 . The resistive element may be a resistive material such as a compressed carbon compound. The resistive element 320 is added to the terminals only in the area 313 where the shunting mechanism makes contact with the socket terminal but not in the area 317 in which the bulb terminals make contact with the socket terminals. The resistive element may be bonded to a conductive plate that is mechanically affixed to the terminal by a rivet like structure 322 or otherwise soldered to the terminal.
[0031] FIG. 5 shows a variation of the embodiment of FIG. 4 in which the resistive element 420 is again affixed to terminals 42 and 44 . In this arrangement a higher resistivity material (e.g. carbon compound) is bonded to or otherwise deposited on to the terminals as part of the manufacturing process. A rivet-like structure or solder may be used to bond the resistive element to the terminal. Conductive contact plate 430 made of the same material as the conductive shunt mechanism may be further affixed to the resistive element. Again, the resistive element(s) 420 are so constructed such that the end-to-end contact resistance, as seen at the socket terminals, through the resistive elements and the shunt mechanism are substantially similar to the resistive characteristics provided by the light bulb assembly, which when inserted into the socket, disengages the shunt mechanism and any associated resistive elements. In alternative arrangements of FIGS. 4 and 5 (not shown) only one terminal includes a resistive element which is properly configured and constructed according to the teachings of the present invention.
[0032] In FIG. 6 , the shunt mechanism 10 is coated at the ends of the legs of the shunt mechanism, as described above. However, in this arrangement, the legs of the shunt mechanism are inverted (pointed up) and its leg ends bend inward towards the socket interior at the contact points 513 and 515 . In this manner, shunt mechanism legs provide contact with the socket terminals through the resistive coating 520 when the shunt is active and are pushed away from the terminals when the bulb seated in the socket
[0033] In FIG. 7 , the inward bending terminals 642 and 644 are the shunting mechanism themselves and their spring activity causes them to come in contact it the middle of the socket at a single contact point 613 when the bulb is not seated in the socket. Higher resistance material (e.g. carbon compounds) provides the resistive element 620 as affixed to the terminals. As with the arrangements above, a separate conductive plate (not shown) may be bonded to the resistive element(s) which, in turn, are mechanically affixed to the terminal by a rivet-like structure or soldered to the terminal.
[0034] FIG. 8 provides for yet another light string socket to which the teachings of the present invention may be applied. In that embodiment, the socket terminals 742 and 744 have flange portions 743 and 745 extending into the socket cavity but allowing for a gap 746 to be formed therebetween. A plunger cartridge 759 having a bottom cartridge portion 758 is disposed within socket 701 between the flange portions 743 and 745 and a securing plate 756 disposed at the bottom of the socket. The plunger cartridge further contains outwardly extending flange portions 753 which, in one variation, may be a continuous circular shelf disposed around the top of plunger cartridge 759 . The flange portions extend outward from said plunger cartridge 759 so as to cause the upper surface area of the plunger cartridge to be larger than gap 745 left by the flange portions 724 and 727 of the terminals.
[0035] Spring element 757 is disposed around the outside of plunger cartridge 759 and is seated between outwardly extending flange portions 753 the on the top of the cartridge and the securing plate 756 disposed at the bottom of the socket. The spring provides upward force on the plunger cartridge 759 so as to place the plunger cartridge 759 in a fully upward extended position, causing the extending flange portions 753 of plunger cartridge 759 to contact flange portions 724 and 727 of the socket terminals when no light bulb assembly is seated in the socket. When a light bulb assembly is seated in the socket, plunger cartridge 759 is pushed downward thereby compressing spring element 757 and releasing the extending flange portions 753 of plunger cartridge 759 from contact with the flange portions 724 and 727 of the socket terminals. It should be appreciated that spring could also be disposed within the plunger cartridge 759 with appropriate provision of cartridge flanges so as to perform the same above-recited function.
[0036] In the embodiment of FIG. 8 , the resistive element 710 , including resistive portion 720 , is placed within the plunger cartridge 759 and includes top lead 724 and bottom lead 727 . Top lead 724 extends from the top of plunger cartridge 759 above flange portion 753 so at to make electrical contact with flange portion 724 of socket terminal 744 . Likewise, bottom lead 727 extends from the bottom of plunger cartridge 759 up through the cartridge and extends outside the cartridge above flange portion 753 so at to make electrical contact with flange portion 743 of socket terminal 742 . The plunger cartridge top and bottom portions may be ultrasonically welded, glued or otherwise bonded together after the resistive element is inserted in the cartridge. Likewise, the securing plates 756 may similarly be bonded or ultrasonic welded to the side walls of the socket securing the spring and lead wires 772 and 774 .
[0037] In operation, when a light bulb assembly is inserted into socket 701 , plunger cartridge 759 is pushed downward compressing spring element 757 and releasing electrical connection of top lead 724 and bottom lead 727 of resistive element 710 from electrically bridging a connection between flange portions 724 and 727 of the socket terminals. In this position, upper side portions of the terminals 742 and 744 are in electrical connection with the bulb leads on the bulb assembly thereby providing electrical current and power to the bulb to illuminate it. (See FIG. 10 .) When the bulb assembly is removed from the socket, plunger cartridge 759 is pushed upwards by spring element 757 causing electrical connection of top lead 724 and bottom lead 727 of resistive element 720 to form a bridging connection between flange portions 724 and 727 of the socket terminals. In this position, the current is passed through the resistive element and through the socket to other sequentially coupled sockets in the light string system.
[0038] After experimental evaluation, a resistive element 710 may comprise a simple, inexpensive carbon resistor having a value of 20 to 22 ohms and a power rating of ¼ watt.
[0039] FIG. 9 provides an alternative arrangement of the placement of the resistive element 810 . In this embodiment the plunger cartridge 859 is composed of a top portion 846 and a bottom portion 848 . Top portion 846 and a bottom portion 848 are threadably engaged to one another via threaded connections 849 disposed within both sections. Engagable slot 807 is provided at the bottom of the plunger cartridge 859 so that a screw driver or other tool may be conveniently used to securely enable the threadable engagement. Top portion 846 further includes the resistive element 810 which contains central portion 825 and resistive element leads 824 and 827 . A resistor, resistive structure, resistive substance, resistive coating, surface mount resistor etc. ( 820 ) may be disposed anywhere within central portion 825 and electrically connected with leads 824 and 826 such that electrical connection is made between the flange portions of the socket terminals through resistive element 820 when the plunger cartridge 859 is fully pushed up (i.e. when the bulb assembly is removed). Otherwise the operation of the embodiment of FIG. 9 is substantially similar to that provided with respect to FIG. 8 .
[0040] FIG. 10 provides the light 801 socket of FIG. 9 with the light bulb assembly 900 inserted into the socket 801 . Light bulb assembly includes lighting element holder or light bulb holder 906 and light element or bulb leads 902 and 904 . Bulb leads 902 and 904 are electrically connected to the filament and/or inner-bulb shunt within bulb 905 , neither of which are shown in FIG. 10 and are also connected to socket terminals 842 and 846 so as to provide power to the light bulb assembly. In the seated position, the bottom end of light bulb assembly 910 pushes the top portion of the plunger cartridge 859 down causing spring element 857 to compress thereby releasing resistive element 820 from electrical connection to the terminal flanges.
[0041] FIG. 11 discloses an embodiment in which the spring element 857 itself is the resistive element 810 . The spring element 857 can be made of any of a number of semi-resistive or semiconductor materials, or a high resistance metallic alloy including, but not limited to, a nickel chrome alloy, or spring element may be coated with resistive coatings either over the entire spring or at its connective ends. Leads 1024 and 1027 are coupled to spring element, one at each end, and the socket terminals and provide electrical connection across those terminals through spring element 857 . Alternatively, one or more of the leads 1024 and 1027 themselves may be the resistive element 810 with the spring being left as a natural copper conductor.
[0042] With respect to creating resistive structures about conductors, one method of applying a carbon compound resistive coating to a wire is to place the formed wire in a mold, close the mold and inject a slurry of the compound into the mold to fill the cavity desired around the wire. While in the mold, the mold and wire are heated for a specific time period at a specific temperature. Depending on the chemicals and chemical processes being used, the resultant compound can be made to bond to the wire. After boding, a plating process may be used to provide the outer conductor wherein the wire ends are placed in a copper plating bath with an electrical bias applied to the bare wire end causing the copper plating to adhere to the carbon compound.
[0043] With respect to the deposition of resistive materials onto a conductive element to create the resistive element of the present invention, any of the heretofore known or later developed methods of material deposition/adherence may be used. For example, one method of applying a carbon compound resistive coating to a wire is to place the wire in a vacuum chamber, with the area not to be coated masked off, and exposing the remaining wire to a heated vapor cloud of the carbon compound with a positive bias on the masked end of the wire. When the vapor cloud having positively charged partials is subject to the electrical field, its particles are caused to adhere to the unmasked portions of the wire. The process is extended until a desired thickness of carbon is deposited on the wire. After removal from the chamber, additional chemical vapor deposition (CVD) processes may be exercised to plated additional conductive and resistive materials on the wire.
[0044] In addition to CVD techniques, sputtering, sintering, electron beam, x-ray lithography and various other chemical deposition techniques may be employed to create resistive structures as contemplated according to the teachings of this invention
[0045] While the invention has been shown and described with reference to specific preferred embodiments, it should be understood by those skilled in the art that various changes in form and detail may be made therein without departing from the spirit and scope of the invention as defined by the following claims. | A shunting mechanism is provided within a socket of a light string system having a resistive element that substantially mirrors the resistive characteristic of the bulb inserted in the socket. The shunting mechanism is disabled when the bulb is inserted into the light string socket. When the bulb is removed from the light string socket, the shunting mechanism bridges the internal socket leads so as to maintain current flow and power delivery at levels similar to those provided when the bulb is present. In one embodiment, the resistive element is a resistive coating on the shunting mechanism or a resistive node on the shunting mechanism. In other embodiments, the resistive element is applied to the socket's internal leads. In yet other embodiments, the resistive element consists of sophisticated electronic circuitry specifically designed to mirror the resistive characteristics of the bulb assembly. | 5 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is based on and claims the benefit of priority of U.S. Application No. 61/972,199, filed Mar. 28, 2014, the teachings of which are hereby incorporated by reference in their entirety.
[0002] Material contained in this document is subject to copyright protection. The copyright owner has no objection to the facsimile reproduction by anyone of the patent document or the patent disclosure, as it appears in Patent and Trademark Office patent files or records, but otherwise reserves all copyright rights whatsoever.
BACKGROUND
[0003] 1. Technical Field
[0004] This application relates generally to distributed data processing systems and to distributed storage systems and services.
[0005] 2. Brief Description of the Related Art
[0006] Distributed computing systems are known in the art. One such distributed system is a “content delivery network” or “CDN” that is operated and managed by a service provider. The service provider typically provides the content delivery service on behalf of third parties. A “distributed system” of this type typically refers to a collection of autonomous computers linked by a network or networks, together with the software, systems, protocols and techniques designed to facilitate various services, such as content delivery or the support of outsourced site infrastructure.
[0007] Other examples of distributed computer systems include distributed storage systems and services, including distributed databases. A distributed storage system can be used to provide a cloud storage solution. A content delivery network may utilize distributed storage to provide a network storage subsystem, which may be located in a network datacenter accessible to CDN proxy cache servers and which may act as a source/origin of content, such as described in U.S. Pat. No. 7,472,178, the disclosure of which is incorporated herein by reference. In this regard, a network storage system may be indexed by distributed databases that map input keys to data that points to storage locations in the manner of a file lookup service. In this way, the storage system may be used for storage of Internet content, such as images, HTML, streaming media files, software, and other digital objects, and as part of a CDN infrastructure.
[0008] Distributed storage systems (including database systems and services) typically rely on a variety of system services to keep the system operating well. Such services might include, without limitation, monitoring for nodes that are down, migrating or replicating data, resolving conflicts amongst replicas, compacting data, age-based deletion of data, and the like. Some services are common to many kinds of storage systems, others are particular to the nature and architecture of the system. For example, consider the variety of existing distributed databases: a SQL database may need different services than a no-SQL database, and a document-based no-SQL database may need different services than a column-based no-SQL database.
[0009] A distributed storage system typically has many nodes, and so it typically has many workers potentially available to perform the necessary work. However, it is challenging to distribute tasks to the workers (and by extension to the nodes that the workers are running on) in an efficient way, given dynamically changing loads, various service types and potential node faults. The teachings hereof address the need to coordinate allocation of work and tasks in distributed computing systems, the need to dynamically adjust this allocation, and the need to minimize the overhead used in doing so. The teachings hereof relate to technical improvements in operation and management of distributed computing platforms, and in analogous technologies, and can be used to improve the operation and efficiency of a distributed computing platform, including distributed storage platforms. Many benefits and advantages will become apparent from the teachings hereof.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The teachings hereof will be more fully understood from the following detailed description taken in conjunction with the accompanying drawings, in which:
[0011] FIG. 1 is a block diagram illustrating hardware in a computer system that may be used to implement the teachings hereof.
DETAILED DESCRIPTION
[0012] The following description sets forth embodiments of the invention to provide an overall understanding of the principles of the structure, function, manufacture, and use of the methods and apparatus disclosed herein. The systems, methods and apparatus described herein and illustrated in the accompanying drawings are non-limiting examples; the claims alone define the scope of protection that is sought. The features described or illustrated in connection with one exemplary embodiment may be combined with the features of other embodiments. Such modifications and variations are intended to be included within the scope of the present invention. All patents, publications and references cited herein are expressly incorporated herein by reference in their entirety. Throughout this disclosure, the term “e.g.” is used as an abbreviation for the non-limiting phrase “for example.”
[0013] In the following description, the term ‘node’ is used to refer to a physical computing machine, virtual machine, or equivalent. The term ‘worker’ is used to refer to a process, thread, managed sequence of instruction execution, or equivalent, that executes on a node to perform work. Depending on the machine, processor and operating system configuration, a node may host one worker or multiple.
[0014] The teachings hereof apply generally to distributed storage systems, including distributed database systems. Some of the examples of tasks/work to be performed herein are applicable to distributed storage systems generally, while others are particular in nature to distributed databases; the teachings hereof can be applied to allocate and manage work in both without limitation.
[0015] Distributed storage systems (including database systems and services) typically rely on a variety of services to keep the system and/or database operating well. Services may be broken down into one or more tasks, and in that way represent a logical grouping of tasks. For example, a cleanup service that deletes old data from a database (e.g., age-based deletion) may be broken down into a plurality of deletion tasks. One task may be to delete old data in a given directory or with a given attribute (such as one owner's data). Another deletion task, meanwhile, may involve deleting old data in another directory or with another attribute (e.g., another owner's data). By breaking the service down into tasks, the tasks can be run in parallel. A service may also be composed of one task. A service may also be composed of tasks that run periodically, e.g., that are repeated every so often.
[0016] Typical services include, without limitation, monitoring for nodes that are down, migrating or replicating data, resolving conflicts amongst replicas, compacting data, periodically deleting old data (data cleanup), propagating changes across replicas or partitions, among others. In a database such as ‘couchdb,’ a typical task is to calculate or refresh a view. Some kinds of services are common to many systems. Others are more specific to nature and architecture of a particular system.
[0017] One way of distributing tasks to workers is to have workers autonomously pick up tasks when they are idle, e.g., from a task table that defines the tasks available and what the task requires (such as which root directory to scan for age-based deletion, or the like). The task table can be maintained in a given designated node, to which workers on other nodes reach out; alternatively, replicas of the task table could be maintained in multiple nodes, assuming appropriate synchronization and coherence services.
[0018] In such a system, when a worker becomes idle, it finds the next available task in the task table and signs up for it (e.g., by inserting its worker identifier into the task table), potentially along with a start_time and completion_time. Multiple workers can be working on multiple tasks simultaneously. Further, if a worker find no tasks (either because all task are taken or the worker limit has been exceeded), it can become a monitor. Both monitors and workers can occasionally check the task table for available tasks (e.g., to see if new tasks have been inserted or the worker limit was raised or some workers have dropped out). Further, additional columns in the task table preferably allow idle monitors to identify failed workers and a given task's most recent checkpoint, so that a stalled task can be resumed by another worker from where it was left off in case of worker failure. For example, a freshly updated heartbeat timestamp indicates that the worker is alive; further, the task completion_time can be monitored to see if the task has failed to finish.
[0019] With such a system, there are multiple workers of each type working concurrently to provide parallelism and fault-tolerance. However, there is a risk that all of the workers run on the same set of nodes in the cluster while others sit idle. As a more concrete example, consider a cluster with 50 nodes and 10 services where each service uses 5 nodes for parallelism and fault-tolerance. Without proper coordination among different services and in the worst case, we could have all 10 services running on nodes 1 , 2 , 3 , 4 , and 5 , while the remaining 45 nodes sit idle doing nothing.
[0020] On the other hand, if the cluster has only 5 nodes, there is no choice but to have all services run on the same 5 nodes. So, a simplistic algorithm to keep services mutually exclusive of each other will not necessarily work.
[0021] To better coordinate workers and provide a better, dynamically adaptive distribution of services and tasks on nodes, a point system can be used. This approach can work well in any size cluster, preferably where workers don't overlap (e.g., workers are not shared across nodes), and including where workers performing different services share nodes.
[0022] In one embodiment, the point system can be as follows:
If a node already has a worker of the same service type as the worker seeking work, Q points are awarded to that node (e.g., Q=1000). If a node already has a worker of a different service type than the worker seeking work, R points are awarded to that node, where R<<Q and preferably about an order of magnitude smaller (e.g., R=100). For services than run occasionally rather than constantly, award S points to a node that may occasionally run this type of service, where S<<R and preferably about two orders of magnitude smaller (e.g., S=1).
[0026] Preferably, the required services and tasks are listed in a single task table in a database on a given node in the system. The task table could also be replicated across nodes, with appropriate synchronization, as noted before.
[0027] An example of shared table is provided below. In this embodiment, each service/task type are identified by the ‘service type’ column in the table below; these may correspond to one of the services described earlier. There are N(x) rows for a specific service type where N(x) is the number of workers to be used for service type ‘x’. The ‘slot’ column in the task table identifies the tasks: 1, 2, 3, . . . N(x) for a given service. The ‘node-id’ column stores the identifier of the node that takes the corresponding slot of the associated task. The ‘worker-id’ column stores an identifier of the particular worker on the identified node that takes the corresponding slot of the associated task. For illustration, a task table may look like this:
[0000]
service_type
slot
node-id
worker-id
. . .
type 1
1
node_1
node_1_wkr1
. . .
type 1
2
node_2
node_2_wkr1
. . .
. . .
type 2
1
node_2
node_2_wkr2
. . .
. . .
[0028] Slots essentially represent units of work. In one embodiment, the ‘slot’ relates to a given task. In other words, referring to the example above, service type 1 might be an age-based deletion service, and there might be a slot (task) corresponding to each directory and/or each customer with data on the system in which age-based deletion needs to occur.
[0029] In another embodiment, the ‘slot’ relates to a time slice (time period) for performing a service—in other words, a single-task service that is performed periodically. For example, if the service-type were for refreshing a view in couchdb, the slots could refer to each time slice during which the view needed to be refreshed. Thus a given worker on a given node would sign up to perform the refresh at slot (time slice) 1 , while another worker would sign up to perform the refresh at slot (time slice) 2 . In this way, the performance of the periodic service is time-divided amongst workers for fault-tolerance and coordination.
[0030] Initially, the table may be totally empty. The first node that runs a process to look for work for service type x will insert N(x) rows in the table where N(x) is a configuration parameter defining the number of workers needed for this service type x, assuming the task table does not have rows for them. If the table already has rows but the configuration parameter has changed, the first node can adjust the number of rows accordingly.
[0031] This first node preferably also fills the node-id column of all these rows with its own ID and fills the worker-id column with the id of the worker (e.g., process or thread) on the node that will be responsible for it. This assures that if this is the only node up in the cluster, all service slots will be assigned to a node to execute it (which will be the first node). If additional nodes in a cluster come up one at a time, it is possible that all slots for all service types are performed by this same first node.
[0032] Subsequent workers on nodes looking for work will find no empty slots but will take over busy workers who have too many slots. The worker on the node looking for work executes a takeover algorithm to determine which node to take from. In one embodiment, the takeover algorithm is as follows:
1. Calculate the total points for each of other nodes. For example, given a service type 1 worker process on node 3 looking for work, and considering the sample table provided above, and for Q=1000, R=100, and S=1, it would be found that node 1 has 1000 points and node 2 has 1100 points. Note that in this implementation, total points are calculated in light of the type of worker who is seeking work; hence, if a service_type 2 worker were looking for work, the point totals would be different: e.g., node 1 has a worker of a service_type 1 (which would warrant award of R=100 points) and no worker that is of service_type 2 (so Q points would not be awarded); meanwhile, node 2 has a worker of service_type 1 (which would warrant award of R=100 points) and a worker of service_type 2 (which would warrant award Q=1000 points). 2. Identify the node with the most points; call this node_max. Continuing this example, this is node 2 with 1100 points. 3. Calculate the total points of the worker's own node; call this self_points. In this example, assume that node 3 has 0 points. 4. The algorithm determines whether to takeover as follows: take over work from node_max if node_max's points are more than T+self_points, where T is equal to Q in a preferred embodiment. In this example, node 2 is node_max with 1100 points, and node 2's 1100 points are more than T+self_points of 1000+0. So, the entry for ‘service_type 1, slot 2’ will be changed to node 3 (and associated worker on node 3) and node 3 will assume the service_type 1 and slot 2 role from now on, and node 2 will become dedicated to run service_type 2.
[0037] By assigning more points (Q>>R) to nodes with same service, the algorithm favors taking over a slot from a node with the most slots of the same type. By requiring a take-over target to have more than T points than self (where preferably T=Q), we prevent slot thrashing between two nodes because after taking over (and thus adding Q points to itself), the takeover node still has less work than the take-over target. (Otherwise, the target node may take this slot back!)
[0038] Subsequently, if a new service_type ‘y’ is desired, the first node to run a process to look for work of that service_type y will insert N(y) rows, and the approach described above can take place.
[0039] Using the foregoing approaches, node and worker distribution automatically adjusts itself over time among many service types (which can be dynamically added) with a top priority to run a given service_type on different nodes if possible, and a second priority to run workers of different service types on different nodes also if possible.
[0040] Note that, in one embodiment, a single SQL query can be used and is sufficient to implement the above take-over algorithm (including point calculations, ranking, comparison, and task table update for the take-over); thus further minimizing communication overhead.
[0041] Those skilled in the art will understand that they can adjust the assigned points for each service_type that has a different workload characteristics. Hence, Q, R, and S may vary by service_type.
[0042] In an alternative embodiment, a leader is involved. For example, a leader process can assign slots (tasks or time slices) to nodes who ask the leader for work. Instead of the requesting worker or node itself calculating the takeover algorithm, the leader periodically calculates the point values. When asked for work, the leader consults the current point values and decides whether to take work from a given node and provide it to the requesting one. In another alternative embodiment, the leader does not wait until someone asks, but instead assigns the work to the node/worker that the leader believes should be working on it. If the worker is too slow (as indicated by missing a time deadline for a checkpoint or work completion), the leader reassigns the task elsewhere, based the point values in the takeover algorithm.
[0043] The following sample SQL code illustrates one implementation of the takeover algorithm:
[0000]
// select worker with more work than self
// must be called after setting m_task_type
void op_multi_worker::set_take_over_target_query( )
{
take_over_target = “(select worker from (select sum(case when
param=‘worker’”
// 1000 points if worker of same task type
“ and task_type=‘“+m_task_type+”’ then 1000 else (case when ”
// 100 points if worker of other task type
“param=‘worker’ then 10 else (case when param=‘monitor’ and ”
// 1 point if a view_query monitor
“task_type=‘view_query’ then 1 else NULL end) end) end) as
score,worker”
“ from ” TASKS_TABLE “ where worker NOTNULL and (param=‘worker’ or ”
// total the points for each node then get the node with the most point
“param=‘monitor’) group by worker order by score desc limit 1) where ”
// it's a target if its pts are more than 1000 + my total points
“score > 1000+(select (case when score ISNULL then 0 else score end)
from”
// I get 0 pt if I'm not a worker or monitor
“ (select sum(case when param=‘worker’ and task_type=‘”+m_task_type+
“’ then 1000 else (case when param=‘worker’ then 10 else (case when ”
“param=‘monitor’ and task_type=‘view_query’ then 1 else NULL end) end)
”
“end) as score from “ TASKS_TABLE ” where worker=‘“+myipa+”’)))”;
take_over_mon_target = “(select id from (select id,count(*) as score,worker
from ”
TASKS_TABLE “ where “ IS_MY_M_MON_TYPE ” group by worker ”
“order by score desc limit 1) where score > 1+(select count(*) from ”
TASKS_TABLE “ where “ IS_MY_M_MON_TYPE ” and worker=‘“+myipa+”’)) ”;
}
[0044] The teachings hereof may, without limitation, facilitate load-balancing via improved distribution of workers of multiple different service types among available nodes in a cluster, as well as the dynamic addition of service types. The teachings hereof apply equally well from a single-node cluster to large clusters with thousands of nodes or more. The number of needed workers per type, the number of service types, and the nodes that are available can change dynamically and the teachings hereof can still be applied.
[0045] It is noted that the foregoing are benefits that may be obtained through the practice of the teachings hereof, but are not necessary to be achieved or required for the practice of the teachings hereof
[0046] Computer Based Implementation
[0047] The subject matter described herein may be implemented with computer systems, as modified by the teachings hereof, with the processes and functional characteristics described herein realized in special-purpose hardware, general-purpose hardware configured by software stored therein for special purposes, or a combination thereof
[0048] Software may include one or several discrete programs. A given function may comprise part of any given module, process, execution thread, or other such programming construct. Generalizing, each function described above may be implemented as computer code, namely, as a set of computer instructions, executable in one or more microprocessors to provide a special purpose machine. The code may be executed using conventional apparatus—such as a microprocessor in a computer, digital data processing device, or other computing apparatus—as modified by the teachings hereof. In one embodiment, such software may be implemented in a programming language that runs in conjunction with a proxy on a standard Intel hardware platform running an operating system such as Linux. The functionality may be built into the proxy code, or it may be executed as an adjunct to that code.
[0049] While in some cases above a particular order of operations performed by certain embodiments is set forth, it should be understood that such order is exemplary and that they may be performed in a different order, combined, or the like. Moreover, some of the functions may be combined or shared in given instructions, program sequences, code portions, and the like. References in the specification to a given embodiment indicate that the embodiment described may include a particular feature, structure, or characteristic, but every embodiment may not necessarily include the particular feature, structure, or characteristic.
[0050] FIG. 1 is a block diagram that illustrates hardware in a computer system 100 on which embodiments of the invention may be implemented. The computer system 100 may be embodied in a client device, server, personal computer, workstation, tablet computer, wireless device, mobile device, network device, router, hub, gateway, or other device.
[0051] Computer system 100 includes a microprocessor 104 coupled to bus 101 . In some systems, multiple microprocessor and/or microprocessor cores may be employed. Computer system 100 further includes a main memory 110 , such as a random access memory (RAM) or other storage device, coupled to the bus 101 for storing information and instructions to be executed by microprocessor 104 . A read only memory (ROM) 108 is coupled to the bus 101 for storing information and instructions for microprocessor 104 . As another form of memory, a non-volatile storage device 106 , such as a magnetic disk, solid state memory (e.g., flash memory), or optical disk, is provided and coupled to bus 101 for storing information and instructions. Other application-specific integrated circuits (ASICs), field programmable gate arrays (FPGAs) or circuitry may be included in the computer system 100 to perform functions described herein.
[0052] Although the computer system 100 is often managed remotely via a communication interface 116 , for local administration purposes the system 100 may have a peripheral interface 112 communicatively couples computer system 100 to a user display 114 that displays the output of software executing on the computer system, and an input device 115 (e.g., a keyboard, mouse, trackpad, touchscreen) that communicates user input and instructions to the computer system 100 . The peripheral interface 112 may include interface circuitry and logic for local buses such as Universal Serial Bus (USB) or other communication links.
[0053] Computer system 100 is coupled to a communication interface 116 that provides a link between the system bus 101 and an external communication link. The communication interface 116 provides a network link 118 . The communication interface 116 may represent an Ethernet or other network interface card (NIC), a wireless interface, modem, an optical interface, or other kind of input/output interface.
[0054] Network link 118 provides data communication through one or more networks to other devices. Such devices include other computer systems that are part of a local area network (LAN) 126 . Furthermore, the network link 118 provides a link, via an internet service provider (ISP) 120 , to the Internet 122 . In turn, the Internet 122 may provide a link to other computing systems such as a remote server 130 and/or a remote client 131 . Network link 118 and such networks may transmit data using packet-switched, circuit-switched, or other data-transmission approaches.
[0055] In operation, the computer system 100 may implement the functionality described herein as a result of the microprocessor executing program code. Such code may be read from or stored on a non-transitory computer-readable medium, such as memory 110 , ROM 108 , or storage device 106 . Other forms of non-transitory computer-readable media include disks, tapes, magnetic media, CD-ROMs, optical media, RAM, PROM, EPROM, and EEPROM. Any other non-transitory computer-readable medium may be employed. Executing code may also be read from network link 118 (e.g., following storage in an interface buffer, local memory, or other circuitry).
[0056] A client device may be a conventional desktop, laptop or other Internet-accessible machine running a web browser or other rendering engine, but as mentioned above a client may also be a mobile device. Any wireless client device may be utilized, e.g., a cellphone, pager, a personal digital assistant (PDA, e.g., with GPRS NIC), a mobile computer with a smartphone client, tablet or the like. Other mobile devices in which the technique may be practiced include any access protocol-enabled device (e.g., iOS™-based device, an Android™-based device, other mobile-OS based device, or the like) that is capable of sending and receiving data in a wireless manner using a wireless protocol. Typical wireless protocols include: WiFi, GSM/GPRS, CDMA or WiMax. These protocols implement the ISO/OSI Physical and Data Link layers (Layers 1 & 2) upon which a traditional networking stack is built, complete with IP, TCP, SSL/TLS and HTTP. The WAP (wireless access protocol) also provides a set of network communication layers (e.g., WDP, WTLS, WTP) and corresponding functionality used with GSM and CDMA wireless networks, among others.
[0057] In a representative embodiment, a mobile device is a cellular telephone that operates over GPRS (General Packet Radio Service), which is a data technology for GSM networks. Generalizing, a mobile device as used herein is a 3G- (or next generation) compliant device that includes a subscriber identity module (SIM), which is a smart card that carries subscriber-specific information, mobile equipment (e.g., radio and associated signal processing devices), a man-machine interface (MMI), and one or more interfaces to external devices (e.g., computers, PDAs, and the like). The techniques disclosed herein are not limited for use with a mobile device that uses a particular access protocol. The mobile device typically also has support for wireless local area network (WLAN) technologies, such as Wi-Fi. WLAN is based on IEEE 802.11 standards. The teachings disclosed herein are not limited to any particular mode or application layer for mobile device communications.
[0058] It should be understood that the foregoing has presented certain embodiments of the invention that should not be construed as limiting. For example, certain language, syntax, and instructions have been presented above for illustrative purposes, and they should not be construed as limiting. It is contemplated that those skilled in the art will recognize other possible implementations in view of this disclosure and in accordance with its scope and spirit. The appended claims define the subject matter for which protection is sought.
[0059] It is noted that trademarks appearing herein are the property of their respective owners and used for identification and descriptive purposes only, given the nature of the subject matter at issue, and not to imply endorsement or affiliation in any way. | In a distributed computing system, the allocation of workers to tasks can be challenging. In embodiments described herein, nodes in such a system can execute takeover algorithms that provide efficient, automated, and stable allocation of workers to tasks. | 7 |
BACKGROUND OF THE INVENTION
[0001] 1. Technical Field
[0002] The present invention relates to a method for making a vertical stand-up package having a compartment constructed using a modified vertical form, fill, and seal packaging machine, and the apparatus and method for making same, that provides for a single piece construction of a vertical stand-up package. The invention allows for use of existing converter and packaging technology to produce a stand up package having one or more open or closed compartments with minimal increased cost and minimal modification.
[0003] 2. Description of Related Art
[0004] Vertical form, fill, and seal packaging machines are commonly used in the snack food industry for forming, filling, and sealing bags of chips and other like products. One such packaging machine is seen diagrammatically in FIG. 1 . This drawing is simplified and does not show the cabinet and support structures that typically surround a machine, but it demonstrates the working of the machine well. Packaging film 110 is taken from a roll 112 of film and passed through tensioners 114 that keep it taut. The film then passes over a former 116 , which directs the film into a vertical tube around a product delivery cylinder 118 . As the tube is pulled downward by drive belts 120 the vertical tube of film is sealed along its length by a vertical sealer 122 , forming a back seal 124 . The machine then applies a pair of heat sealing jaws 126 against the tube to form a transverse seal 128 . This transverse seal 128 acts as the top seal on the bag 130 below the sealing jaws 126 and the bottom end seal on the bag 132 being filled and formed above the jaws 126 . After the transverse seal has been formed, a cut is made across the sealed area to separate the finished bag 130 below the seal 128 from the partially completed bag 132 above the seal. The tube is then pushed downward to draw out another package length. Before the sealing jaws form each transverse seal, the product to be packaged is sent through the product delivery cylinder 118 and is held within the tube above the transverse seal 128 . The material that is fed into the form, fill and seal machine is typically a packaging film such as polypropylene, polyester, paper, polyolefin extrusions, adhesive laminates, and other such materials, or from layered combinations of the above. For many food products, where flavor retention is important, a metalized layer will form the inner most layer.
[0005] One modification to a vertical form, fill, and seal packaging machine is disclosed in U.S. Pat. No. 6,722,106 (“the '106 patent”), which is assigned to the same assignee as the present invention. The '106 patent discloses a method for making a free standing package called a vertical stand up pouch. The modification uses two forming plates 104 and a tension bar 102 to hold the packaging film tube in tension from inside the tube. Tension is applied on the outside of the film and in the opposite direction of the tension provided by the forming plates 104 by a fixed or stationary tucker mechanism 106 positioned between the forming plates 104 . When the tucker bar 106 is properly positioned, it provides a crease or fold in the tube of the packaging film between the two forming plates 104 . This creates a gusset 135 that permits the package to stand upright on the gusset 135 . The crease is formed prior to formation of the transverse seal by the seal jaws 126 . Consequently, once the transverse seal is formed, the crease becomes an integral feature of one side of the package.
[0006] The vertical form and fill machine thereafter operates basically as previously described in the prior art, with the sealing jaws 126 forming a lower transverse seal (and upper transverse seal for the bag below), and product being introduced through the forming tube 101 into the sealed tube of packaging film which now has a crease on one side. The film is then pulled downward by moving belts 120 and the upper transverse seal is formed, thereby completing the package. An example of the vertical stand up package formed is shown in FIGS. 2 a and 2 b . The outside layer of packaging film show the graphics 179 oriented 90 degrees clockwise from graphics orientation normally present on a pillow pouch formed by a standard prior art vertical form, fill and seal machine. As shown in FIG. 2 b the transverse seals 128 of the vertical stand up package are oriented vertically once the bag stands up on one end as shown in FIG. 2 b . FIG. 2 a shows the crease 176 that was formed by the tucker bar 106 and forming plates 104 shown in FIG. 1 to create a gusset 135 that permits the package to stand upright. Various modifications of the vertical stand up pouch, methods for making the pouch, and apparatuses for making the pouch are disclosed in U.S. Pat. Nos. 6,729,109 and 6,679,034.
[0007] Another self standing flexible pouch is disclosed in U.S. Pat. No. 6,679,630 also assigned to the same assignee as the present invention. FIG. 3 a is cross-sectional view of the self standing flexible package disclosed in the '630 patent. Referring to FIG. 3 a , the '630 patent teaches a package 70 having a flap 78 formed by creating a bend 84 in the film to form an inner portion of flap 78 . An opening 90 is formed between the inner and outer portions of the flap 78 . FIG. 3 b shows a completed package 70 in a standing or display position. Referring to FIGS. 3 a and 3 b , as package 70 is shown standing, flap 78 extends outward and away from back forming pocket 80 . To enclose and retain any product within the package a back seal 124 seals the film tube and transverse end seals 128 seal the terminal ends of package 70 . The transverse seals 128 also serve to retain the flap 78 to the terminal ends of package 70 . Unfortunately, the '630 patent requires the flap 78 to be manually drawn away from the back for the package 70 to stand erect with the use of a flap 78 . Thus, the package requires manual manipulation to stand up. In addition, because packages are typically opened at the transverse seals, product can spill out of the package after the package is opened, when the package is in the stand up position. Thus, there is a need to provide a package having a compartment or pocket that permits the compartment to hold different contents than are held in the main portion of a package when the package stands erect. Consequently, a need exists for a vertical stand-up package having one or more open compartments that are accessible while the package is standing erect that minimizes the use of film.
[0008] The prior art discloses other containers often associated with TV dinners having multi-compartment food containers where the compartments are adjacent and integrated into the container. Unfortunately, many of these food containers are made from more expensive thermoforming techniques. Consequently, a need exists for a multi-compartment food container that can be made from an economical modification of a vertical form, fill, and seal machine.
SUMMARY OF THE INVENTION
[0009] The proposed invention involves producing a vertical stand up package having one or more open or closed compartments constructed from a single sheet of material using a vertical form, fill, and seal machine modified with a spiral former, a first and second filling structure, and a gusseting mechanism. The former receives flexible packaging film and forms a tube having an overlap end and an inner end. The overlap is sealed to the tube thereby causing the inner end to form an internal compartment wall. The gusseting mechanism creates a vertical tuck along the length of the bag while it is being formed permitting the package to stand up once the transverse end seals are made.
[0010] The method disclosed and the package formed as a consequence is a substantial improvement over prior art packages having a compartment. The method works on existing vertical form, fill, and seal machines requiring little modification. There are no jaw carriage modifications involved. The bag makers can be easily converted back to a pillow pouch configuration with a relatively few simple changes. The same metalized or clear laminations used as materials in pillow pouches can also be used with the invention. The above as well as additional features and advantages of the present invention will become apparent in the following written detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The novel features believed characteristic of the invention are set forth in the appended claims. The invention itself, however, as well as a preferred mode of use, further objectives and advantages thereof, will be best understood by reference to the following detailed description of illustrative embodiments when read in conjunction with the accompanying drawings, wherein:
[0012] FIG. 1 is a perspective view of a prior art form, fill, and seal machine.
[0013] FIGS. 2 a and 2 b are perspective views of prior art vertical stand-up packages.
[0014] FIG. 3 a is a cross-sectional view of a prior art package capable of self support having a pouch.
[0015] FIG. 3 b is a perspective view of a prior art package.
[0016] FIG. 4 is a perspective view of one embodiment of the present invention depicting a modified form, fill, and seal machine.
[0017] FIG. 5 a is a simplified top view of the dual delivery tube assembly of one embodiment of the present invention.
[0018] FIG. 5 b is a cut away perspective view of the package in accordance with one embodiment of the present invention.
[0019] FIG. 5 c is a cut-away side view of the package in accordance with one embodiment of the present invention.
[0020] FIG. 5 d depicts a cut away top view of one embodiment of the present invention having salsa poured into the compartment.
[0021] FIG. 6 a is a front view of one embodiment of the vertical stand-up package having a compartment.
[0022] FIG. 6 b is a perspective bottom view of the package depicted in FIG. 6 a.
[0023] FIG. 7 a is a perspective view of a folding device adjacent the vertical form fill and seal machine along line 7 A- 7 A of FIG. 4 in accordance with one embodiment of the present invention.
[0024] FIG. 7 b is a perspective view of the folding device depicted in FIG. 7 a along line 7 B- 7 B of FIG. 4
[0025] FIG. 7 c is a perspective view of a folding device depicted in FIG. 7 a along line 7 C- 7 C of FIG. 4 .
[0026] FIG. 8 a is a simplified top view of the multi-delivery tube assembly in accordance with one embodiment of the present invention.
[0027] FIG. 8 b is a cut-away perspective view of the package made from the assembly depicted in FIG. 8 a
DETAILED DESCRIPTION
[0028] FIG. 4 is a perspective view of one embodiment of the present invention depicting a modified form, fill, and seal machine. A spiral former 426 receives the packaging film 110 and directs the compartment terminal end 410 around a fill tube or first filling structure 418 to receive a first item 718 . The former 426 simultaneously directs the tube terminal end 622 (film overlap end) to overlap the compartment terminal end 410 (film inner end). Thus, in the embodiment shown, the spiral former 426 creates a tube having an enclosed channel in communication with a first filling structure 418 and an open channel in communication with a second filling structure 420 . The second filling structure 420 is adjacent the first filling structure 418 and situated so as to permit a second item 720 to be placed in the open channel. The open channel becomes the compartment when the package is sealed.
[0029] FIG. 5 a is a simplified top view depicting the former and dual delivery tube assembly of one embodiment of the present invention. In the embodiment shown, an indention in the first filling structure 418 creates a channel for placement of the second filling structure 420 . This indention, however, is not required and is shown to be illustrative of one embodiment. The film tube comprises an inner compartment wall 640 bounded by a compartment terminal end 410 and a compartment seal end 422 .
[0030] Referring to FIGS. 4 and 5 a , as the film tube is pulled downward by drive belts 120 , the vertical tube terminal end 622 of film is sealed to the compartment seal end 422 by a vertical sealer 122 . The vertical sealer 122 can use heat seal or cold seal technology. The tube then passes over two forming plates 104 and a tension bar 102 . A tucker bar 106 , positioned between the forming plates 104 , provides a crease or fold in the tube of packaging film between the two forming plates 104 . The sealing jaws 126 then form a first end seal.
[0031] FIG. 5 b is a cut away perspective view of the package in accordance with one embodiment of the present invention. Referring to FIGS. 5 a and 5 b , the lap seal 522 , created by the vertical sealer 122 , has sealed the seal end 422 of the compartment wall 640 and the tube terminal end 622 . The compartment terminal end 410 of the compartment wall 640 is secured within the package by the first end seal 631 at the location generally depicted by numeral 412 . A compartment 620 is thereby formed that is bounded by an overlapped segment of film 520 , or overlap wall 520 of the tube, the lap seal 522 and the compartment wall 640 . The main portion 618 is bounded by the compartment wall 640 and the gusset 680 .
[0032] FIG. 5 c is a cut-away side view of the package in accordance with one embodiment of the present invention. In the embodiment shown, the package 600 comprises two compartments 618 620 open to one another. A first item 718 rests in the main portion 618 of the package 600 while a second item 720 is disposed within the compartment portion 620 of the package 600 . The first and second items are separated by a compartment wall 640 . As shown by FIG. 5 c , the package is formed by a single sheet of film formed into a tube having an overlap wall 520 . The terminal end 622 of the overlap wall 520 is sealed with a lap seal 522 to the compartment seal end 422 of the compartment wall 640 . It should be noted that the height of the compartment wall 640 can be adjusted as desired. Additionally, as will be discussed in greater detail below, the top of the compartment wall 640 can be sealed to the overlap wall 520 to form a closed compartment. Such embodiment could prove advantageous, for example, to permit placement of a liquid in either compartment or to prevent the compartments from sharing headspace.
[0033] Referring to FIGS. 4, 5 a , and 5 b , upon completion of the first end seal 631 , a first item 718 can be dropped through a first filling structure 418 in communication with the main portion 618 of the tube. Similarly, a second item 720 can be dropped through a second filling structure 420 in communication with the compartment portion 620 of the tube. The items can be dropped simultaneously. Once the first item 718 and second item 720 have been placed in the package, a second end seal can be provided by the sealing jaws 126 .
[0034] FIG. 6 a is a front view of one embodiment of the vertical stand up package having a compartment. FIG. 6 b is a bottom perspective view of the package depicted in FIG. 6 a . The flexible vertical stand up package 600 rests on the gusset 680 having a crease 676 and, unlike a standard pillow pouch package, the end seals 631 are oriented in a vertical direction. A score line 615 can facilitate opening the package by removing the top. In a preferred embodiment, the lap seal 522 is located adjacent the gusset 680 to provide additional stability for the stand up package 600 .
[0035] One advantage of the package formed by the present invention is that complementary items can be stored in the package. For example, in one embodiment the first item can comprise tortilla chips and the second item can comprise pre-packaged salsa. The salsa can be pre-packaged in a traditional pillow package by a prior art vertical form, fill, and seal machine similar to that depicted in FIG. 1 . The vertical stand up package can then be opened, the pre-packaged salsa can be retrieved from the open compartment, opened, and poured into the pouch from which it was retrieved. In an alternative embodiment, salsa or other liquid can be directly placed into a closed compartment.
[0036] FIG. 5 d depicts a cut away top view of one embodiment of the present invention having salsa poured into the compartment 620 . Salsa, when poured into the compartment 620 , applies pressure at the compartment wall 640 and can press the compartment wall 640 in the direction of the arrows 623 shown in FIG. 5 c and FIG. 5 d to form a dipping well. Surprisingly, when the compartment terminal end 410 is folded over a portion of the compartment wall 640 , the integrity of the compartment 620 is enhanced and salsa, or other product, is less likely to spill from the compartment 620 over the compartment wall 640 into the main portion 618 of the package. Thus, the present invention permits a consumer to purchase a package having chips and salsa, and to then use the package to consume the chips and salsa directly from the stand up package without the chips spilling out of the package or using (and potentially dirtying) a salsa dish. Such package can be ideal for picnics or anytime a ready-to-eat product is desired.
[0037] FIG. 7 a is a perspective view of a folding device adjacent the vertical form fill and seal machine along line 7 A- 7 A of FIG. 4 in accordance with one embodiment of the present invention. FIG. 7 b is a perspective view of the folding device depicted in FIG. 7 a along line 7 B- 7 B of FIG. 4 . FIG. 7 c is a perspective view of a folding device depicted in FIG. 7 a along line 7 C- 7 C of FIG. 4 . Referring to FIGS. 4, 5 c , 7 a - 7 c , the rolled edge can be formed with a folding device 700 near the former 426 to permit a portion of the film which eventually becomes the compartment wall 640 terminal end 410 to fold over a portion of itself so as to provide a j-shaped rolled edge or fold having a trough 411 and a terminal end 410 . In the embodiment shown, the folding device 700 comprises a tucker bar 702 and a pair of rollers 704 705 . The angle that the tucker bar 702 engages the film 110 can be adjusted to obtain the desired fold. In the embodiment shown, the v-shaped bottom roller 704 comprises a channel 706 . The top disc-shaped roller 705 is disposed within the channel 706 . The tucker bar 702 , positioned between the tensioner 114 and the pair of rollers 704 705 provides a j-shaped fold having a terminal end 410 and a trough end 411 .
[0038] While the folding device 700 as shown comprises a tucker bar 702 and a pair of rollers 704 705 , in one embodiment, the folding device 700 comprises the tucker bar 702 . In one embodiment, the trough end 411 of the fold passes through the channel 706 of the bottom v-shaped roller 704 . The outer edge of the disc-shaped top roller 705 is bounded on two sides by the packaging film 110 as the packaging film 110 passes through the channel 706 of the bottom v-shaped roller 704 . In one embodiment, the former 426 comprises a gutter 710 mounted adjacent the edge of the former. The gutter 710 can be substantially perpendicular to the former edge.
[0039] FIG. 8 a is a simplified top view of the multi-delivery tube assembly in accordance with one embodiment of the present invention. In the embodiment shown, extensions 160 are attached to the first filling structure 418 . As shown in FIG. 8 a , the multi-delivery tube assembly comprises a first filling structure 418 , a second filling structure 420 and a third filling structure 421 . In addition, the multi-delivery tube assembly depicted in FIG. 8 a comprises a first vertical sealer 122 , a second vertical sealer 124 and a third vertical sealer 126 for sealing portions of the overlap segment 520 of film to a portion of the inner compartment wall 640 .
[0040] FIG. 8 b is a cut-away perspective view of the package made from the assembly depicted in FIG. 8 a . As shown in the Figure, the overlap segment 520 comprises a first longitudinal seal 522 , a second longitudinal seal 524 , and a third longitudinal seal 526 . In the embodiment shown, the package comprises three compartments 618 620 621 closed from one another. In one embodiment, one or more of the longitudinal seals 522 524 526 comprises a cold seal. Cold seal technology is well known in the art and is widely used to close food packages having heat-sensitive foods such as chocolate bars where heat sealing of the package is not desirable. Cold seal adhesives are typically coated or printed onto a flexible packaging film to permit sealing of the package with pressure.
[0041] It should be noted that there are several potential embodiments of the present invention. For example, referring to FIG. 8 b , in one embodiment if the third longitudinal seal 526 is omitted, the package can have a first compartment 618 , a sealed second compartment 620 and a third open compartment 621 . Thus, a package having two compartments 618 621 open to one another and a closed compartment 620 can be produced.
[0042] Examples of package applications, such as complementary products that can be packaged together in the main portion and compartment include crackers and cheese, cake mix and pre-packaged icing, or ready to eat cereal, milk, and/or a utensil such as a spoon. A pre-packaged seasoning can be placed in the compartment portion and a dehydrated food, such as noodles, can be placed in the main portion. The seasoning can be removed, water added to the main portion 618 , the entire package can then be heated in a microwave, the seasoning can be added, and the consumer can consume the food product directly from the main portion 618 of the package.
[0043] Promotional items can be also placed in the compartment with product placed in the main portion of the package. Thus, a consumer desiring to immediately access the promotional item can easily do so without immersing one's hand and fingers in product. For example, a promotional coupon can be placed into compartment portion of the package while potato chips are placed into the main portion. A consumer may only want a portion of potato chips, but may want to also access the promotional coupon. The promotional coupon, in prior art packages having no compartment often falls to the bottom of the package. Thus, a consumer may be forced, in a prior art package, to dig with his or her hand through the potato chips in order to access the promotional coupon. The present invention, on the other hand, permits a consumer to simply reach directly into the compartment to retrieve the promotional coupon without contacting product. The food package need not be limited to shelf-stable food products. For example, the package of the present invention can be used to store cereal and pre-packaged milk in the refrigerated section of a grocery store.
[0044] The present invention can be achieved with relatively inexpensive modification of existing form, fill, and seal machinery to produce a vertical stand up package having one or more open or closed compartments. Further, the multi-compartment package of the present invention is one-half to one-third the cost of a multi-compartment thermoformed package.
[0045] While the invention has been particularly shown and described with reference to a preferred embodiment, it will be understood by those skilled in the art that various changes in form and detail may be made therein without departing from the spirit and scope of the invention. | A method for making a vertical stand up package having one or more open or closed compartments within the package, and method and apparatus for manufacturing the same, constructed by modification to existing vertical form, fill and seal packaging machines. The invention involves producing a flat bottom bag that can stand upright having an internal compartment from a single sheet of flexible packaging film. A different product can be placed into the compartment. The compartment can also be used as a dipping well. In one aspect a multi-compartment package can be made. | 1 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of co-pending U.S. provisional patent application Ser. No. 61/873,237, filed Sep. 3, 2013, which is herein incorporated by reference in its entirety.
BACKGROUND
[0002] Composite wood particulate products, such as particleboard (PB), medium density fiberboard (MDF), and oriented strand board (OSB) can employ formaldehyde-free isocyanate adhesives instead of formaldehyde-containing adhesives such as phenol-formaldehyde, urea-formaldehyde and melamine-formaldehyde resins. Historically, none of these commercial composite wood particulate products manufactured with isocyanate adhesives employ fillers and/or extenders for any purpose.
SUMMARY
[0003] It would be desirable to produce composite wood products using aldehyde-free isocyanate adhesives which include fillers and/or extenders. The subject systems and methods include interactive extender-filler-containing polymeric, aldehyde-free, isocyanate adhesives which can readily be employed in the production of composite wood products. These interactive extender-filler-containing polymeric isocyanate adhesives are extremely important since they substantially reduce the relatively high cost of polymeric isocyanate adhesives (as compared to the cost of phenol formaldehyde adhesives). They also include interactive extender-fillers which act as compatibilizers for facilitating the effective and efficient distribution of the water and isocyanate to form a more evenly dispersed polymeric adhesive admixture.
DESCRIPTION OF THE DRAWINGS
[0004] FIG. 1A shows a block diagram of a method of making an interactive extender-filler-water slurry.
[0005] FIG. 1B depicts a block diagram of a method of making an adhesive with the interactive extender-filer-water slurry made by the method shown in FIG. 1A .
[0006] FIG. 1C is another block diagram of a method of making a wood particulate product using an adhesive made by the method shown in FIG. 1B .
[0007] FIG. 2 depicts the mixing rheology of pure pMDI and of a pMDI-water-aged tree bark slurry.
[0008] FIG. 3 depicts flow curves for pMDI and pMDI-water-interactive filler systems after 1 hour mixing at 100 s −1 shear rate.
[0009] FIG. 4 is a schematic diagram of an exemplary adhesive mixing apparatus.
DETAILED DESCRIPTION
[0010] In one embodiment, in the application of the interactive extender-filler-containing polymeric, aldehyde-free isocyanate adhesives in the production of composite wood products the addition of water during the adhesive/wood blending process is provided in a manner which facilitates effective and efficient admixing of the water and a polymeric isocyanate adhesive due to the presence of the interactive extender-filler composition. Ultimately, this substantially improves the board properties in spite of the fact that a significant portion of the more costly polymeric, aldehyde-free isocyanate adhesive has been replaced by the substantially less costly interactive extender-filler material which is not an adhesive material but which enhances the adhesive properties of the polymeric isocyanate.
[0011] In an embodiment herein, the polymeric isocyanate adhesive is a diisocyanate. In a further embodiment, the polymeric isocyanate adhesive is a tri-isocyanate. In still another embodiment, the polymeric isocyanate adhesive is at least one of a trimethylene diisocyanate, tetramethylene diisocyanate, pentamethylene diisocyanate, or a hexamethylene diisocyanate. In still another embodiment the polymeric isocyanate adhesive can be one or more of the following polymeric isocyanate adhesives: methylene diisocyanate (pMDI), aromatic disiisocyanates such as 2,4 tolylene diisocyanate, and 2,6 tolylene diisocyanate, methylene diphenlydiiocyanates, and polymeric isocyanates based on methylene diisocyanates.
[0012] However, polymeric isocyanate adhesives and water do not mix readily. Instead they undergo phase separation.
[0013] FIG. 1A shows a method of producing an interactive extender-filler-water slurry 100 . The method 100 can include providing an interactive extender-filler 102 and providing water 104 . The method 100 further includes admixing the interactive extender-filler and water to form the slurry 106 . Optionally, a rheology modifier can be added to the interactive extender-filler 108 and/or the interactive extender-filler can be particularized 110 .
[0014] FIG. 1B shows a method of producing an interactive, aldehyde-free, extender-filler-water-isocyanate adhesive that can be used in a composite wood particulate product. Producing the adhesive includes the same method steps of FIG. 1A to first form the interactive extender-filler slurry. Isocyanate is provided 112 and then the slurry is then intermixed with the isocyanate to form the adhesive 114 .
[0015] FIG. 1C shows a method of producing a wood particulate product that uses the interactive, aldehyde-free, extender-filler-water isocyanate adhesive produced by the method shown in FIG. 1B . To produce the wood particulate product, the wood particles are provided 118 and then are blended with the interactive, aldehyde-free, extender-filler-water isocyanate adhesive 120 . The blended wood particles and adhesive form a mat 122 and the mat is then pressed to form the composite wood particulate product 124 . Optionally, one or more of a catalyst, fire retardant, pigment, or biocide can be added to the adhesive 116 before it is blended with the wood particles.
[0016] The subject interactive extender-filler facilitates uniform mixing of polymeric isocyanate adhesives and water. In an embodiment, it has now been determined that by introducing interactive extender fillers into the water, then mixing the aqueous interactive extender filler mixture with the polymeric isocyanate adhesives, it will facilitate the blending of water with the polymeric isocyanate adhesives.
[0017] In another embodiment, the interactive extender-fillers provides for a higher level of compatibility between the water and the polymeric isocyanate adhesives, resulting in better mixing of water and polymeric isocyanate adhesives phase, and thereby better stability of the adhesive system. In a further embodiment, the interactive extender-filler composition acts as a compatibilizer which allows the water to be more effectively distributed throughout the polymeric isocyanate adhesive. This results in more effective mixing of the polymeric isocyanate adhesives and water, which in turn will improve the distribution of polymeric isocyanate adhesives and water throughout a wood particulate product, thereby resulting in improved board panel properties which at the same time substantially reduce the final product cost.
[0018] In still another embodiment, the subject method also substantially reduces the over-penetration of the polymeric isocyanate adhesives into the wood particles which form the composite wood product. This further minimizes the amount of polymeric isocyanate adhesives which are employed in the formation of the composite wood product, and in turn significantly increases the cost savings with respect to the production of these products.
[0019] In one embodiment, the interactive extender-filler is aged tree bark. In another embodiment, aged alder tree bark is the interactive filler. In a further embodiment, the aged tree bark can be aged softwood bark. In still a further embodiment, the aged softwood bark can be from at least one of the following trees: pine, including but not limited to southern yellow pine, loblolly pine, white pine, ponderosa pine, sugar pine, and lodge pole pine, fir, including but not limited to Douglas fir and grand/white fir, and hemlock, and larch. In a further embodiment, the aged tree bark can be aged hardwood bark. In still a further embodiment, the aged hardwood bark can be from at least one of the following trees: maple, including but not limited to southern red maple, sugar maple, and white maple, oak, including but not limited to red oak, white oak, and yellow oak, luan, mahogany, eucalyptus, acacia, poplar, cottonwood, and aspen.
[0020] In one embodiment, the aged tree bark is produced by exposing tree bark to the atmosphere in an open dry area for a predetermined time period. In another embodiment, the aged tree bark is produced by storing tree bark in a dry covered outdoor area to allow moisture to escape from the tree bark. In a further embodiment, the aged tree bark is produced by exposing tree bark to the atmosphere in an open dry area for a predetermined time period and then storing tree bark in a dry covered area to allow moisture to escape from the tree bark.
[0021] In one embodiment, the aged tree bark is naturally produced without the addition of chemicals. In another embodiment, the aged tree bark is a dark brown color. In still a further embodiment, the aged tree bark readily breaks apart upon handling by an end user. In yet another embodiment, the aged tree bark has a rotten smell.
[0022] The optimal time to produce the aged tree bark varies depending on the species of wood employed and the aging process employed. In one embodiment, aged tree bark has an optimal aging time of at least about 1 week, in another embodiment at least about 3 weeks, and in a further embodiment at least about 6 weeks, in a still another embodiment up to about 16 weeks, in yet another embodiment up to about 12 weeks and in still a further embodiment up to about 9 weeks.
[0023] In another embodiment, the aged tree bark is separated from any white wood. In a further embodiment, aged tree bark is dried. In still another embodiment, the aged tree bark is dried to a moisture content of from about 5%, in still a further embodiment, the aged tree bark is dried to moisture content of from about 6%, and in yet another embodiment, the aged tree bark is dried to moisture content of from about 8%. In another embodiment, the aged tree bark is dried to moisture content of up to about 16%, and in still a further embodiment, the aged tree bark is dried to moisture content of up to about 14%, and in yet another embodiment, the aged tree bark is dried to moisture content of up to about 12%.
[0024] In an embodiment herein, the dried aged tree bark which is employed to produce the interactive extender-filler is particularized so that it can be readily dispersed in the subject adhesive system. In one embodiment, the interactive extender-filler has an average particle size of up to about 1000 microns, in another embodiment an average particle size of up to about 500 microns, in a further embodiment an average particle size of up to about 400 microns, in still a further embodiment an average particle size of up to about 250 microns, and in still another embodiment an average particle size of from about 30 microns, in a further embodiment an average particle size of from about 50 microns, and in yet another embodiment an average particle size of from about 100 microns.
[0025] In one embodiment, the interactive extender-filler is substantially stable in water. In another embodiment, it is compatible with polymeric isocyanate adhesives. In a further embodiment, it prevents precuring of polymeric isocyanate adhesives. In still another embodiment, it exhibits an optimal viscosity profile for improved adhesive distribution during spray application.
[0026] In an embodiment, the interactive filler-extender/water slurry is added to the water prior to blending of the water-containing slurry and polymeric isocyanate adhesives. This extends the use of polymeric isocyanate adhesives in the production of composite wood products. Thus, this method of application allows for a reduction in the amount of polymeric isocyanate adhesives which are required to be added to the mixture in order to produce the panel.
[0027] In an embodiment herein, the water-polymeric isocyanate adhesives reaction at room temperature is significantly reduced in the presence of interactive extender-fillers in the water phase. This substantially reduces the chance of pre-cure and in turn significantly overcomes potential loss of effective polymeric isocyanate adhesive availability for adhesive bonding purposes.
[0028] In an embodiment herein, the interactive extender-filler-water slurry when mixed with polymeric isocyanate adhesive provides unique rheological properties. In another embodiment, it provides excellent high low-shear viscosity. In a further embodiment, it provides outstanding low high-shear viscosity. This rheological profile in one embodiment allows efficient spraying of the adhesive system without significant build-up and clogging of the spraying equipment as well. In still another embodiment it provides for better distribution and higher availability of adhesive at the wood-adhesive bond line. Consequently, this reduces the polymeric isocyanate adhesive requirement while maintaining bond strength.
[0029] In yet a further embodiment, a rheology modifier can be added to the interactive extender-filler. In another embodiment, the rheology modifier can be added to the interactive extender-filler slurry.
[0030] Rheology modifiers are chemical additives which are used in a formulation to change/modify flow properties of the product. These additives can be inorganic or organic. In an embodiment inorganic rheology modifiers can be a clay material. In another embodiment, organic rheology modifiers can be synthetically produced. In a further embodiment they can be natural products. In still another embodiment the organic rheology modifiers can be synthetic polymers. In still a further case the natural products can be fatty acids, xanthan gum, or grain flours, for example.
[0031] In yet another embodiment, one or more of the following rheology modifiers can be used to improve stability, dispersability in water and sprayability:
Clay products such as BENTONE EW-NA from Elementis Specialties Gum products such as guar gum and xanthum gum such as Kelzan-S® Cellulosic products such as Bermocoll EBS 451 from AkzoNobel INC Grain products such as Wheat Flour, Wheat Bran, Corn Flour, Soy Flour and Oat Fiber Other rheology modifier additives such as BYK-420 from BYK
[0037] Additives and Instruments
[0038] Furthermore, in a still further embodiment, the emission of volatile monomeric isocyanate is substantially reduced when the above-described method of making a wood particulate product based on an aldehyde-free adhesive is employed. Moreover, in still another embodiment which is provided by the above-described method, face pitting of the composite wood particulate product is substantially reduced which leads to a smoother surface finish.
[0039] As previously stated, an aldehyde-free isocyanate-water-interactive extender-filler is employed herein in making the composite wood particulate products. In one embodiment, the amount of isocyanate employed is from about 10% by weight, in another embodiment from about 15% by weight, in a still further embodiment from about 20% by weight, and in still another embodiment up to about 80% by weight, in a further embodiment up to about 75% by weight, and in a further embodiment up to about 70% by weight. In yet another embodiment, the amount of water employed is from about 10% by weight, in another embodiment from about 15% by weight, in a still further embodiment from about 20% by weight, and in still another embodiment up to about 70% by weight, in a further embodiment up to about 65% by weight, and in a further embodiment up to about 60% by weight. In yet another embodiment, the amount of interactive filler-extender employed is from about 5% by weight, in another embodiment from about 7.5% by weight, in a still further embodiment from about 10% by weight, and in still another embodiment up to about 25% by weight, in a further embodiment up to about 20% by weight, and in a further embodiment up to about 15% by weight.
[0040] The polymeric interactive extender filler-water slurry provides a pathway for efficient addition of catalysts, fire retardants, pigments and biocides directly to the polymeric isocyanate adhesive before spraying on the wood furnish.
EXAMPLE
Interactive Extender Filler/Water Slurry Preparation
[0041] An exemplary interactive extender filler/water slurry was prepared, as follows:
Blending of dry fillers: An interactive extender filler which was aged alder tree bark having a particle size less than 100 mesh (150 microns) was dry blended with 0.5% (by weight) of a rheology modifier such as Kelzan-S®. Mixing of the slurry: The interactive extender-filler and Kelzan-S® powder blend were mixed with water at 25% filler to 75% water by weight. The slurry was prepared in the following manner:
Required amount of water was charged in a steel container, attached to a lab disperser. The interactive extender-filler and Kelzan-S dry powder blend was then added to the water slowly under constant mixing at 5,000 to 12,000 rpm. After the addition of powder blend, an additional 10 to 20 minutes of mixing was performed to produce an interactive extender-filler-water slurry.
Particleboard Fabrication
[0047] An exemplary particleboard was fabricated employing a polymeric isocyanate adhesive (pMDI) and the above interactive filler-extender/water slurry, as follows:
1. Wood particulate material (furnish) were dried to a moisture content of 3 to 4% by weight based on the weight of the furnish. 2. Required amount of furnish was added to an 18.927 liter (5 gallon) ribbon blender. 3. The pMDI polymeric isocyanate adhesive (Rubinate 1840) and the above described filler/water slurry were loaded into a 1:1 400 ml MIXPAC™ equipped with a static mix tube. The MIXPAC™ is a dual component cartridge, manufactured by Sulzer Ltd., that dispenses two fluids simultaneously at a ratio of 1:1 by volume. The two components are extruded through a long static mix tube with numerous plastic mixing elements which cause turbulent fluid flow thoroughly mixing the two components before exiting the end of the mix tube in the form of a single mixed material. 4. A mechanically driven applicator, manufactured by Albion, is used to dispense the interactive filler-extender/water slurry and pMDI from the MIXPAC™ at a constant dispensing rate (0.025 to 0.05 kg/min), the pMDI and the interactive filler-extender/water slurry were mixed in line and sprayed onto the furnish through a spray nozzle attached to the end of the static mix tube under 69 to 138 kPa (10-20 psi) pressure. 5. The pMDI content in the panel was maintained at up to 3% based on the dry furnish weight. 6. After adhesive application the air was turned off and blending continued for 5 minutes. 7. The blended adhesive and wood furnish was then formed into mats and pressed to ¾ inch thick panels with a target density of 34.6 lbs/cubic ft. The press temperature was set to 176.67° C. (350° F.) and the pressing time was 7 min (including 60 sec to consolidate mat). 8. Finished particleboard was allowed to cool before cutting into 0.051 m by 0.051 m (2 inch×2 inch) specimens for internal bond testing.
Internal Bond Strength
[0056] Internal bond testing of the finished particleboard described above was conducted.
[0057] Approximately 0.0381 m (1.5 inch) was trimmed off each side of the roughly 0.3048 meter (1 ft) square panels before cutting them into 0.051 m by 0.051 m (2 inch×2 inch) test specimens. Internal bond strengths of the panels were then tested according to ASTM D1037-12. For low density composite particulate wood products, in one embodiment, the internal bond strength is at least about 10 psi, in another embodiment at least about 12 psi, and in a further embodiment at least about 13 psi, and in still another embodiment up to about 22 psi, in still a further embodiment up to about 20 psi, and in yet another embodiment up to about 19 psi. For high density composite particulate wood products, in one embodiment, the internal bond strength is at least about 90 psi, in another embodiment at least about 95 psi, and a further embodiment at least about 100 psi, and in still another embodiment up to about 130 psi, in still a further embodiment up to about 125 psi, and in yet another embodiment up to about 120 psi.
[0058] Rheology of Adhesive Systems
pMDI and the interactive filler-extender/water slurry were mixed using a static mix tube. 40 ml of mixed adhesive system was loaded into a concentric cylinder cup of a TA Instruments DH-1 Rheometer equipped with a ribbon helical mixing accessory capable of mixing the adhesive system with a precisely-controlled shear rate. The resulting viscosity change was measured in real time. Specimens were sequentially tested at room temperature as follows:
a) Mixing at 100 s −1 shear rate for 1 hour while measured viscosity at 10 second intervals. b) Measured viscosity vs. shear rate after 1 hour mixing.
[0064] FIG. 2 shows the mixing rheology of pure pMDI and pMDI-interactive extender-filler slurry, respectively. Mixing pMDI with pure water causes a significant increase in the viscosity over time. This is indicative of the severe reaction between pMDI and water which produces polyureas. Therefore, mixing pMDI with water only is not desirable and this will cause pre-mature reaction (pre-cure) and potential reduction in the pMDI availability for bonding.
[0065] Contrarily, in the presence of the interactive extender-filler, this pre-cure reaction is dramatically reduced. This conclusion is demonstrated by the data indicating little or no increase in the viscosity over time for adhesive systems which employ an interactive extender-filler. Furthermore, with aging, the blend viscosity of the adhesive system including an interactive extender-filler increases, indicating better compatibility of the pMDI and the water phase. With aging, the hydrophobicity of the subject fillers increases. This makes the aged tree bark fillers relatively more compatible to pMDI phase as compared to un-aged fillers and wood-flour. Aged tree barks thereby provide stability to the pMDI-water emulsion systems in addition to inhibiting the pre-cure reaction. FIG. 2 also shows that with extreme aging (in this case greater than 8 weeks) fillers fail to inhibit the pMDI-water reaction efficiently. Therefore, a controlled aging process is essential to impart required characteristics to the tree bark fillers.
[0066] FIG. 3 shows flow curves for respective pMDI and pMDI-water-fillers systems after 1 hour mixing at 100 s −1 shear rate. These flow curves show that the addition of pure water into pMDI increases its viscosity (see FIG. 2 ). However, the resultant product does not show any shear thinning (pseudoplastic) behavior under higher shear rate. High shear rate thinning is extremely important for efficient spraying of adhesive during panel fabrication. Addition of the subject fillers imparts significant shear thinning characteristics.
[0067] It has also been determined that with increasing aging the extent of shear thinning increases. More specifically, with higher aging the resultant blend shows high low-shear viscosity and low high-shear viscosity. This combination of viscosity properties is very important. The presence of high low-shear viscosity prevents over penetration of adhesive into the wood and consequently more adhesive is available for bonding. Moreover, the presence of low high-shear viscosity enables more efficient spraying without blocking and clogging of the spraying equipment. Therefore, it is evident that the use of an interactive extender-filler, typically in the form of optimally aged tree bark, changes fundamental rheology of the adhesive system, thereby providing less pre-cure, minimizing over penetration of adhesive and providing better adhesive distribution by efficient spraying.
[0068] FIG. 4 shows an example system 400 for producing the adhesives described above. First, the slurry is mixed in the slurry supply 402 that includes the interactive extender-filler and water admixed together, as described above in FIG. 1A . A pMDI supply 404 , like any type of isocyanate described above, contains the pMDI that is used to make the adhesive. Each of the slurry supply 402 and the pMDI supply 404 are fed into respective recirculators 406 , 408 . The respective recirculators 406 , 408 each admix the slurry and the pMDI prior to intermix the slurry with the pMDI to make the adhesive.
[0069] The supply lines for the slurry and the pMDI have respective pumps 410 , 412 that cause the slurry and pMDI, respectively, to cause the slurry and pMDI to exit their respective supplies 402 , 404 and move into the recirculators 406 , 408 , respectively. Respective flow meters 414 , 416 are included in each supply line for the slurry and the pMDI that help regulate the flow rate of the slurry through its supply line and the pMDI through its supply line. Further, the slurry and pMDI supply lines each have pressure sensors 418 , 420 that regulate the pressure of the slurry and the pMDI, respectively through their respective supply lines. In the example system 400 shown in FIG. 4 , the recirculators 406 , 408 for each of the slurry and the pMDI produce recirculated slurry and pMDI, respectively, to a mix tube 422 that intermixes the slurry and pMDI to form the adhesive.
[0070] It will be appreciated that variations of the above-disclosed systems and methods for producing slurries, adhesives, and wood particulate products, or alternatives thereof, may be desirably combined into many other different systems, methods, or applications. Also various presently unforeseen or unanticipated alternatives, modifications, variations, or improvements therein may be subsequently made by those skilled in the art. | The disclosed composite wood particulate products, adhesives contained in such wood particulate products, and methods of making the adhesive and the wood particulate products employ an aldehyde-free adhesive, and more specifically a formaldehyde-free adhesive. The aldehyde-free adhesive includes an inert additive that extends a resin, such as an isocyanate resin, and forms an evenly dispersed, less expensive polymeric adhesive admixture. The extender-filler of the resin is mixed with water to form a slurry. The slurry can then be mixed with a resin, like the isocyanate resin, to form the adhesive. Various rheology modifiers can be added, if desired, to the extender-filler or the slurry. The adhesive can be blended with wood particles to form a mat that is then pressed into a composite wood particulate product. | 2 |
This is a divisional of application Ser. No. 08/398,465, filed on Mar. 3, 1995 U.S Pat. No 5,563,833.
RELATED APPLICATION
U.S. patent application Ser. No. 08/398,468, filed Mar. 3, 1995, entitled "BIST Tester for Multiple Memories"(Atty. Docket No. BU9-94-146).
FIELD OF THE INVENTION
This invention relates generally to testing of memory devices, and in one aspect to a built-in self-test for VLSI circuits which are contained on semiconductor chips. In a more particular aspect, this invention relates to a built-in test for memories on semiconductor chips wherein there are a plurality of memories on the chip and wherein one memory is associated with another; i.e., one memory provides at least part of the information required by one or more additional memories known as associated memories during conventional operation. Such a memory relationship can be, for example, on microprocessors wherein there are conventional memories which store data such as data cache unit (DCU) memories and which have associated therewith CAM memories, i.e., content addressable memories, which supply part of the address to the DCU memories during conventional operation, although other types of associated memories can be tested according to this invention.
BACKGROUND ART
Testing of associated memories of the type described above, formed on semiconductor substrates, has often been done by the provision of a built-in self-test (BIST). BISTs include a state machine formed on the silicon substrate which contains the associative memories and the other VLSI circuit components such as the logic components of a microprocessor chip. Such a BIST is shown in copending application Ser. No. 08/398,468, filed Mar. 3, 1995 and entitled "BIST Tester for Multiple Memories" (Atty. Docket No. BU9-94-146); and a state machine for testing a DCU type memory is shown in U.S. Pat. No. 5,173,906.
In testing multiple memories, conventional prior art practice has been to surround each of the memories with latches and multiplexors and to test each memory independently, from data supplied by the state machine of the BIST or through a scan-chain from an off-chip tester. Also, conventional prior art has employed a separate BIST for each memory. While in many cases this works quite well, it does have certain drawbacks, especially in the case of testing associated memories. One such drawback is the requirement of a significant amount of chip area or "real estate" needed for forming the latches and multiplexor which bound the various memories. Another drawback is the totally independent testing of an associated memory (i.e., one that in normal operation receives a portion of its information or data, such as a portion of the address, from another memory) is that the path between the two memories is not tested. This is because the test signals to this dependent memory are separately supplied from the BIST rather than being supplied through the source memory. Thus, totally independent testing does not test the performance of the associated memories using the critical path between one memory and the other. Any problems or improper functioning of the critical data path between the two memories in the transfer of data is not detected by this type of testing since each memory is tested separately and independently from data generated from the BIST machine which does not use one memory to supply data to another memory, i.e., with the signal timings and along the path which the data flows during functional operation. While the problem of testing associated memory is extant in BIST tests, it also exists in other types of tests of memories, e.g., signals from off-chip testers applied to test memory circuits and other dependent circuits.
SUMMARY OF THE INVENTION
According to the present invention, an associated memory structure comprised of a plurality of memories amenable for testing and a method of testing the memories is provided. First and second memories are formed (on a semiconductor substrate in the preferred embodiment) wherein the data in the first memory provides a basis for at least a portion of the input to the second memory during functional operation of the two memories. Means for inputting test signals into the first memory is provided, and preferably an output latch for receiving the output test data from the first memory is provided. Means are provided for loading the first memory with data which is utilized as a basis for providing at least a portion of the input to the second memory. An access path from the output port of the first memory to the input port of the second memory is provided to thereby allow use of the data in the first memory to generate at least a portion of the input of the second memory. The first memory is first tested independently of the second memory. Thereafter, the first memory is loaded with preconditioned algorithmic data that is used as a basis for inputs to the second memory during testing of the second memory. The second memory is then tested by generating inputs to the first memory during the test of the second memory, which will cause outputs of the first memory to be supplied to the second memory which constitutes at least a portion of test data inputted to the second memory. A latch is provided to capture the output of the test data from the second memory.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagrammatic view of the functioning of a content addressable memory (CAM) and its function to provide input to a data cache unit (DCU) memory in one embodiment of this invention;
FIG. 2 is a block diagram showing a typical prior art construction of a typical configuration for testing the functioning of a CAM memory associated with a DCU memory;
FIG. 3 is a block diagram showing the construction according to this invention of the interconnection for testing the functioning of a CAM memory and a DCU memory receiving some input data therefrom;
FIG. 4 is a block diagram of the invention showing specific architecture that provides for parallel processing of the CAM and RAM;
FIG. 5 is a block diagram of the invention showing the circuitry of a single CAM column and associated cascaded OR;
FIG. 6 is a circuit diagram of the invention showing a specific first cascaded OR circuit that is associated with every CAM address location;
FIG. 7 is a circuit diagram of the invention showing a specific second circuit in the cascaded OR that receives output signals from the first cascaded OR circuit shown in FIG. 6; and
FIGS. 8a and 8b illustrate a circuit diagram of the invention showing a third circuit in the cascaded OR that receives output signals from the second circuit of the cascaded OR shown in FIG. 7.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The embodiment described here utilizes a content addressable memory (CAM) and a random access memory (RAM) where the RAM obtains part of its addressing from the CAM. According to prior art techniques, each would need input and output latches and would be tested independently. As described herein, a method and structure has been provider test the two memories while maintaining their interdependent nature during test just as in functional operation. This method provides a reduction in area consumption by test-only circuitry and also enhances the test quality by eliminating timing differences between test operation and functional operation.
Referring now to FIG. 1, a representation of a typical content addressable memory (CAM) 10 and its functioning to provide a partial input to a data cache unit (DCU) memory 12 is shown. In this representation, eight column locations (Column 0-Column 7) are provided, and 64 rows of wordlines (WL0-WL63) are provided. Eight bits of binary data ("1"s, "0"s) are stored in each row/column location and form the basis of the data to which inputs are compared. Each row/column location has at least one additional data valid bit (not shown) that must be set true for the output compare to be functional.
The test inputs are from a built-in self-test (BIST) state machine such as that described in related application Ser. No. 08/398,468, filed Mar. 3, 1995, and entitled "BIST Tester for Multiple Memories"(Atty. Docket No. BU9-94-146) or from BISTs as described in U.S. Pat. No. 5,173,906 which is incorporated herein by reference.
In operation, the CAM 10 receives the necessary compare data CD as input to input port 14 of the CAM 10 wherein the compare data CD is compared to determine if that particular bit pattern is stored at a given word line. (In this embodiment, eight bit patterns are compared, but other patterns can be used.) This is shown diagrammatically in FIG. 1 wherein a series of bit patterns are stored in the CAM 10. In the illustrated embodiment, each wordline (row) contains eight 8-bit patterns. Each pattern is stored at a different column location (Column 0-Column 7) on the wordline. The CAM 10 works on the principle that eight data bits are stored in each column/row location, and that the input is supplied to input port 14 as compare data bits CD. If a match occurs at a column location on the selected wordline, then the column comparator asserts a "1". If columns happen to match the compare data CD, then all eight column comparators would assert "1"s and the CAM 10 output at output port 16 would be "11111111". If a mismatch is found in a column on the selected wordline, then the column comparator output is forced to a "0". The eight comparator outputs from output port 16 of CAM 10 are supplied as one part of the input to DCU 12 at input port 18 thereof. In the illustration as shown, if compare data bits 00010000 were supplied to input port 14, there would be a comparison in column 3 of the selected wordline causing the column 3 comparator to assert a "1" and the remaining seven column comparators to output "0"s which would result in the CAM 10 outputting via output port 16 the 8-bit address 00010000 to input port 18 of the DCU 12. The CAM output matches the 8-bit pattern in column 3 because the column locations were purposely written with the patterns shown in FIG. 1 and not because the CAM actually outputs the pattern store in column 3. This operation is well known in the art and need not be further described.
The input port 18 of the DCU 12 receives the output from the CAM 10 as a one of eight bit address. A word address, defined as WA, data, and Read/Write (R/W) control supplied by the BIST state machine is also received at port 18. The path from the CAM 10 to the DCU will be described presently. In any event, the output of the CAM is a function of the data stored therein and the compare data CD.
Referring now to FIG. 2, a typical prior art configuration or construction and interconnect of a CAM 10 and DCU 12 with the necessary latches and multiplexors used to both verify the integrity of and control the selection between the operational path and the test paths to and from memories 10 and 12 is shown. It is to be understood that this figure is representative of only one particular configuration involving two specific types of associated memories, which is but one of several possible connections of multiplexors and latches for functional operation and testing. Nevertheless, FIG. 2 represents a typical implementation of both operational and test paths for these types of associated memories.
As indicated above, in this embodiment, the CAM 10 is provided which in normal operation (i.e., not test mode) provides a part of the bit address to the DCU 12. The remainder of the bit address, as well as the wordline address for the DCU 12 is provided from a separate source, i.e., a source different from the CAM. Data and R/W control are also provided from a source separate from the CAM. Thus, in operation, when the memories are being utilized and there needs to be an access to the DCU memory 12, a portion of the address for such access is supplied by the CAM 10. Such type of associated memory operations is well known in the
Also as is well known in the art, it is necessary to test both the CAM and the DCU memories before chip functional operation. To this end, in the past, both the CAM 10 and the DCU 12 have been tested independently through all phases of BIST testing, even though there is an associative relationship between the DCU 12 and the CAM 10 during functional operation. The testing and operation of the memories 10 and 12 is typically carried out using a prior art structure similar to that in FIG. 2.
The operational path between memories 10 and 12 is comprised of CAM output 24 being supplied as input to multiplexor group 26 (which in structure is defined by eight multiplexors), and the output 28 of multiplexor group 26 provided as input to input port 18 on the DCU 12 as an 8-bit predecoded address. The test path into the DCU 12 is comprised of an 8-bit predecoded address provided as input 32 to multiplexor group 30 (which in structure is defined by eight multiplexors); the output 34 of multiplexor group 30 is supplied to latch group 36 (which in structure is defined by eight latches); the output 37 of latch group 36 is supplied as the other input to multiplexor 26; and the output 28 of multiplexor group 26 is provided to DCU's inputs port 18. A second test path for verifying CAM outputs is comprised of output 24 being supplied as input to multiplexor group 26, output 28 of multiplexor group 26 being routed along feedback path 42 to the other input of multiplexor group 30, output 34 of multiplexor group 30 being supplied to latch group 36, and output 37 of latch group 36 being supplied to CAM data compression 44. CAM data compression 44 can be actuated by load result signal LR1 from the BIST. Similarly, latch 46 receives an output from output port 48 of the DCU 12, and provides DCU data compression 52 with an output. DCU data compression can be actuated by lead result signal LR2.
Still referring to FIG. 2, when the CAM 10 is operating in a functional manner, i.e., supplying functional data, the output from the CAM 10 is supplied to the multiplexer 26, and the select signal 38 selects this input 24 as that passed to output 28 of multiplexer 26 which is delivered to the input port 18 of the DCU memory 12 to supply the eight pro-decoded address bits.
However, as indicated before, the CAM 10 and the DCU memory 12 must be tested before they are put into operation or made functional. To this end, both the CAM and the DCU memories are tested separately. To test the CAM 10, the necessary test patterns are supplied as inputs to the CAM and to compare with data in memory, and the compare results are outputted from output port 16 to the functional data line 24 to the multiplexer 26. Conventional test patterns can be applied as is well known in the art in this case, the signal select 38 is used to select the CAM out 24 to provide the output 28 from the multiplexer 26 which then feeds back signal 42 to provide the output from multiplexer 30 to the latch 36 which constitutes the test data being captured from the CAM 10. The output 37 from latch group 36 (which in structure is defined by eight latches) is delivered to the data compression 44, and the lead result signal is actuated during the testing of the CAM to lead the test results. Thus, the CAM 10 is tested independently of the DCU.
Turning now to the testing of the DCU memory 12 and still referring to FIG. 2, when the memory 12 is to be tested, the select signal 40 selects the BIST input signal 32 to be outputted as the output 34 from the multiplexor 30 to the latch 36. The latch 36 supplies as output 37 a signal to the multiplexor 26 where the select signal 38 selects the input 37 to the multiplexor 26 as the output 28 to the input port 18 of the memory 12. Thus, for testing the DCU memory 12, the 8-bit pre-decoded address which is provided to the input port 18 of the DCU 12 is not provided from the CAM 10 (from which it is provided during functional operation), but rather is provided from the BIST test machine and controlled by the signal patterns thereof. There are two undesirable results of this construction. First, a significant amount of area is required because of the utilization of two multiplexors and a latch. Moreover, and more significantly, the timings of signals on the functional path through the CAM memory 10 to the input port 18 of the DCU 12 for the eight bits of the address is not being tested, and the timing of these functional signals may vary from the timing of the test signals generated by the BIST machine. Thus, while the DCU 12 may perform well with all of the signals from the BIST machine in the test mode, in actual operation the DCU memory 12 may not properly function when it receives addresses at input port 18 from the CAM memory 10 based on the timing of the CAM memory 10 and the timing of the functional path.
Turning now to FIG. 3, construction of the interconnection between the CAM memory 10 and the DCU memory 12 according to the present invention is shown. According to this invention, the functional output 24 from the output port 16 of the CAM 10 is asserted directly on the input port 18 of the DCU 12 without the interposition of any multiplexors or latches in the path and is used both in the functional mode and the test mode of the DCU 12. A latch 36 is provided to receive the output from the output port 16 of the CAM memory 10 which is the same type of latch as shown in FIG. 2, and a data compression 44 also is provided which is the same as shown in FIG. 2. A latch 46 is connected to the output port 48 of the DCU memory 12 which in turn is provided with a data compression store 52 that is actuated by load result signal LR2.
In conventional operation of the embodiment as shown in FIG. 3, the output from the output port 16 of the CAM memory 10 is supplied directly to the input port 18 of the DCU memory 12 as eight pre-decoded address signals in the same way that the input signal is provided in the prior art from the multiplexor 26, although in this case it is supplied directly to the input port 18. During the normal operation and supplying of the data as the functional data on line 24 to the input port 18, data is being supplied to the latch 36, but signal LR1 to the data compression 44 is not actuated so that the outputted data is not captured with load result.
The testing of the CAM and the DCU memories in the embodiment as shown in FIG. 3 is as follows. For testing purposes, the CAM memory is first tested by supplying the necessary input patterns thereto as described with respect to FIG. 2 from a BIST. The output of the compare pattern is loaded into the latch 36 and the load result signal LR1 is actuated to enable the data compression 44 to test the CAM in the same way the CAM memory 10 has been tested in the prior art.
Once the CAM memory 10 has been tested, the DCU memory 12 can then be tested. The CAM memory 10 is loaded with the preconditioned decode addresses by BIST for the particular tests being performed on the DCU memory from the BIST. Then, the DCU memory 12 is tested, supplying the word address portion of addresses through the port 18 just as in FIG. 2. However, compare data CD is provided to the CAM input port 14 by the BIST which corresponds to the three-bit portion of address being tested in the DCU 12 and the output from the CAM 10 provides the 1 out of 8 select address as input to the DCU 12 during the test. The output from the DCU memory 12 is outputted from port 48 into latch 46, and the load result signal LR2 is actuated to capture the output and determine pass/fail result of the test in the data compression store 52. Thus, the testing of the DCU 12 is done utilizing input from the CAM memory 10 using its particular signal timings on the path 24 which will be the same as utilized during actual operation of the memory devices rather than a separate timing path from the testing machine as in the prior art.
The following FIGS. 4-7 describe parallel processing of the CAM and the RAM in a DCU. CAM designs have been classically used in the word dimension as fully associative elements. An address field is compared against a column of CAM cells organized N cells wide and R rows deep. If a match occurs, a wordline associated with the matched row is selected. The selected wordline drives across standard memory cells which contain the desired data. This prior art process creates a situation where the RAM is waiting for the CAM to process its row selection address. In current processor architectures, a key design goal is to design processors that operate at ever faster processing speeds. This design goal holds true for both testing and general operation of the microprocessor architecture.
In reference to FIG. 4, there is a block diagram showing an architecture that provides parallel processing of the CAM and RAM which does not require the RAM to wait for the CAM to process the row address for the RAM. In addition, there is a CAM design that performs associative or semi-associative decode bit addressing of a RAM. It is noted that RAM 300 and MUX 500 can be operated as a TAG, a data storage array architecture, or a DCU, generally indicated by element number 360. In operation, decoder 100 will select which one of 64 rows in the CAM 200 and RAM 300 will be selected when the decoder receives a row address signal 105. Concerning the operation of the RAM 300, the selected RAM row will download all data stored in the selected data locations onto the associated eight RAM columns, referred to as C1-C8. For example, data locations 320 through 340 would be downloaded to C1 through C8, respectively. The RAM data will thereby be routed to MUX 500, illustrated as an 8×1 MUX, where one of the eight inputs from the RAM will be enabled to immediately route one of the columns of RAM data to output line 510. Concerning the operation of the CAM 200, a row address 105 signal arrives at the decode 100, a compare address 400 is simultaneously routed, via lines 420, to every CAM location (i.e., locations 220 to 240) on every CAM row. If there is a match on the selected row, then a cascaded OR 260 (one per column C1 to C8) will pull the associated CAM column output line 110 high. The output lines 110, which form a bus 120, are each coupled to MUX 500. In operation, for example, CAM column C1 can output a signal to output line 110 that will program MUX 500 to allow data in RAM column C1 to be output to output line 510. In summary, by using a row decode circuit 100 to simultaneously select the row of the RAM and CAM, and by using bit addressing of the CAM, the MUX 500 can be enabled before the data in the selected row of the RAM arrives. Therefore, the RAM processing will not have to wait for the CAM processing to first be completed.
In reference to FIG. 5, there is shown a block diagram of the specific circuitry for a single CAM column and associated cascaded OR. The column of CAM locations and associated OR is divided into four equal blocks 600a-600d each having equal numbers of rows or address locations, i.e., location 220. In this example for illustration purposes, there are ten bit cells in each CAM location. When the location receives the compare address, the results will either cause match line 610 to be a high or low voltage level. For example, when the compare address 400 matches the location 220, the cascaded OR coupled to the first CAM column C1 will be activated to output a high signal on the matching column output line 110. More particularly, the sequence of events are as follows: match line 610 outputs a high voltage, wordline select (WLS) 630 strobes, first cascaded OR circuit 620 will pull line 650 low, the second cascaded OR circuit 640 outputs a high voltage on line 670a, and the third cascaded 0R circuit 660 will output a high voltage signal on the associated output line 110. It should be noted that WLS 630 is the input from the decode circuit 100. It should be further noted that the decode circuit 100 includes the wordline driving circuitry (not shown).
In reference to FIG. 6, there is a circuit diagram of the first cascaded OR circuit 620 that is coupled to every CAM address location. In operation, if a match occurs between the compare address and the CAM location, match line 610 will remain high, via PFET 614, and NFET 619 will remain activated. Output line 650 will then be brought low after WLS 630 strobes. If there is no match, the following sequence occurs: match line 610 is brought low, NFET 619 will be turned off, so that when WLS strobes, NFET 618 will be activated, and output line 650 is maintained high. Whether there is a match or not, circuit 620 needs to be reset to the starting conditions. The starting conditions are reset after WLS strobes, by strobing rest RST1, causing PFET 612 to pull line 610 high with the assistance of PFET 614 so that output line 650 will be maintained high. It is pointed out that PFET 616 operates to reduce noise and prevent NFET 619 from turning on when there is no match. It is also noted that when WLS 630 strobes, it strobes across the entire eight columns in the CAM.
Referring now to FIG. 7, there is a specific circuit diagram of a second circuit 640 in the cascaded OR. In operation, when output line 650 remains high, via PFET 656, PFET 652 remains deactivated; preventing output line 670a from being pulled high. When output line 650 is pulled low by activating NFETs 618 and 619, PFETs 656 and 654 are overpowered, and output line 670a is driven high turning off PFET 654. To rest circuit 650 to the initial conditions, reset signal RST2 strobes causing PFET 658 to pull output line 650 high with the assistance of PFET 656. It is noted that PFET 654 is used to reduce noise effects and prevents PFET 652 from accidentally turning on by assisting in pulling line 650 high.
Referring now to FIGS. 8a and 8b, there is a circuit diagram of a third circuit 660 in the cascaded OR in operation, when any of the output lines 670a-670d are brought high, a related NFET 720a-720d will drive node 722 low, which will drive output line 110 high via inverter 924. In contrast, when output lines 670a-670d all remain low, node 722 remains high, thus leaving output 110 low. It is noted that PFETs 710a-710d are used to reduce noise effects and prevent accidental turning on of the driving NFETs 720a-720d. To reset circuit 660, NAND gate 726 is activated by only strobing reset RST1, because SET is always maintained high after the initial start up of the integrated circuit. As a result, RST2 is driven low, and NFETs 700a-700d are activated to restore all output lines 670a-670d to a low voltage level. Additionally, PFET 920 will pull node 722 high, thus driving output line 110 low with the assistance of NFET 900 and inverter 924. It is noted that the SET signal is pulsed when the ship is powered up to initiate the cascaded OR for operation.
It is noted that there are many variations that one skilled in the art may employ in practicing the bit decoding of the RAM. In particular, the CAM columns may be divided into any number of parts and not just the four as illustrated. The re-partitioning of the CAM would then require a reconfiguration of the cascaded 0R circuitry to provide for more levels or stages. Similarly, one skilled in the art would easily conceive of other logic devices other than the cascaded OR as illustrated.
Accordingly, the preferred embodiment of the invention will provide for parallel processing of the CAM and the RAM. Since the CAM processing is faster, the RAM data is immediately output upon reaching the MUX circuitry. With the foregoing description in mind, however, it is understood that this description is made only by way of example. Additionally, the invention is not limited to the particular embodiments described herein. Moreover, it is noted that there are various rearrangements, modifications, and substitutions that may be implemented without departing from the true spirit of the invention as hereinafter claimed.
Thus, it can be seen that according to the present invention where there are associative memories, i.e., one memory dependent upon another for its input during normal operation, testing of the associative memory is performed during the test function by actually providing signals for test purposes from the memory associated therewith from which it will receive signals as during functional operation to thereby provide a more accurate and reliable test of the two memories and utilizing less chip area.
The particular invention as has been described in the preferred embodiment as it is utilized to test a CAM memory and an associated DCU memory. However, it is to be understood that the invention has equal applicability to the testing of many types of memory configurations wherein one memory is associated with another. One example of this is in certain TAG memories, i.e., memories which provide a tag of data which are added to data in another memory. These memory configurations can be tested in this manner. Moreover, the invention is not limited to BISTs, but is also applicable to other types of memory testing where one memory is dependent upon another during functional operation; e.g., memories where signals are received from off the chip for memory.
Accordingly, the preferred embodiment of the operation of a CAM decoder to supply addresses to associated memories during BIST testing has been described. With the foregoing description in mind, however, it is understood that this description is made only by way of example, that the invention is not limited to the particular embodiments described herein, and that various rearrangements, modifications, and substitutions may be implemented without departing from the true spirit of the invention as hereinafter claimed. | An associated memory structure having a plurality of memories amenable for testing and a method of testing the memories is provided. First and second memories are formed, wherein data in the first memory provides a basis for at least a portion of the input to the second memory during functional operation of two memories. Preferably, an output latch for receiving the output test data from the first memory is provided. Means are provided for loading the first memory with data which is utilized as a basis for providing at least a portion of the input to the second memory. An access path from the output port of the first memory to the input port of the second memory allows use of the data in the first memory to generate at least a portion of the input to the second memory. The first memory is first tested independently of the second memory. Thereafter, the first memory is loaded with preconditioned data that is used as a basis for inputs to the second memory during testing of the second memory. The second memory is then tested by generating inputs to the first memory during testing of the second memory. Thus, outputs of the first memory constitute at least a portion of test data inputted to the second memory. A latch is provided to capture the output of the test data from the second memory. | 6 |
FIELD OF THE INVENTION
[0001] Present invention relates generally to intensive use furniture for use in institutional settings such as prisons, jails, detention centers and psychiatric facilities. And more particularly to furniture for use by individuals where using a contraband barier to secure the furniture components to each other, and to the floor or wall, sealing close seams at the interface is important to prevent urine and other liquids from penetrating into and under the product and prevent concealment of contraband.
BACKGROUND OF THE INVENTION
[0002] Intensive use furniture is designed for use in demanding environments. Facilities housing individuals for rehabilitation from health or legal problems require furniture for safely furnishing living quarters while being durable.
[0003] Intensive use furniture was formerly made of steel or wood. In previous years, fiberglass construction was used to replace wood and metal. Fiberglass offered a more appealing aesthetic than steel or wood, and more resistant to damage by the user and damage by bodily fluids. Wood furniture, for example is known to have problems with bed bugs in these settings. Fluids can rot and damage wood furniture resulting in weakness and creating odors. Fiberglass however, had several limitations. Fiberglass cracked and splintered if a direct force was applied. Manufacturing fiberglass furniture was very slow and involved custom production.
[0004] Intensive use furniture for such facilities requires durability and ease of cleaning. Furthermore, it is desired that furniture used in such intensive use facilities prevent improper use of that furniture by the user such as concealing items within or underneath the furniture. Typically, an inmate in a correctional or psychiatric facility may try to conceal drugs, weapons or other contraband in the furniture. The structure of the furniture must avoid all of these problems.
[0005] In addition, intensive use furniture is usually fixed to the floor or walls. This fixture must be relatively simple, secure and preferably sealing the seams between the furniture and the adjoining surface. Preferably, the fixation method is provided with a means for preventing tampering by the user of the furniture. Securing the furniture to the floor or wall further reduces the safety concerns on both the prisoners or patients and staff resulting in a safer environment.
[0006] It is desirable to provide furniture for such facilities having durability, aesthetically pleasing characteristics and design for comfortable use. Therefore there is a need to provide an intensive use furniture product without using assembly fasteners and having more impact-resistance, less weight and with much greater load-bearing capacity than fiberglass, wood or metal construction furniture. The furniture must sealingly attach to a mounting surface such as a wall or floor.
BRIEF SUMMARY OF THE INVENTION
[0007] One embodiment of the present invention is directed to a line of furniture for use in demanding environments, comprising components for use in individual's cell or room, as well as use in common areas such as a bed, night stand, wardrobe, desk, footstool and wall shelving units. The individual components are rotationally molded using a flame retardant linear low-density polyethylene with a hollow or honeycomb interior and may be filled with polyurethane foam for increased durability and sound absorption. The components comprise a shell having a mounting surface, the mounting surface having an outer edge surrounding the shell. The mounting surface is adapted for sealingly attaching to a structural element such as a wall or floor. The shell is attached to the wall or floor by an attachment means such as threaded fastener extending though a bolt hole in the mounting surface wherein an insert of metal or hard plastic may be inserted in the bolt hole for support. Generally horizontal surfaces on shelves, wardrobes, and the like are formed to gently slope downward away from a support wall to prevent the user from placing items on top of the furniture and to resist supporting a ligature or climbing on top of the furniture. The mounting surface includes a contrband barrier for sealing seems between the mounting surface of the shell and the wall, floor or furniture component by a caulk channel formed around the entire perimeter of the mounting surface to isolate the interior portion of the mounting surface from fluids, contraband, weapons or other materials and contraband at the outer edge. The caulk channel in the mounting surface is adapted to receive a bead of caulk for forming a fluid resistant barrier between the furniture and the adjoining wall or floor surface. The bolt holes may be concealed by covers affixed over the bolt holes by adhesive or the like forming a smooth or recessed outer surface of the shell over the fasteners protecting the structural attachment to the floor or wall.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
[0008] FIG. 1 is a perspective view of an first embodiment of an intensive use bed
[0009] FIG. 2 is a perspective view of the underside of the intensive use bed of FIG. 1 .
[0010] FIG. 3 is a perspective view of an second embodiment of an intensive use bed
[0011] FIG. 4 is a perspective view of the underside of the intensive use bed of FIG. 3 .
[0012] FIG. 5 is a front plan view of a first embodiment of a fastener cover of FIG. 1 .
[0013] FIG. 6 is a section view taken at 6 - 6 of FIG. 5 of the first embodiment of a fastener cover.
[0014] FIG. 7 is a perspective view of the first embodiment of a fastener cover of FIG. 5 .
[0015] FIG. 8 is a front plan view of a second embodiment of a fastener cover of FIG. 3 .
[0016] FIG. 9 is a section view taken at 9 - 9 of FIG. 8 of the second embodiment of a fastener cover.
[0017] FIG. 10 is a perspective view of the second embodiment of a fastener cover of FIG. 8 .
[0018] FIG. 11 is a front top perspective view of an intensive use nightstand.
[0019] FIG. 12 is a front bottom perspective view of an intensive use nightstand.
[0020] FIG. 13 is a section view taken at 13 - 13 of FIG. 11 .
[0021] FIG. FIG. 14 is a section view taken at section 14 of FIG. 13 .
[0022] FIG. 15 is a front plan view of an intensive use three shelf wall shelf.
[0023] FIG. 16 is a section view taken at 16 - 16 of FIG. 15 .
[0024] FIG. 17 is a perspective view of an intensive use desk.
[0025] FIG. 18 is a section view taken at 18 - 18 of FIG. 17 .
[0026] FIG. 19 is a section view taken at 19 of FIG. 18 .
[0027] FIG. 20 is a top perspective view of an intensive use footstool.
[0028] FIG. 21 is a bottom perspective view of an intensive use footstool.
[0029] FIG. 22 is a bottom plan view of the intensive use footstool.
[0030] FIG. 23 is a section view taken at 23 - 23 of FIG. 22 .
[0031] FIG. 24 is a section view taken at 24 - 24 of FIG. 22 .
[0032] FIG. 25 is a bottom perspective view of an intensive use Wardrobe.
[0033] FIG. 26 is a top perspective view of an intensive use wardrobe.
[0034] FIG. 27 is a front elevation view of the intensive use wardrobe of FIG. 25 .
[0035] FIG. 28 is a section view taken at section 28 - 28 of FIG. 27 .
[0036] FIG. 29 is a section view taken at 29 - 29 of FIG. 27 .
[0037] FIG. 30 is a section view taken at 30 - 30 of FIG. 27 .
[0038] FIG. 31 is a detail section view taken at section 31 of FIG. 30 .
[0039] FIG. 32 is a detail section view taken at section 32 of FIG. 30 .
[0040] FIG. 33 is a detail section view taken at section 33 of FIG. 29 .
[0041] FIG. 34 is a top plan view of the intensive use wardrobe of FIG. 26 .
[0042] FIG. 35 is a bottom perspective view of an intensive use table base.
[0043] FIG. 36 is a bottom perspective view of a second embodiment of an intensive use table base
[0044] FIG. 37 is a top perspective view of a third embodiment of an intensive use table base.
[0045] FIG. 38 is a top perspective view of a fourth embodiment of an intensive use table base.
[0046] FIG. 39 is a bottom plan view of the second embodiment of an intensive use table base of FIG. 36 .
[0047] FIG. 40 is a perspective view of an intensive use table having a tabletop attached to a table base.
[0048] FIG. 41 is a perspective view of a first embodiment of an intensive use bookshelf.
[0049] FIG. 42 is a perspective view of a second embodiment of an intensive use bookshelf.
DETAILED DESCRIPTION OF THE INVENTION
[0050] FIGS. 1 through 4 illustrate an intensive use furniture component shown as a first and second embodiment of a bed 20 . Referring to a FIGS. 1 and 3 , the bed 20 is rectangular having a top surface 22 , a pair of end side walls 24 and a front and rear side walls 26 . The bed 20 has an attachment means 27 formed in the end, rear and front walls 24 , 26 . The attachment means may comprise a plurality off fastener pockets 32 disposed in spaced relation on the end surfaces and front and rear surfaces for receiving fasteners (not shown) therein for extending through the shell to attach the bed 20 to the floor F ( FIG. 5 ). The top surface 22 has a ridge 33 surrounding the support portion 35 forming a recessed pocket on the top of the bed. The ridge and support surface form a recessed pocket as a means for locating a mattress (not shown) as well as containing the seepage of bodily or other undesirable fluids within the ridge 33 . Each of the surfaces may have a contoured or smooth non-penetrable outer shell for resisting penetration by fluids. A cover 25 may be placed over the fastener pockets 32 to protect the fasteners from the user and to prevent fluid from seeping into the pockets or contraband being placed in the fastener pocket 32 . Referring to FIGS. 2 and 4 , the intensive use bed 20 is shown in a bottom perspective view. The intensive use bed 20 has a bottom surface 34 forming the mounting surface for attaching the bed to a floor F ( FIG. 5 ). The bottom surface is formed comprising a plurality of openings 36 forming a honeycomb structure 38 to improve strength and reduce the weight of the bed 20 . A bottom plate 39 may be plastic welded or adhesively attached over the bottom surface 34 to cover the openings 36 to increase strength and to prevent contraband or fluid from residing in the openings, for example if the bed is not attached to the floor. The honeycomb structure 38 comprises a plurality of end support beams 40 extending between the end walls 24 . The honeycomb structure 38 further comprises the plurality of edge support beams 42 extending between the front walls 26 and the rear walls forming a plurality of chambers 43 ( FIG. 6 ) enclosed in the shell of the bed and open recesses 36 opening to the bottom surface 34 .
[0051] As illustrated in FIGS. 1 to 4 , the outer walls 24 , 26 may have contoured ridges 37 formed in the surface to provide ridges for support of the walls and improve the aesthetic appearance of the bed. The fastener pockets 32 formed in the outer walls 24 , 26 are generally scalloped shaped. A fastener hole 40 is formed in the fastener pocket 32 to accommodate a fastener such as a bolt or the like being inserted into the mounting location and attached to the floor under the bed. The fastener pockets 32 of the bed also accept tie down buckles 45 for use in psychiatric applications.
[0052] Referring to FIGS. 3 and 4 , the bed 20 illustrated as a second embodiment has a pair of storage openings 28 opening into the front surface 26 . The storage surface 26 has a gently sloped storage cavity floor 27 to prevent fluid collection and ease spray cleaning and drying.
[0053] Referring to FIGS. 5 and 8 , the fastener pocket 32 is shown having a contoured surface 45 extending to a bolt hole 40 formed from through the mounting surface, shown as mounting flange 46 . The mounting flange 46 is formed in each of the fastener pockets 32 having a top side 39 in the fastener pocket 32 adjacent the contoured surface and a bottom side 41 on the bottom surface 34 . The fastener hole 40 extends from the top side 39 to the bottom side 41 and is adapted to receive a fastener such as a bolt extending through the mounting flange for attachment to a structure such as the floor F. A metallic or plastic insert 50 may be inserted in fastener hole 44 to provide additional support for the mounting flange 46 to prevent crushing the flange when the bolt is tightened. As illustrated in FIG. 5 , contoured cover 49 a and in FIG. 8 , flat cover 49 b are used to hide the bolt to prevent tampering. The cover 49 a, 49 b is attached by plastic welding or adhesive 51 , forming a slightly recessed surface with respect to the walls 24 , 26 .
[0054] Referring to FIGS. 6 and 7 the contoured cover 49 a has a shape for being received in fastener pocket 32 as shown in FIG. 5 .
[0055] Referring to FIGS. 9 and 10 , the contoured cover 49 b has a generally planar shape having a contoured outer edge to fit into and cover the fastener pocket 32 as illustrated in FIG. 8 .
[0056] Continuing to refer to FIGS. 5 and 8 , foam 52 is injected into the generally hollow chambers of the honeycomb structure of the bed 20 . A caulk channel or groove 54 is shown intermediate the outer edge 56 of the bottom surface 34 and the fastener hole 40 . The caulk channel 54 extends around the entire perimeter of the lower surface. The caulk channel 54 is preferably semicircular in cross sectional shape and preferably has a radius of between 0.07 inches and 0.25 inches.
[0057] Referring to FIGS. 11-14 , an alternate embodiment of an intensive use furniture component is illustrated as an intensive use nightstand 60 . The intensive use nightstand 60 has a top surface 62 , a pair of side surfaces 64 and a front surface 68 . Front surface 68 is shown having two openings 70 for holding items such as books. Or clothes. Nightstand 60 has rounded corners 72 and a smooth outer surface on the top 62 and sides 64 . The nightstand 60 may have a mounting surface on the base 78 and/or the back surface 79 . The nightstand is shown having a plurality of fastener holes 76 formed in the base 78 .
[0058] Referring to FIG. 13 , a section view of the nightstand 60 is illustrated showing two openings 70 and a generally horizontal lower surface 80 and fastener holes 76 extending from the lower opening 70 through the base 78 . An insert may be molded into fastener holes 76 to prevent crushing the base 78 when fasteners are tightened.
[0059] Referring to FIG. 14 , a caulk channel 77 is illustrated on lower surface 81 of base 78 and the back surface 79 . Caulk channel 77 extends around the entire perimeter of base 78 and spaced from the outer edge of the base 78 , to sealingly attach the nightstand to the floor in conjunction with fasteners (not shown) extending through fastener holes 76 . The caulk channel 77 is preferably formed intermediate the fastener holes 76 and the outside perimeter of the base 78 . Alternately, the nightstand may be adapted having a mounting surface on the back surface 79 for attachment to a wall W. Referring to FIG. 14 , a detailed view taken from view 14 of FIG. 6 is illustrated showing a caulk channel 82 on the vertical rear surface 79 . The caulk channel 82 extends around the entire perimeter of the vertical rear surface 79 for sealingly attaching the nightstand 62 adjacent wall W. The nightstand 60 has gently sloped storage cavities 73 to prevent fluid collection and ease spray cleaning and drying.
[0060] Referring to FIGS. 15 and 16 , a third embodiment of an intensive use furniture component is illustrated as a wall shelf 90 . Wall shelf 90 is illustrated as a three-shelf 92 wall shelf, however additional configurations may also be manufactured having more or fewer shelves 92 . The wall shelf 90 as a top 94 , a bottom 96 and two sides 98 . Each shelf 92 extends between the two sides 98 and is defined by the opening between adjacent shelves. The wall shelf 90 is preferably formed by rotational molding forming a hollow outer core 97 that is filled with structural foam 100 . A mounting flange 99 is formed around the perimeter of the wall shelf 90 having a plurality of spaced fastener holes 95 for accepting threaded fasteners to attach wall shelf 90 to a wall.
[0061] Referring to FIG. 16 , a section view of the wall shelf of FIG. 8 is illustrated having shelves 92 defining openings 106 . The wall shelf 90 of FIGS. 15 and 16 is generally mounted vertically having a longer vertical length and shorter horizontal width. Top 94 and bottom 96 are formed having non-horizontal surfaces to prevent items from being placed on top of the wall shelf 90 or to resist climbing thereon by the users. A flat rear surface 108 forms a mounting surface adapted to mount against a wall W by fasteners extending through the fastener holes 94 . The shelves 92 are gently sloped and form storage cavities to prevent fluid collection and ease spray cleaning and drying.
[0062] A caulk channel 110 is formed on the mounting flange 99 for accepting a bead of caulk (not shown) to sealingly attach the wall shelf to the wall W and eliminate any gaps between the wall shelf and the wall.
[0063] Referring to FIGS. 17-19 an additional embodiment of an intensive use furniture component is shown as a desk 120 . The desk 120 has an upper surface 122 having rounded corners and a pair of support legs 124 and a rear support panel 126 . The support legs have a mounting surface 121 on the bottom for attaching to the floor F, the mounting surface having a perimeter surrounding bolt holes 125 . A plurality of fastener openings 128 are shown formed in the lower portion of the support legs 124 having the bolt holes extending through the mounting surface to the floor with the head of the bolt adapted to be recessed in the fastener opening 128 . As illustrated in FIGS. 18 and 19 , the desk 120 may be rotationally molded forming a hollow shell having a core 130 which may be filled with foam 132 such as polyurethane. The upper surface 122 comprises a separately manufactured hard writing surface constructed from one of a high pressure laminate, thermo laminate, wood, plastic sheet or other planar material which may be separately manufactured and attached to the support legs 124 . It is anticipated the support legs may further comprise a caulk groove on the top mounting surface 123 attached to the upper surface 122 to provide a contraband barrier between the legs and the writing surface. The writing surface may also be integrally molded with the legs 124 .
[0064] Referring to FIGS. 17 and 18 , the fastener openings 128 are generally scallop shaped openings in the support legs 124 . The fastener openings 128 provide a recessed mounting for fasteners extending through fastener hole 134 . Referring to FIG. 12 , the support legs 124 are preferably formed by a molding process to create a hollow shell 130 which may be filled with the structural foam 132 . A caulk channel 138 is formed on the lower surface 140 on each support leg on 24 . The caulk channel extends around the perimeter of the floor surface 140 of the support leg. The caulk channel is adapted to receive the bead of caulk for sealing and attaching the desk 120 to the floor. As discussed with respect to the bed 20 above, the fastener openings may be closed with covers to conceal the bolts B ( FIG. 6 ).
[0065] Referring to FIGS. 20-24 , an alternative embodiment of an intensive use furniture component is shown as a footstool 150 . The footstool 150 has a mounting flange 152 surrounding a foot support 154 having a top surface 156 . Footstool 150 is secured to a floor surface 158 by fasteners 159 extending through each of a plurality of fastener holes 156 formed in the base. A foam fill hole 157 is formed in the bottom 155 to provide access for blowing in or inserting foam in the footstool hollow shell.
[0066] As illustrated in FIG. 20 , the footstool 150 has a bottom 158 and a hollow interior cavity 160 . The footstool 150 may be formed by rotational molding or similar process to form a substantially hollow shell 164 that may be filled with foam 166 ( FIG. 15 ) for support and sound deadening. A central cavity 162 extending from the bottom 158 reduces the amount of material used for forming the footstool 150 . Bottom 158 may also comprise a plurality of support ridges 172 adding structural integrity to the mounting flange on 52 . The support ridges 172 extend from the central cavity 162 to a position adjacent caulk channel 174 . Fastener holes 156 are formed in a circumferential position with respect to the bottom 158 . Caulk channel 174 is formed in the bottom 158 intermediate the fastener holes 158 and the outer perimeter 176 .
[0067] Referring to FIGS. 23 and 24 , foam 166 is used to support the hollow shell 164 . The caulk channel 174 is disposed on the bottom 158 adjacent the outer perimeter 176 for receiving a bead of caulk 178 for sealingly attaching the footstool 152 to a floor surface F. The support ridges 172 are molded into the bottom 158 to provide structural support for the base.
[0068] Referring to FIGS. 25 to 34 , an alternate embodiment of an intensive use furniture component is illustrated as a wardrobe 190 comprising cabinet 191 having a top 192 , sides 194 , a base 196 , a back panel 197 and an optional, at least one door 198 attached to the cabinet 191 . The wardrobe 190 is adapted for mounting to a floor surface or an adjacent wall surface of both. The wardrobe 190 has a plurality of fastener openings 200 formed on the top 192 for receiving fasteners to attach to an adjacent wall W. An integrally molded sloped top surface 193 is used to prevent storage and concealment of contraband and further resist climbing. The sloped surfaced could be a separate piece and attached during manufacturing or installation by fasteners or adhesive as is well known n the art of fastening plastic components together.
[0069] The hinged door illustrated in FIG. 25 , preferably uses a piano style hinge 202 to create the strongest and most secure attachment to the wardrobe 190 as illustrated in FIGS. 25 , 26 and 28 - 33 . The door may also be reversible as a left or right hinge depending on the installation requirements. A tambour door option may also be considered unique in the field. The door can be molded the same as the other components in the product line or may be different such as HPL (high pressure laminate) laminate, thermoformed laminate, MDF or wood. The door is positioned to allow for complete 270 degree opening around the piano hinge as necessary to prevent overstressing the hinges as shown in FIG. 34 . Metal inserts 204 ( FIGS. 25 , 26 and 28 ) are used throughout the product to attach the hinges to increase attachment strength and security. A locking means 206 may be included through integrated or separate latch features.
[0070] Referring to FIGS. 26 and 28 , the clothes hanging feature 210 is molded as an integral J-bar 212 feature to prevent a traditional bar being used as a ligature support. The geometry of the J-bar 212 is preferred to be integrated into the part, but may be a separate piece fastened into the cabinet 191 . A removable piece could be used as a weapon in these intended environments. The cabinet 191 has recessed pockets 214 at the upper portion having internal j-bar 212 on the lower front surface for securely supporting the hook of a standard clothes hangar. The upper portion of the wardrobe 190 is filled to resist hiding contraband or other material above the j-bar 212 . A hangar recess 216 is formed between the j-bar 212 and the back 218 of the cabinet 191 to accommodate the hangar. Fastener holes 220 are formed in the back 218 and extend through the back panel 197 which is adapted to be a mounting surface for attachment to a wall W. Fasteners 224 are extending from inside the cabinet through the back panel to the wall W. Additional fasteners 224 are disposed in fastener pockets 226 on the top of the cabinet 191 as illustrated in FIG. 34 . As discussed above, covers may be used to conceal the fasteners and close the fastener pockets 226 . A lower shelf 230 is formed in the cabinet 191 forming a storage opening 228 between the shelf 230 and the base 196 .
[0071] Referring to FIGS. 35-40 an intensive use table 240 is illustrated. The table 240 has a base 242 a - d having a vertical wall 243 having an outer surface 244 , a floor end 246 and a table top end 248 . The tabletop end 248 comprises a mounting surface for attachment to a tabletop 250 ( FIG. 20 ). The mounting surface may have a caulk groove 251 formed therein for acting as a contraband barrier 252 . The table base 242 a - d may have a contoured outer surface defined by ridges 260 for additional support. The ridges may be linear, parallel, curved or otherwise formed to provide structural support for the As illustrated in FIGS. 37 and 38 , the top of the base has a hollow cavity 262 that may be filed with sand during installation. The tabletop 250 is attached by fasteners extending through the base 242 at bolt holes 263 and attaching to the underside 264 of the top 250 . The top may be formed as the writing surface of the desk 120 described above.
[0072] Referring to FIGS. 49 and 50 , an alternate embodiment of an intensive use furniture component is shown as a book shelf 270 . Referring to FIG. 49 , the bookshelf 272 has a base 273 adapted to support a pair of vertical ends 272 and a support leg 274 . Bookshelf 270 may be formed with more or fewer legs 274 depending on its intended use and the size of the shelf 276 . Ends 272 and support leg 274 are formed with rounded corners 278 to prevent supporting clothes being hung thereon, a ligature or the like. The shelf 276 is formed with a gently sloping surface angle to allow liquids to run off and facilitate cleaning. Bolt holes 280 are formed in the base 273 to attach the book shelf to the wall W. A caulk bead is formed on the base at the back opposite the shelf 276 as a contraband barrier sealing between the wall W and the base.
[0073] Referring to FIG. 50 , the bookshelf 290 has upper support legs 292 supporting shelf 276 on base 273 . Fastener pockets 294 are formed at the junction of the shelf 276 and base 273 . Bolt holes 280 are formed through the base and disposed in the fastener pockets 294 . The fastener pockets 294 are adjacent the outer edge of the base 273 facilitating closure of the fastener pocket with a cover as described above regarding the intensive use bed 20 .
[0074] Referring generally to FIGS. 1 to 17 , the intensive use furniture products are preferably rotationally molded in flame retardant, plastic resin with a hollow interior. In the preferred embodiment, the plastic resin may be High Density Polyethylene (HDPE) or Linear Low Density Polyethylene (LLDPE). The resin may contain additives such as flame-retardants to meet government standards. As a means to increase product strength and durability, a secondary material is used to fill the hollow cavities left during the molding process. Molding plastic could be done by rotational, blow, injection, thermo forming or compression molding where one or more pieces may be used to create the hollow cavity.
[0075] The secondary material filling the cavities of the molded products may be structural polyurethane foam selected for increased durability and sound absorption. The filler may be injected under pressure and may consist of urethane foam or other material that can conform to the irregular cavities created during the molding process. The filled, rotationally molded products are significantly more impact-resistant, with much greater load-bearing capacity, than the fiberglass predecessors. Because the products are produced from molds, the production capacity increases allow more efficient manufacturing and a product that is less expensive to ship and install.
[0076] A fire retardant additive is added to the linear low-density polyethylene and molded into the intensive use furniture products to meetfire rating standards such as the State of California, Technical Bulletin No. 133, Flammability Test Procedure for Seating Furniture for Use in High-Risk and Public Environments.
[0077] In the molding process, nylon may be added to the plastic mix for molding the forming the substantially hollow shell to reduce de-lamination between the polyethylene walls and polyurethane foam filler.
[0078] Due to the intensive-use nature of the products, the individual components preferably include a means of securely fastening the product to a floor, wall or other desired mounting surface. In the preferred embodiment, the components are typically bolted to a structurally sound mounting surface such as a floor (bed, nightstand, stool) or a wall (Wardrobe, wall shelf, wall storage units) through molded-in bolt hole locations. Additionally each mounting position may be reinforced with metal inserts disposed in the bolt holes by insertion during the molding process or during finishing operations, to prevent crushing of the plastic surrounding the bolt holes or on a mounting flange.
[0079] To facilitate a tighter fit to the floor and eliminate gaps, each product features a semicircular shaped, hidden caulk channel on the underside of the unit, along the outer edge and preferably around the entire mounting surface forming a closed circuit of caulk adjacent the perimeter of the mounting surface. The caulk channel has a diameter profile to accommodate a standard bead of sealant such as caulk to seal any seams between the intensive use furniture and the mounting surface, the size of which may vary with the particular components. This allows the end-user to seal the floor and back edges of wall or floor mounted products to prevent concealment of contraband, prevent fluids from penetrating the surface mounting areas and facilitate cleaning of the component and surrounding areas.
[0080] The present invention has been shown and described with reference to the foregoing exemplary embodiments. It is to be understood, however, that other forms, details, and embodiments may be made without departing from the spirit and scope of the invention which is defined in the following claims. | The invention is directed to a rotary molded bed having a sleeping surface surrounded by a raised edge, storage compartments molded into the side of the bed and a means for attaching a base of the bed to a floor. The rotationally molded bottom may comprise a flat surface or a honeycombed configuration. The hollow bed body may be filled with structural foam to provide support. The base is attached to a floor surface preferably having fastener openings in the base adapted to hold fasteners recessed in the base, the fasteners extending through a floor mount surface in the base. The fastener openings may have covers adapted to close the fastener openings to prevent tampering with the fasteners. | 0 |
FIELD OF THE INVENTION
The present invention relates to the regulation of fluid pressure. It has particular application to the control of gas mass flow rates through the control of pressure. It is especially useful in controlling the flow of a gaseous fuel supplied to an internal combustion engine, for example in automotive use where control of fuel is important for performance and emission control.
BACKGROUND
In the preferred applications the final control of the gas flow to an engine is typically by a venturi (carburation system) or a solenoid valve (fuel injection system). Both of these require precise and accurate control of the input pressure to the device. In automotive use the pressure in the fuel storage container may range from 0.6 MPa to over 30 MPa (90 to 4500 psig) necessitating the use of sophisticated regulation systems to achieve a constant output pressure with the requisite variable mass flow rate.
The known regulators are mechanical. These regulators are preset by the manufacturer and may be difficult to adjust correctly after installation. Recent automotive regulations in many countries prohibit adjustment to a regulator after installation as tampering with the emission system. This requires that the regulator remains in tolerance for long periods, normally amounting to a number of years or a representative cumulative distance.
Existing natural gas vehicle (NGV) regulators for fuel injection applications are mechanical systems with either one or two stages of pressure regulation. Three or four stages of pressure regulation are used in conventional carburetor-mixer NGV fuel systems. Mechanical regulators can be designed to address many of the problems, but this may increase the number of moving parts, which in turn may affect reliability and cost. Although these systems have demonstrated good performance in many applications, there are problems associated with their use.
Droop: One difficulty with mechanical regulators is that the output pressure decreases or droops, when the fuel flow rate is increased significantly, which frequently happens in automotive applications. Typically, the fuel flow rate increases by a factor of 30 on acceleration from idle to maximum engine speed at wide open throttle. This can cause pressure droop between 70 and 140 kPa (10 to 20 psig) for mechanical regulators. Pressure droop complicates the calibration of fuel injected engines because there must be compensation for the pressure reduction in the calibration tables to maintain a proper air fuel ratio. Systems with droop require sophisticated and expensive compensation systems.
Resonance: The spring and diaphragm arrangement in a mechanical regulator may be sensitive to resonance. The flow dynamics of the manifold that connects the fuel injectors to the regulator can be prone to pressure resonances of 70 to 210 kPa (10 to 30 psig).
Hysteresis: The spring and diaphragm arrangement in a mechanical regulator may be sensitive to hysteresis which can result in a pressure reduction of 70 kPa (10 psig).
Temperature: The spring and diaphragm arrangement in a mechanical regulator may be sensitive to temperature effects. Elastomeric diaphragms are less flexible in cold weather, which decreases the ability of the fueling system to respond to changes in vehicle operation.
Transient response:
Mechanically regulated systems cannot compensate for the inertial lag from injectors on fuel injected natural gas vehicles. Current injectors have an opening time of up to 4 milliseconds, which is a significant portion of their pulse width operation.
The present invention aims at a system that ameliorates the problems with the mechanical regulators of the prior art.
SUMMARY
According to one aspect of the present invention there is provided a fluid regulator comprising:
a regulator housing having a fluid inlet;
a solenoid valve coupled to the housing for controlling the flow of fluid into the housing through the fliuid inlet from a source of fluid;
pressure monitoring means for monitoring fluid pressure in the housing;
control means coupled to the pressure monitoring means and to the solenoid valve for controlling operation of the solenoid valve to produce a desired fluid pressure in the housing.
A regulator of this sort, composed of one solenoid valve and a controller, which will normally be entirely electronic, has only one moving part. Other advantages of this system over conventional mechanical systems include reduced production costs, increased accuracy, an increased dynamic range, reduced size and improved reliability.
The control means preferably include means for establishing a set point pressure to which the desired pressure corresponds and means for controllably varying the set point pressure. The variable pressure provides an increased dynamic range and permits the system to increase the flow rate very quickly to meet rapidly varying gas requirements. It will also reduce wear on the solenoid valve by reducing the frequency of operation. In some cases the variable pressure system can improve safety as the pressure can be reduced to zero to use the regulator as a shut-off valve.
The control means preferably deliver a pulsed electrical signal to the solenoid valve for operating the valve. Mass flow through the valve is controlled by controllably varying the electrical signal. The signal variations may be variations in the pulse width, the pulse frequency or both.
The regulator may be incorporated into the fuel supply for an internal combustion engine, between the engine and a gas supply. In this application, the system may include means for monitoring certain control parameters of the engine. These may include throttle position, manifold vacuum, engine speed and others indicative of the fuel demand on the engine. The control means may then include means for establishing a set point pressure to which the desired gas pressure corresponds and means for varying the set point pressure according to the monitored control parameters. This is particularly useful in automotive applications where the fuel demand can vary widely and rapidly.
The regulator of the invention can be designed to require less auxiliary heating, or none whatsoever. The reasons for this are as follows;
Although gas temperature at the orifice of the solenoid valve can be significantly below freezing, there is not enough time for ice to form in the orifice because of non-equilibrium effects in the natural gas-water mixture.
The high velocity of the gas stream (sonic) keeps the orifice free from ice blockage.
High frequency movement of the valve stem and ball against the valve seat prevents ice from forming.
The electrical energy from the solenoid valve is dissipated as heat in the gas stream.
According to another aspect of the present invention there is provided a method of regulating the pressure of a gas, said method comprising:
supplying the gas to a regulator chamber through a solenoid valve;
operating the solenoid valve with a pulsed electrical signal; and
controlling the electrical signal to obtain a desired output pressure in the chamber.
While the method and apparatus are described herein in the environment of gas pressure regulation, the principles of the invention are also applicable to the control of pressure in a liquid.
BRIEF DESCRIPTION OF THE DRAWINGS
In the accompanying drawings, which illustrate an exemplary embodiment of the present invention:
FIG. 1 is a schematic illustration of a pressure regulator according to the present invention;
FIG. 2 schematically illustrates the regulator control volume;
FIG. 3 is a plot illustrating the predicted characteristics of a modeled regulator according to the present invention with a proportional controller;
FIG. 4 is a view like FIG. 3 with a proportional-integral-derivative controller;
FIG. 5 is a view like FIG. 3 of a prototype regulator; and
FIG. 6 is a view like FIG. 5 with a proportional-integral control.
DETAILED DESCRIPTION
Referring to the accompanying drawings, and especially to FIG. 1, there is illustrated an electronic regulator 10 that includes a regulator housing 12 with a gas inlet 14 for receiving gas at a supply pressure from a gas source 15 and an outlet 16 for discharging gas at a controlled pressure to the fuel system of an internal combustion engine 17. A high speed solenoid valve 18 is coupled to the housing. It is normally closed and blocks flow from the gas inlet to the gas outlet. The regulator is preferably built into the gas source 15 to eliminate any high pressure gas line between the two components.
A pressure transducer 20 is mounted on the housing to monitor the gas pressure downstream from the solenoid valve. The signal from the pressure transducer is delivered to an analog to digital converter 22 which serves as an interface for the pressure measurement. The output from the converter is delivered to a microprocessor 24 which in turn controls operation of the solenoid valve 18. The microprocessor contains algorithms that provide for proportional-integral-derivative control of the control system. Proportional control allows for fast response. Integral control reduces the steady state error between the set point pressure and the measured pressure to zero. Derivative control increases the response to rapid changes in flow demand. Instrumentation 26 on the engine monitors engine control parameters that are measures of the fuel demand of the engine. The output from this instrumentation is also delivered to the microprocessor which varies the operation of the solenoid to meet the engine fuel demand.
A mathematical model was developed to investigate the controllability of a regulator designed according to this concept, and to help develop control algorithms for the regulator.
The pressure control model is based on the solution to the transient equations for the conservation of mass and energy in a control volume. Models were also developed for pulse-width modulation, fluid injection into a control volume, PID control, and heat transfer from the walls. A frequency modulation model was also developed.
As illustrated in FIG. 2, the regulator pressure chamber can be represented by a control volume of volume, V. The fluid has a mass, M, and energy, E, as shown in FIG. 2. Natural gas injection is represented by the inlet mass flow, m s , through the cross-sectional area of the throat, A t . The outlet mass flow rate or load flow rate, m 1 , is represented by a look up table of flow rates in time.
The following equations were solved using a first-order finite difference scheme.
Conservation of Mass ##EQU1## where M=mass of fluid in the control volume (kg)
m s =supply mass flow rate (kg/s)
m 1 =load mass flow rate (kg/s)
Conservation of Energy ##EQU2## where E=energy in control volume (J)
N is =isentropic efficiency
v=exit velocity (m/s)
C p =specific heat at constant pressure (J/kgK)
C v =specific heat at constant volume (J/kgK)
P=regulator pressure (Pa)
T=regulator temperature (K)
ρ=regulator density (kg/m 3 )
q=heat addition (W)
The following first-order integration routine was used for Equation 1:
M.sup.t+1 =M.sup.t +(m.sub.s -m.sub.1)Δt (3)
where Δt=time step(s)
A similar integration scheme was used for Equation 2.
The fluid enters the control volume at sonic velocity, c t if the pressure ratio, P s /P is greater than the critical pressure ratio 0.528, as indicated by the following equation: ##EQU3## where R=gas constant (J/kg K)
γ=C p /C v
The temperature, T t and pressure, P t at the throat are defined by the following equations for isentropic flow: ##EQU4## where P s =supply pressure (kPa)
T s =supply temperature (K)
The mass flow rate into the control volume, m s , was calculated by the following equation for sonic flow: ##EQU5## where C d =discharge coefficient
A t =area of the throat (m 2 )
The opening time of the solenoid valve was modeled by the following equation: ##EQU6## where m si =mass flow rate at time t (kg/s)
m so =mass flow rate at time t-Δt (kg/s)
Δt=time step(s)
τ o =opening time constant of solenoid valve(s) ##EQU7## Equation of State
P=zρRT
where
z=compressibility factor
Wall Heat Transfer
q=hA.sub.w (T.sub.w -T)
where
h=heat transfer coefficient of the wall (W/m 2 /K)
A w =surface area of the wall (m 2 )
T w =wall temperature (K)
The measured pressure, P m and the error in the pressure, E r were represented by the following equations: ##EQU8## where P m =measure pressure (Pa)
τ m =time constant of the pressure transducer(s)
P sp =set-point pressure of the controller (Pa)
The error signal, E r is multiplied by the proportion gain, k p the integral gain, k i and derivative gain, k d , to calculate the controller output, F af and pulse width, T i , as follows: ##EQU9## Pulse width and frequency modulation are used in the model to control the outlet pressure base on the following relationships:
T.sub.i =T.sub.b (1+F.sub.af)
f=f.sub.b (1+F.sub.af)
where
T b =base pulse(s)
T i =pulse width(s)
f=frequency of injection
f b =base frequency of injection (Hz =f(p s )
Note that f b is also modified according to the following equation:
f=f.sub.b +f.sub.0
For a vehicle application, the frequency of injection can be made proportional to engine speed, obviating the need for frequency modulation according to the above equations.
The model was run to compare proportional control with proportional-integral-derivative control for the electronic regulator. The flow rate was increased from 0.1 to 1.0 g/s at the 10 second mark as shown in FIG. 2. The controller increased the pulse width from 3 ms to 8.5 ms. The model predicts a droop in pressure of about 100 kPa (14 psig) for proportional control. The model was run at a supply pressure of 6.9 MPa (1000 psig), a control pressure of 820 kPa (105 psig) and a proportional gain k p =6. The droop is reduced to about 15 kPa (2 psig) for the proportional-integral-derivative controller shown in FIG. 4. For this case k i =9 and k d =2. Similar improvements were found in a prototype bench test of the regulator as illustrated in FIGS. 5 and 6. In this case, the improved results were achieved using a proportional-integral controller.
An electronic pressure regulator according to the present invention may be used as a separate system similar to conventional regulators, or it may be a system integrated into the central computer of a motor vehicle. The electronic regulator can be configured to permit electronic control of the set-point pressure of the regulator to increase the dynamic range of the fuel system.
While one embodiment of the present invention has been described in the foregoing, it is to be understood that other embodiments are possible within the scope of the invention and are intended to be included within the scope of this application. | A gas regulator has a has an internal gas chamber and a solenoid valve that controls gas flow into the clamber. A pressure monitor monitors the pressure in the chamber and controls the operation of the solenoid valve to produce a desired pressure in the chamber. The solenoid control signal is a pulsed signal with a variable pulse width, frequency or both. The pressure maintained in the chamber may itself be varied by altering the set point pressure, for example according to the operating parameters of an engine. | 8 |
FIELD OF THE INVENTION
[0001] This invention relates generally to verifying a description of a network and, more particularly, to confirming that the description of the network is consistent with communication paths of the network.
BACKGROUND OF THE INVENTION
[0002] Networks, such as communication networks, transmit various types of data concurrently, such as text, voice, video and other multimedia files. Communication networks are becoming increasingly complex, especially due to their increasing speeds of operation, the number of interconnected devices and the formation of large networks from sub-networks. Another factor increasing the complexity of communication networks is the layered nature in which a logical link at one technological level is provided as a service by a different technology level. For example, a web browser process might establish a TCP (Transmission Control Protocol) connection to a server process; the connection appears to the two processes as a link. In fact, data sent across the connection traverses an underlying connectionless IP (Internet Protocol) network; a link in the IP network might be provided by a complex hierarchy of connection-oriented ATM (Asynchronous Transfer Mode), SONET (Synchronous Optical Network), and DWDM (Dense Wavelength Division Multiplexing) networks. The layering complexity of networks can only be expected to increase in the future, with the advent of wireless links, virtual private networks and overlaid protocols, such as SIP (Session Initiation Protocol).
[0003] Computer tools may be used to design, inventory, analyze, optimize and test networks. These computer tools need a language to describe networks, and fundamental to any such language is a model of network topology, which is a set of links and connections in the network. Conventional computer tools do not permit a uniform network description across multiple levels. Each specific network technology typically has an associated description provided by a standards document; these technology descriptions are usually very detailed and not easily abstracted. Conventional computer tools may use a specific model of network topology; however, the definition of a term in the model of one tool may not match the definition of the same term of another tool. This inconsistency requires a detailed analysis of the semantic model to transfer data between tools.
[0004] Thus, conventional approaches do not provide models that can uniformly describe networks across multiple levels. Therefore, it would be an advancement in the art to be able to efficiently confirm that a network is operating according to its specifications.
SUMMARY OF THE INVENTION
[0005] Generally, a method and system are disclosed for verifying a description of a network represented by network map data. Logical links of a network are accessed and a determination is made whether each logical link corresponds to a network communication path. The network communication path is represented by physical link data, connection data, and adapter data.
[0006] If the logical links correspond to the communication paths, an affirmative indication is generated. If the logical links do not correspond to the communication paths, a negative indication is generated. These indications can be provided to an output module.
[0007] A more complete understanding of the present invention, as well as further features and advantages of the present invention, will be obtained by reference to the following detailed description and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 illustrates a network environment in which the present invention can operate;
[0009] FIG. 2 is a schematic block diagram of the terminal of FIG. 1 ;
[0010] FIG. 3 shows an example of a schematic representation of logical map data and physical map data;
[0011] FIG. 4 shows an example of a representation of physical link data;
[0012] FIG. 5 shows an example of a representation of adapter data;
[0013] FIG. 6 shows an example of a representation of connection data;
[0014] FIG. 7 shows an example of a representation of binding data; and
[0015] FIGS. 8A-8C show a flowchart of steps for a verification algorithm according to the present invention.
DETAILED DESCRIPTION
[0016] The present invention provides an algorithm to verify a description of the topology of a network. This verification is a pre-condition for many algorithms that manipulate such descriptions, including algorithms that perform network optimization and reorganization, summarize traffic, compute reliability, detect recent changes and analyze alarms. As discussed further below, the topology of the network is described in a language, such as, for example, NetML, which is a language for recording the physical and logical topology of a communications network. NetML is an XML-based language that is applicable across multiple network levels and to a variety of network technologies. Fundamental to NetML is a formal topology model that includes network map data, which is, for example, an abstract computer representation of a network. The network map data includes: physical map data, which represents a set of communication paths; logical map data, which represents a plurality of logical links; and binding data, which represents an association, relationship or correlation between the physical map data and the logical map data.
[0017] A verification algorithm, which may use NetML syntax, validates the network map data by establishing that each logical link of the logical map data corresponds to a communication path of the physical map data. The physical map data is analyzed to determine communication paths using physical link data, which is representative of an association of two physical end ports, adapter data, which is representative of adapter type and layer, and connection data, which is representative of an association of two physical ports of a physical link or a physical port of a physical link and a port of an adapter. An indication of whether each of the logical links corresponds to a communication path is provided to an output facility, such as a user interface or display device. If each logical link of the logical map data corresponds to a conductive path, the network map data is consistent, or valid; if not, the network map data is determined to be inconsistent, or invalid, and thus does not accurately represent the network it models.
[0018] FIG. 1 illustrates a network environment 100 in which the present invention can operate. A user employing a terminal, or workstation 102 , accesses remote processing terminals, or facilities, 112 ( a ) through ( n ) (where n is any suitable number), customer premise equipment (CPE) 150 ( a ) through ( n ) (where n is any suitable number) and server terminal 106 , via a network 108 . Network 108 is a network of interconnected terminals or devices. Network 108 may be, for example, a LAN (local area network), a WAN (wide area network), Internet, a PSTN (public switched telephone network), a WLAN (wireless local area network), a PBX (private branch exchange) or combinations thereof, or other interconnection of processing or communication devices.
[0019] Server 106 and facilities 112 ( a ) through ( n ) (generally referred to herein as facilities 112 ) are typically servers, or other computing devices, with memory and processing capability, coupled to network 108 via associated bi-directional transmission media 136 and 132 ( a ) through ( n ), respectively. The CPE 150 ( a ) through ( n ) (generally referred to herein as CPE 150 ) may be, for example, telephone devices, PBX (private branch exchange) equipment, facsimile machines, scanners, or any other equipment arranged to be connected to network 108 , via associated interconnection media 152 ( a ) through ( n ) (where n is any suitable number) (generally referred to herein as interconnection medium 152 ). The interconnection medium 152 are, for example, wired or wireless connections. The user may access remote server terminal 106 , facilities 112 and CPE 150 using software, such as an applet, operating among the terminal 102 , the network 108 , and the server terminal 106 , facilities 112 and CPE 150 .
[0020] Terminal 102 , which is coupled to network 108 via interconnection medium 142 , may be, for example, a personal computer (PC), hand-held device (e.g. PDA), or other processing module, as discussed further below in conjunction with FIG. 2 . The terminal 102 has adequate memory and adequate processing speed to retrieve network data from remote locations and process, store and output data.
[0021] An abstraction, or description of the network topography, also referred to herein as network map data, or a network map, describes network connections, and may be stored at a remote location, such as server terminal 106 and accessed by terminal 102 . One way to process the network map data is to download it to terminal 102 , process the data and store an indication either at terminal 102 or at a remote location.
[0022] The terminal 102 can access a verification algorithm that processes the network map data to determine whether it is valid. For example, FIG. 1 shows connections between network 108 and facilities 112 and CPE 150 , which may be a source of the network map data, as well as the network used to provide the environment in which the present invention operates.
[0023] FIG. 2 is a schematic block diagram of the terminal 102 shown in FIG. 1 . Terminal 102 includes: a central processing unit (CPU) 226 ; a memory module 216 ; a display device (shown as element 118 in FIG. 1 ); input device (shown as element 116 in FIG. 1 ); and other peripheral devices (not shown). Terminal 102 may be embodied as a commercially available computing system such as a PC or workstation, and may include other conventional components and peripherals that are not shown in FIG. 2 .
[0024] The processor 226 may be used to access and process the data stored in memory 216 .
[0025] The memory 216 typically includes read only memory (ROM) (not shown), random access memory (RAM) (not shown) and an operating system (not shown). Memory 216 stores the network map data 218 and verification algorithm 800 . Network map data 218 includes logical map data 301 , physical map data 302 and binding data 700 . Physical map data 302 includes physical link data 400 , adapter data 500 and connection data 600 . The components of memory 216 are discussed below in conjunction with FIGS. 3-8 .
[0026] While FIG. 2 shows that the verification algorithm 800 is stored as program code in a single location, the verification algorithm 800 may also include sections of code stored in more than one location and accessed as necessary. The memory 216 may also store an output from the verification algorithm 800 .
[0027] Although only one central processing unit (CPU) 226 is shown in FIG. 2 , there may be a plurality of such units, depending on the application.
[0028] In order to verify the network map data, it is necessary to describe the network topology. NetML is one language that can be used to describe the topology of a telecommunications network, which includes physical links, logical links, ports and internal cross-connects. NetML is an interchange language that can conform to a particular XML schema. To promote interoperability of tools, NetML is based on a model that is independent of any particular technology and applicable to most common technologies. NetML assigns physical links a type, or layer, which characterizes the format of the data. NetML identifies a link independent of network hierarchy and uniformly incorporates both circuit-switched networks, such as SONET, and packet-switched networks, such as IP and Ethernet, allowing descriptions of communications paths that traverse both packet and circuit switched networks. NetML also provides an XML representation that allows interchange of network descriptions among computer tools.
[0029] FIG. 3 shows an example of a schematic representation 300 of logical map data 301 and physical map data 302 , which may be generated using NetML, stored in memory and analyzed, processed and manipulated by a processor.
[0030] Logical map data 301 shows logical link 332 , which is a representation of a communication path from logical link port 330 to logical link port 331 . Typically, logical map data 301 includes a plurality of logical links; however, FIG. 3 shows a single logical link 332 for explanation purposes. In order to confirm that the logical link 332 actually corresponds to a communication path between ports 330 and 331 , the physical map data 302 and binding data (shown as element 700 in FIG. 2 ) are analyzed using the verification algorithm (shown as element 800 in FIG. 2 ).
[0031] Physical map data 302 includes physical link data, adapter elements and network elements. These components are discussed in more detail below.
[0032] Physical Link Data
[0033] Generally, physical link data includes one or more physical links. A physical link represents an ability to transmit data from one place to another and has two ports, one being a start port and the other being an end port.
[0034] A physical link is characterized by its layer. A layer is an aggregate set of conventions required to interpret the information flowing on the link as a bit stream. The layer may include, for example, specifications for bandwidth, bit encoding scheme, error correction codes, signaling protocol, framing format and header information.
[0035] As shown in FIG. 3 , physical link 309 has start port 307 and end port 308 . Physical link 329 has start port 321 and end port 322 . Data injected into a start port traverses the associated physical link and is ejected at the end port of the link. A physical link is bi-directional, so data injected at either port will be ejected at the other port. Since start port 307 and end port 308 are connected to each other by physical link 309 , physical link 309 forms a communication path between start port 307 and end port 308 . Similarly, since start port 321 and end port 322 are connected by physical link 329 , physical link 329 forms a communication path between those ports.
[0036] Physical links and ports may be interpreted concretely, as physical objects. Physical links 309 and 329 could be, for example, copper or fiber cables and ports 307 , 308 , 321 and 322 could be physical connectors at the end of the cable. Also, physical links 309 , 329 could be wireless connections and the ports 307 , 308 , 321 and 322 could be connectors attached to antenna circuitry.
[0037] A further discussion of physical link data is provided in relation to FIG. 4 .
[0038] Adapter Elements
[0039] As shown in FIG. 3 , adapter data is generated by analyzing adapter elements 311 , 316 324 and 338 , also referred to as adapters herein. Adapters perform adaptation, or conversion between layers of a network. Adaptation represents both encapsulation, the encoding of one data stream with another, for example, by adding extra header information, and multiplexing, where several data streams are combined into a single stream. Each adapter has an indexed set of guest ports (user ports) and an indexed set of host ports (provider ports). For example, adapter 338 has guest ports 303 , 304 and 305 . Guest port 303 has a label A, guest port 304 has a label B and guest port 305 has a label C. Adapter 311 has guest ports 312 , 313 and 314 , with labels A, B and C, respectively. Adapter 316 has guest ports 317 , 318 and 319 with labels A, B and C, respectively. Adapter 324 has guest ports 325 , 326 and 327 with labels A, B and C, respectively. Adapters 302 , 311 , 316 and 324 have host ports 306 , 315 , 320 and 328 , respectively.
[0040] The adapter elements are configured to perform adaptation or conversion between layers of a network. Each adapter has an associated adapter type. The adapter type determines the layer and label of a host port and a sequence of layers and labels for guest ports. An adapter is labeled with its type, and the layers and labels of its ports must agree with the corresponding layers and labels in the type for the adapter to perform adaptation operations.
[0041] For example, an adapter that has a single guest port and a single host port causes any data stream of the appropriate layer to be injected into the guest port where it is adapted (converted) to the layer of the host port and then ejected. An adapter that has several guest ports and a single host port causes the data streams injected into the guest ports to be multiplexed together and ejected from the host port. Adapters are bi-directional, so they can be used to convert data back from the host layer to the guest layer or layers.
[0042] A communication path can be established by injecting data into a guest port of an adapter, the adapted data is ejected from the host port, traverses a link (or, more generally, another communication path) to another adapter host port, where it is then de-multiplexed, or “unadapted,” and ejected from the guest port with the same label as the first guest port. The adapter types and guest port labels and layers must match in order to establish a communication path. The adapter type determines the layer of a host port and a sequence of layers for guest ports. An adapter is labeled with its type and the layers of its ports must agree with the corresponding layers in the type.
[0043] A further discussion of adapter data is provided in relation to FIG. 5 .
[0044] Network Elements (Connection Data)
[0045] Network elements, 310 323 and 336 , also referred to as nodes herein, show that connection data can be generated by compiling, or combining, a plurality of links and associated ports, and/or portions of a plurality of links and associated ports, together. Examples of connection data representing a communication path are: port 306 and port 307 ; port 308 and port 315 ; port 320 and port 321 ; and port 322 and port 328 .
[0046] A further discussion of connection data is provided in relation to FIG. 6 .
[0047] The physical map data 302 , which may be represented as NetML, may include a plurality of network layers, such as, for example, SONET, SDH (Synchronous Digital Hierarchy), IP and ATM. As discussed above, a link or port is characterized by its layer, which is the relevant set of information required to characterize the data flowing on a link. The layer may include specifications for bandwidth, bit encoding scheme, error correcting codes, signaling protocol, framing format, header information or other information and may be viewed as an aggregate.
[0048] For example, a sequence of adaptations allows a layered interpretation of the data actually transferred over a plurality of physical links. Data at a first port may be IP; at a second port the data can be interpreted as IP over ATM; and at a third port, the data can be interpreted as IP over ATM over SONET. The data at a fourth port can be interpreted as the direct encapsulation of IP over SONET.
[0049] FIG. 4 shows an example of a representation of physical link data 400 , which is a component of the physical map data (shown in FIG. 3 as 302 ). The representation of physical link data 400 is typically an abstraction of the physical link data, described in relation to FIG. 3 , and represented in a form that can be stored in memory and analyzed, processed and manipulated by a processor, as described herein. The physical link data 400 is, for example, a data structure or matrix that has a field 402 that identifies each of a plurality of physical links, a field 404 that identifies a start port for each physical link, a field 406 that identifies an end port for each physical link and a field 408 that identifies links 309 and 329 as physical links.
[0050] While the example of FIG. 4 shows that field 402 identifies two physical links ( 309 and 329 ), it should be understood that the number of physical links is a function of the physical map data.
[0051] As shown in FIG. 4 , physical link 309 (field 402 ) has start port 307 (field 404 ), end port 308 (field 406 ). Physical link 309 is a physical link (field 408 ) because start port 307 is connected to end port 308 .
[0052] FIG. 4 also shows that physical link 329 (field 402 ) has start port 321 (field 404 ) and end port 322 (field 406 ).
[0053] FIG. 5 shows an example of a representation of adapter data 500 , which is a component of the physical map data (shown in FIG. 3 as 302 ). The representation of adapter data 500 is typically an abstraction of the adapter data, described in relation to FIG. 3 , and represented in a form that can be stored in memory and analyzed, processed and manipulated by a processor, as described herein. The adapter data 500 is, for example, a data structure or matrix that has a field 502 that stores adapter identification data, a field 504 that stores host port data and a field 506 that stores guest port data, in three sub-fields, A, B and C, that identify a label of the particular guest port.
[0054] As shown in FIG. 5 , adapter 302 (field 502 ) has a host port 306 (field 504 ) and three guest ports, 303 , 304 and 305 (field 506 ). Guest port 303 has label A, guest port 304 has label B and guest port 305 has label C. Similarly, adapter 311 has a host port 315 and guest ports 312 , 313 and 314 , having labels A, B and C, respectively. Adapter 316 has host port 320 and guest ports 317 , 318 and 319 , having labels A, B and C, respectively. Finally, adapter 324 has host port 328 and guest ports 325 , 326 and 327 , having labels A, B and C, respectively.
[0055] FIG. 6 shows an example of a representation of connection data 600 , which is a component of the physical map data (shown in FIG. 3 as 302 ). Connection data 600 represents an association of two physical ports of a physical link or a port of a physical link and a port of an adapter. A port may be connected to another port at the same layer and data ejected from one port is injected into a connected port. The representation of the connection data 600 is typically an abstraction of the connection data, described in relation to FIG. 3 , and represented in a form that can be stored in memory and analyzed, processed and manipulated by a processor, as described herein. The connection data 600 is, for example, a data structure or matrix that has a field 602 that stores first port data and field 604 that stores second port data. As shown in FIG. 6 , port 306 is connected to port 307 . Similarly, ports 308 and 315 are connected, ports 313 and 317 are connected, ports 320 and 321 are connected and ports 322 and 328 are connected. This connection data 600 is used to determine communication paths of the physical map data (shown in FIG. 3 as 302 ).
[0056] FIG. 7 shows an example of a representation of binding data 700 , which is a component of the network map data (shown in FIG. 2 as 218 ). Binding data 700 is an association between the physical map data (shown in FIG. 3 as 302 ) and the logical map data (shown in FIG. 3 as 301 ). The representation of the binding data 700 is typically an abstraction of the binding data represented in a form that can be stored in memory and analyzed, processed and manipulated by a processor, as described herein. The binding data 700 is, for example, a data structure or matrix that has a field 702 that identifies link 332 , start port field 704 , end port field 706 , start port binding field 708 and end port binding field 710 . The binding data associates start port 330 (field 704 ) of logical link 332 to port 304 (field 708 ) and end port 331 (field 706 ) to port 325 (field 710 ). Therefore, in order to establish a communication path corresponding to logical link 332 , the physical map data (shown in FIG. 3 as 302 ) is analyzed using a verification algorithm to verify that a path exists between port 304 , which is bound to port 330 , and port 325 , which is bound to port 331 .
[0057] Binding data 700 shows that ports 330 and 304 and ports 331 and 325 , respectively, are bound. As shown in FIG. 3 , data injected into guest port 304 , having label B, is multiplexed, via adapter 302 , with other data streams that are injected at guest ports 303 and 305 and ejected from host port 306 . Host port 306 and start port 307 are connected, as a result of connection data 600 , shown in FIG. 6 , and the data ejected from host port 306 is injected into start port 307 , traverses physical link 309 , and is ejected from end port 308 . End port 308 and end port 315 are connected, as a result of connection data 600 , shown in FIG. 6 , and the data is injected into host port 315 , where it is reverse multiplexed, or “unadapted,” by adapter 311 and ejected from guest port 313 (the label B of port 313 matches the label B of port 304 ). The connection data 600 , shown in FIG. 6 , shows guest ports 313 and 317 are connected and the data is injected into guest port 317 .
[0058] Data from port 317 is multiplexed by adapter 316 and ejected from host port 320 . Connection data 600 , shown in FIG. 6 , shows that host port 320 is connected to start port 321 . The data traverses physical link 329 and is ejected from end port 322 . The connection data 600 , shown in FIG. 6 , shows that end port 322 is connected to host port 328 . The data is reverse multiplexed, or “unadapted” by adapter 324 and ejected from guest port 325 . The binding data shows that guest port 325 is associated with port 331 of logical link 332 . Hence, logical link 332 is valid since it has a corresponding communication path through physical map data 302 .
[0059] FIGS. 8A-8C , generally referred to herein as FIG. 8 , are a flowchart of exemplary steps for a verification algorithm 800 . These steps, or functional features, are shown as blocks and are suitably stored on a computer-readable medium, which can be read by a computer, or other processing device, as described herein. The steps may be program code or a series of manipulations of data. While FIG. 8 shows steps in a particular sequence, this is for explanation purposes, and it is within the scope of the invention that the specific sequence may be modified as a function of specific applications, program code and design considerations.
[0060] Generally, verification algorithm 800 , which is described using examples used in FIGS. 2-7 , shows steps to verify that the logical links of logical map data (shown in FIG. 3 as 301 ) correspond to communication paths of the network using the physical map data (shown in FIG. 3 as 302 ). The algorithm may function in a parallel processing environment wherein criteria are being analyzed substantially simultaneously or in a serial processing environment, in which the analysis is performed substantially sequentially. While FIG. 8 shows an example of validating a single logical link it should be apparent to one skilled in the art that the algorithm can be used to verify a plurality of logical links.
[0061] A communication path between two ports X ( 304 of FIG. 3 ) and Y ( 325 of FIG. 3 ) exists if: the two ports are the start and end ports of a link; or if ports X and Y are each guest ports of an adapter with identical labels, and there is a communication path between the host ports of the two adapters; or there are two intermediate connected ports, with a communication path from port X to one of the intermediate ports, and from another intermediate port to port Y.
[0062] Step 802 begins the algorithm for verifying whether there is a communication path from a port X ( 304 of FIG. 3 ) to a port Y ( 325 of FIG. 3 ), which may be the start and end ports of physical map data that are bound to start and end ports of a logical link to be verified (link 332 of FIG. 3 ). The physical map data ( 302 of FIG. 2 ) includes ports, indicated as N, P, Q, R and S, (examples of ports are provided in FIG. 3 as elements 303 , 304 , 305 , 306 , 307 , 308 , 312 , 313 , 314 , 315 316 , etc.) and adapters T and U (examples of adapters are provided in FIG. 3 as elements 338 , 311 , 316 and 324 ). Step 804 determines whether X (port 304 of FIG. 3 ) is a start port or end port of a physical link. If so, “yes” line 808 leads to step 842 . Step 842 sets port N to be the other port of the physical link containing port X (port 304 of FIG. 3 ). Step 846 determines if port N is the same port as port Y (port 325 of FIG. 3 ). If so, “yes” line 848 leads to step 890 . Step 890 establishes that the logical link with link ports that are bound to ports X (port 304 of FIG. 3 ) and Y (port 325 of FIG. 3 ) corresponds to a communication path of the physical map data and the particular logical link is valid.
[0063] If step 846 determines that port N is not port Y (port 325 of FIG. 3 ), then “no” line 850 leads to step 852 . Step 852 determines whether another port is connected to port N. If so, “yes” line 856 leads to step 858 , which establishes P as the other port connected to port N. Line 860 leads to decision block 876 , which determines whether there is a path from port P to port Y (port 325 of FIG. 3 ). If so, “yes” line 880 leads to step 890 , which determines that a path exists. If not, “no” line 878 leads back to decision step 852 .
[0064] If decision step 852 determines that there is not another port connected to port N, “no” line 854 leads to step 862 , which determines that a path does not exist, and the logical link does not correspond to a communication path and, therefore, the network data is not valid. Line 864 leads to step 868 , which establishes a reason for the invalidity. The reason generated may identify one or more logical links that do not correspond to a communication path. This reason can identify whether the failure was attributed to link data, connection data, adapter data or a combination thereof. The step of generating a reason is optional and can be omitted.
[0065] Step 870 stores reasons for the failure. Step 872 generates an accumulation of invalid logical links, such as a manifest, or record. This manifest may include the reasons for the invalidity. As a further embodiment, the manifest can optionally be transmitted to an output module or facility.
[0066] Step 874 generates a response, or negative indication, or alert, reflecting the inconsistency. This negative indication may be output to a user device, or display device or may be stored in a remote or local memory. End step 892 ends the algorithm.
[0067] Returning to step 804 , if port X (port 304 of FIG. 3 ) is not a start port or an end port, “no” line 810 leads to decision step 812 , which determines whether X (port 304 of FIG. 3 ) is a guest port. If not, “no” line 814 leads to leads to step 862 , which indicates that there is not a communication path from port X (port 304 of FIG. 3 ) to port Y (port 325 of FIG. 3 ). If decision block 812 determines that port X (port 304 of FIG. 3 ) is a guest port, “yes” line 816 leads to step 818 . Step 818 establishes: T (adapter 338 of FIG. 3 ) to be an adapter containing port X (port 304 of FIG. 3 ); R (port 306 of FIG. 3 ) is the host port of adapter T (adapter 338 of FIG. 3 ); and L (label B of FIG. 3 ) is the label of guest port X (port 304 of FIG. 3 ). Decision step 820 determines whether there is another adapter different than adapter T (adapter 338 of FIG. 3 ). If not, “no” line 822 leads to line 814 , discussed above. If decision step 820 determines that there is another adapter different from adapter T, “yes” line 824 leads to step 826 . Step 826 establishes: U (adapter 311 of FIG. 3 ) as another adapter different from adapter T; and Q (port 315 of FIG. 3 ) as the host port of adapter U (adapter 311 of FIG. 3 ). Decision block 828 determines whether there is a path from host port R (port 306 of FIG. 3 ) to host port Q (port 315 of FIG. 3 ) of adapter U (adapter 311 of FIG. 3 ). If not, “no” line 830 leads to step 826 . If so, “yes” line 832 leads to decision block 834 , which determines whether adapter U (adapter 311 of FIG. 3 ) has a guest port (port 313 of FIG. 3 ) with label L. If not, “no” line 836 leads to step 826 . If so, “yes” line 838 leads to step 840 , which establishes N as the guest port (port 313 of FIG. 3 ) with label L. Step 846 , discussed previously, is reached from step 840 .
[0068] When all of the logical links of a logical map have been validated, or verified, by establishing that each logical link represents a communication path, a match indication is generated. This affirmative indication may be output to a user device, or display device or may be stored in a remote or local memory. If each of the logical links is not valid, the network map data is not valid.
[0069] While FIG. 8 shows an example of the sequence of steps, it is also an embodiment of the present invention that the sequence may be varied. Various permutations of the algorithm are contemplated as alternate embodiments of the invention.
[0070] As described above, layers and adapter types can be discriminated in the network and these layers and types may be preserved during the manipulations of the present invention.
[0071] It is also a further embodiment of the present invention that the verification algorithm determines a communication path corresponding link as efficiently as possible. For example, as soon as a logical link is verified, processing terminates for that logical link.
[0072] As is known in the art, the methods and apparatus discussed herein may be distributed as an article of manufacture that itself comprises a computer readable medium having computer readable code means embodied thereon. The computer readable program code means is operable, in conjunction with a computer system, to carry out all or some of the steps to perform the methods or create the apparatuses discussed herein. The computer readable medium may be a recordable medium (e.g., floppy disks, hard drives, compact disks, or memory cards) or may be a transmission medium (e.g., a network comprising fiber-optics, the world-wide web, cables, or a wireless channel using time-division multiple access, code-division multiple access, or other radio-frequency channel). Any medium known or developed that can store information suitable for use with a computer system may be used. The computer-readable code means is any mechanism for allowing a computer to read instructions and data, such as magnetic variations on a magnetic media or height variations on the surface of a compact disk.
[0073] It is to be understood that the invention may be practiced with other computer system configurations, including, for example, hand-held devices, multiprocessor systems, microprocessor-based or programmable consumer electronic devices, network PC's, minicomputers, mainframe computers, and other devices with processing capabilities. The embodiment may also be practiced in distributed computing environments where tasks are performed by remote processing devices that are linked through a communications network. In a distributed computing environment, program modules may be located in both local and remote memory storage devices.
[0074] It is to be understood that the embodiments and variations shown and described herein are merely illustrative of the principles of this invention and that various modifications may be implemented by those skilled in the art without departing from the scope and spirit of the invention. | An apparatus and method are disclosed for verifying that a description of a network corresponds to communication paths of the network. The verification is accomplished by accessing data that represents of a plurality of logical links of the network. A determination is made whether each of the logical links correspond to a communication path of the network. This determination utilizes criteria, which includes: link data; adapter data; and connection data. Thereafter, an indication of whether the logical links correspond to communication paths of the network is provided. If each logical link does not have a corresponding communication path, additional information related to the reason for the non-correspondence may be provided. | 7 |
[0001] This application is a continuation of U.S. application Ser. No. 11/178,415 (now U.S. Pat. No. 8,034,360) filed Jul. 12, 2005, which is a continuation of U.S. application Ser. No. 09/857,691 (now U.S. Pat. No. 6,972,128) filed Sep. 5, 2001, which is a national stage of PCT/GB99/04129 filed Dec. 9, 1999. The entire contents of the above-identified applications are hereby incorporated by reference.
FIELD OF THE INVENTION
[0002] This invention is concerned with agents for the treatment of primary, metastatic and residual cancer in mammals (including humans) by inducing the immune system of the mammal or human afflicted with cancer to mount an attack against the tumour lesion. In particular, the invention pertains to the use of whole-cells, derivatives and portions thereof with or without vaccine adjuvants and/or other accessory factors. More particularly, this disclosure describes the use of particular combinations of whole-cells and derivatives and portions thereof that form the basis of treatment strategy.
BACKGROUND TO THE INVENTION
[0003] It is known in the field that cancerous cells contain numerous mutations, qualitative and quantitative, spatial and temporal, relative to their normal, non-cancerous counterparts and that at certain periods during tumour cells' growth and spread a proportion of these are capable of being recognised by the hosts' immune system as abnormal. This has led to numerous research efforts world-wide to develop immunotherapies that harness the power of the hosts' immune system and direct it to attack the cancerous cells, thereby eliminating such aberrant cells at least to a level that is not life-threatening (reviewed in Maraveyas, A. & Dalgleish, A. G. 1997 Active immunotherapy for solid tumours in vaccine design in The Role of Cytokine Networks, Ed. Gregoriadis et al., Plenum Press, New York, pages 129-145; Morton, D. L. and Ravindranath, M. H. 1996 Current concepts concerning melanoma vaccines in Tumor Immunology—Immunotherapy and Cancer Vaccines, ed. Dalgleish, A. G. and Browning, M., Cambridge University Press, pages 241-268. See also other papers in these publications for further detail).
[0004] Numerous approaches have been taken in the quest for cancer immunotherapies, and these can be classified under five categories:
Non-Specific Immunotherapy
[0005] Efforts to stimulate the immune system non-specifically date back over a century to the pioneering work of William Coley (Coley, W. B., 1894 Treatment of inoperable malignant tumours with toxins of erisipelas and the Bacillus prodigosus. Trans. Am. Surg. Assoc. 12: 183). Although successful in a limited number of cases (e.g. BCG for the treatment of urinary bladder cancer, IL-2 for the treatment of melanoma and renal cancer) it is widely acknowledged that non-specific immunomodulation is unlikely to prove sufficient to treat the majority of cancers. Whilst non-specific immune-stimulants may lead to a general enhanced state of immune responsiveness, they lack the targeting capability and also subtlety to deal with tumour lesions which have many mechanisms and plasticity to evade, resist and subvert immune-surveillance.
Antibodies and Monoclonal Antibodies
[0006] Passive immunotherapy in the form of antibodies, and particularly monoclonal antibodies, has been the subject of considerable research and development as anti-cancer agents. Originally hailed as the magic bullet because of their exquisite specificity, monoclonal antibodies have failed to live up to their expectation in the field of cancer immunotherapy for a number of reasons including immune responses to the antibodies themselves (thereby abrogating their activity) and inability of the antibody to access the lesion through the blood vessels. To date, three products have been registered as pharmaceuticals for human use, namely Panorex (Glaxo-Wellcome), Rituxan (IDEC/Genentech/Hoffman la Roche) and Herceptin (Genentech/Hoffman la Roche) with over 50 other projects in the research and development pipeline. Antibodies may also be employed in active immunotherapy utilising anti-idiotype antibodies which appear to mimic (in an immunological sense) cancer antigens. Although elegant in concept, the utility of antibody-based approaches may ultimately prove limited by the phenomenon of ‘immunological escape’ where a subset of cancer cells in a mammalian or human subject mutates and loses the antigen recognised by the particular antibody and thereby can lead to the outgrowth of a population of cancer cells that are no longer treatable with that antibody.
Subunit Vaccines
[0007] Drawing on the experience in vaccines for infectious diseases and other fields, many researchers have sought to identify antigens that are exclusively or preferentially associated with cancer cells, namely tumour specific antigens (TSA) or tumour associated antigens (TAA), and to use such antigens or fractions thereof as the basis for specific active immunotherapy.
[0008] There are numerous ways to identify proteins or peptides derived therefrom which fall into the category of TAA or TSA. For example, it is possible to utilise differential display techniques whereby RNA expression is compared between tumour tissue and adjacent normal tissue to identify RNAs which are exclusively or preferentially expressed in the lesion. Sequencing of the RNA has identified several TAA and TSA which are expressed in that specific tissue at that specific time, but therein lies the potential deficiency of the approach in that identification of the TAA or TSA represents only a “snapshot” of the lesion at any given time which may not provide an adequate reflection of the antigenic profile in the lesion over time. Similarly a combination of cytotoxic T lymphocyte (CTL) cloning and expression-cloning of cDNA from tumour tissue has lead to identification of many TAA and TSA, particularly in melanoma. The approach suffers from the same inherent weakness as differential display techniques in that identification of only one TAA or TSA may not provide an appropriate representation of a clinically relevant antigenic profile.
[0009] Over fifty such subunit vaccine approaches are in development for the treatment of a wide range of cancers, although none has yet received marketing authorisation for use as a human pharmaceutical product. In a similar manner to that described for antibody-based approaches above, subunit vaccines may also be limited by the phenomenon of immunological escape.
Gene Therapy
[0010] The majority of gene therapy trials in human subjects have been in the area of cancer treatment, and of these a substantial proportion have been designed to trigger and/or amplify patients' immune responses. Of particular note in commercial development are Allovectin-7 and Leuvectin, being developed by Vical Inc for a range of human tumours, CN706 being developed by Calydon Inc for the treatment of prostate cancer, and StressGen Inc.'s stress protein gene therapy for melanoma and lung cancer. At the present time, it is too early to judge whether these and the many other immuno-gene therapies' in development by commercial and academic bodies will ultimately prove successful, but it is widely accepted that commercial utility of these approaches are likely to be more than a decade away.
Cell-Based Vaccines
[0011] Tumours have the remarkable ability to counteract the immune system in a variety of ways including: downregulation of the expression of potential target proteins; mutation of potential target proteins; downregulation of surface expression of receptors and other proteins; downregulation of MHC class I and II expression thereby disallowing direct presentation of TAA or TSA peptides; downregulation of co-stimulatory molecules leading to incomplete stimulation of T-cells leading to anergy; shedding of selective, non representative membrane portions to act as decoy to the immune system; shedding of selective membrane portions to anergise the immune system; secretion of inhibitory molecules; induction of T-cell death; and many other ways. What is clear is that the immunological heterogeneity and plasticity of tumours in the body will have to be matched to a degree by immunotherapeutic strategies which similarly embody heterogeneity. The use of whole cancer cells, or crude derivatives thereof, as cancer immunotherapies can be viewed as analogous to the use of whole inactivated or attenuated viruses as vaccines against viral disease. The potential advantages are:
(a) whole cells contain a broad range of antigens, providing an antigenic profile of sufficient heterogeneity to match that of the lesions as described above; (b) being multivalent (i.e. containing multiple antigens), the risk of immunological escape is reduced (the probability of cancer cells ‘losing’ all of these antigens is remote); and (c) cell-based vaccines include TSAs and TAAs that have yet to be identified as such; it is possible if not likely that currently unidentified antigens may be clinically more relevant than the relatively small number of TSAs/TAAs that are known.
[0015] Cell-based vaccines fall into two categories. The first, based on autologous cells, involves the removal of a biopsy from a patient, cultivating tumour cells in vitro, modifying the cells through transfection and/or other means, irradiating the cells to render them replication-incompetent and then injecting the cells back into the same patient as a vaccine. Although this approach enjoyed considerable attention over the past decade, it has been increasingly apparent that this individually-tailored therapy is inherently impractical for several reasons. The approach is time consuming (often the lead time for producing clinical doses of vaccine exceeds the patients' life expectancy), expensive and, as a ‘bespoke’ product, it is not possible to specify a standardised product (only the procedure, not the product, can be standardised and hence optimised and quality controlled). Furthermore, the tumour biopsy used to prepare the autologous vaccine will have certain growth characteristics, interactions and communication with surrounding tissue that makes it somewhat unique. This alludes to a potentially significant disadvantage to the use of autologous cells for immunotherapy: a biopsy which provides the initial cells represents an immunological snapshot of the tumour, in that environment, at that point in time, and this may be inadequate as an immunological representation over time for the purpose of a vaccine with sustained activity that can be given over the entire course of the disease.
[0016] The second type of cell-based vaccine and the subject of the current invention describes the use of allogeneic cells which are genetically (and hence immunologically) mismatched to the patients. Allogeneic cells benefit from the same advantages of multivalency as autologous cells. In addition, as allogeneic cell vaccines can be based on immortalised cell lines which can be cultivated indefinitely in vitro, thus this approach does not suffer the lead-time and cost disadvantages of autologous approaches. Similarly the allogeneic approach offers the opportunity to use combinations of cells types which may match the disease profile of an individual in terms of stage of the disease, the location of the lesion and potential resistance to other therapies.
[0017] There are numerous published reports of the utility of cell-based cancer vaccines (see, for example, Dranoff, G. et al. WO 93/06867; Gansbacher, P. WO 94/18995; Jaffee, E. M. et al. WO 97/24132; Mitchell, M. S. WO 90/03183; Morton, D. M. et al. WO 91/06866). These studies encompass a range of variations from the base procedure of using cancer cells as an immunotherapy antigen, to transfecting the cells to produce GM-CSF, IL-2, interferons or other immunologically-active molecules and the use of ‘suicide’ genes. Groups have used allogeneic cell lines that are HLA-matched or partially-matched to the patients' haplotype and also allogeneic cell lines that are mismatched to the patients' haplotype in the field of melanoma and also mismatched allogeneic prostate cell lines transfected with GM-CSF.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] The invention will now be described with reference to the following examples, and the Figures in which:
[0019] FIGS. 1A , 1 B and 1 C show T-cell proliferation data for patients 112, 307, and 406;
[0020] FIGS. 2A , 2 B and 2 C show Western Blot analysis of serum from patients 115, 304 and 402;
[0021] FIGS. 3A , 3 B and 3 C show shows antibody titres of serum from patients 112,305 and 402;
[0022] FIGS. 4A , 4 B and 4 C show shows PSA data for patients 110, 303 and 404; and
[0023] FIG. 5 shows survival curves for C57 mice immunised with normal melanocyte.
DESCRIPTION OF THE INVENTION
[0024] The invention disclosed here relates to a product comprised of a cell line or lines intended for use as an allogeneic immunotherapy agent for the treatment of cancer in mammals and humans.
[0025] All of the studies of cell-based cancer vaccines to date have one feature in common, namely the intention to use cells that contain at least some TSAs and/or TAAs that are shared with the antigens present in patients' tumour. In each case, tumour cells are utilised as the starting point on the premise that only tumour cells will contain TSAs or TAAs of relevance, and the tissue origins of the cells are matched to the tumour site in patients.
[0026] A primary aspect of the invention is the use of immortalised normal, non-malignant cells as the basis of an allogeneic cell cancer vaccine. Normal cells do not posses TSAs or relevant concentrations of TAAs and hence it is surprising that normal cells as described herein are effective as anti-cancer vaccines. The approach is general and can be adapted to any mammalian tumour by the use of immortalised normal cells derived from the same particular tissue as the tumour intended to be treated. Immortalised normal cells can be prepared by those skilled in the art using published methodologies, or they can be sourced from cell banks such as ATCC or ECACC, or they are available from several research groups in the field.
[0027] For prostate cancer, for example, a vaccine may be based on one or a combination of different immortalised normal cell lines derived from the prostate which can be prepared using methods reviewed and cited in Rhim, J. S. and Kung, H-F., 1997 Critical Reviews in Oncogenesis 8(4):305-328 or selected from PNT1A (ECACC Ref No: 95012614), PNT2 (ECACC Ref No: 95012613) or PZ-HPV-7 (ATCC Number: CRL-2221).
[0028] A further aspect of the invention is the addition of TSAs and/or TAAs by combining one or more immortalised normal cell line(s) with one, two or three different cell lines derived from primary or metastatic cancer biopsies.
[0029] All the appropriate cell lines will show good growth in large scale cell culture and sufficient characterisation to allow for quality control and reproducible production.
[0030] The cell lines are lethally irradiated utilising gamma irradiation at 20-400 Gy to ensure that they are replication incompetent prior to use in the mammal or human.
[0031] The cell lines and combinations referenced above, to be useful as immunotherapy agents must be frozen to allow transportation and storage, therefore a further aspect of the invention is any combination of cells referenced above formulated with a cryoprotectant solution. Suitable cryoprotectant solutions may include but are not limited to, 10-30% v/v aqueous glycerol solution, 5-20% v/v dimethyl sulphoxide or 5-20% w/v human serum albumin may be used either as single cryoprotectants or in combination.
[0032] A further embodiment of the invention is the use of the cell line combinations with non-specific immune stimulants such as BCG or M. Vaccae , Tetanus toxoid, Diphtheria toxoid, Bordetella Pertussis , interleukin 2, interleukin 12, interleukin 4, interleukin 7, Complete Freund's Adjuvant, Incomplete Freund's Adjuvant or other non-specific agents known in the art. The advantage is that the general immune stimulants create a generally enhanced immune status whilst the combinations of cell lines, both add to the immune enhancement through their haplotype mismatch and target the immune response to a plethora of TAA and TSA as a result of the heterogeneity of their specific origins.
[0033] The invention here relates to a product comprised of a cell line or lines intended for use as an allogeneic immunotherapy agent for the treatment of cancer in mammals and humans. All of the studies of cell-based cancer vaccines to date have one feature in common, namely the intention to use cells that contain at least some TSAs and/or TAAs that are shared with the antigens present in patients' tumour. In each case, tumour cells are utilised as the starting point on the premise that only tumour cells will contain TSAs or TAAs of relevance, and the tissue origins of the cells are matched to the tumour site in patients. A primary aspect of the invention is the use of immortalised normal, non-malignant cells as the basis of an allogeneic cell cancer vaccine. Normal cells do not possess TSAs or relevant concentrations of TAAs and hence it is surprising that normal cells are effective as anti-cancer vaccines. For prostate cancer, for example, a vaccine may be based on one or a combination of different immortalised normal cell lines derived from the prostate. The cell lines are lethally irradiated utilising gamma irradiation at 50-300 Gy to ensure that they are replication incompetent prior to use in the mammal or human.
Example 1
Growth, Irradiation, Formulation and Storage of Cells
[0034] An immortalised cell line derived from normal prostate tissue namely PNT2 was grown in roller bottle culture in RPMI 1640 media supplemented with 2 mM L-glutamine and 5% foetal calf serum (FCS) following recovery from liquid nitrogen stocks. Following expansion in T175 static flasks the cells were seeded into roller bottles with a growth surface area of 850 cm 2 at 1−20×10 7 cells per roller bottle.
[0035] An immortalised cell line derived from primary prostate tissue namely NIH1542-CP3TX was grown in roller bottle culture in KSFM media supplemented with 25 ug/ml bovine pituitary extract, 5 ng/ml of epidermal growth factor, 2 nM L-glutamine, 10 nM HEPES buffer and 5% foetal calf serum (FCS) (hereinafter called “modified KSFM:) following recovery from liquid nitrogen stocks. Following expansion in T175 static flasks the cells were seeded into roller bottles with a growth surface area of 1,700 cm2 at 2−5×107 cells per roller bottle.
[0036] Two secondary derived cell lines were also used, namely LnCap and Du145 both of which were sourced from the ATCC. LnCap was grown in large surface area static flasks in RPMI media supplemented with 10% FCS and 2 mM L-glutamine following seeding at 1−10×10 6 cells per vessel and then grown to near confluence. Du-145 was expanded from frozen stocks in static flasks and then seeded into 850 cm 2 roller bottles at 1−20×10 7 cells per bottle and grown to confluence in DMEM medium containing 10% FCS and 2 mM L-glutamine. All cell lines were harvested utilising trypsin at 1× normal concentration. Following extensive washing in DMEM the cells were re-suspended at a concentration of 5−40×10 6 cells/ml and irradiated at 50-300 Gy using a Co 60 source. Following irradiation the cells were formulated in cryopreservation solution composing of 10% DMSO, 8% human serum albumin in phosphate buffered saline, and frozen at a cell concentration of 5−150×10 6 cells/ml, in liquid nitrogen until required for use.
Vaccination
[0037] Prostate cancer patients were selected on the basis of being refractory to hormone therapy with a serum PSA level of at least 30 ng/ml. Ethical permission and MCA (UK Medicines Control Agency) authorization were sought and obtained to conduct this trial.
[0038] One of three vaccination schedules was followed for each arm of the trial:
[0000]
Cell Lines Administered
Dose
Trial Arm A
Trial Arm B
Trial Arm C
1, 2 and 3
PNT2
Du145
LnCap
4 and
PNT2/Du145/
PNT/Du145/
PNT2/NIH1542/LnCap
subsequent
NIH1542
LnCap
[0039] The cells were warmed gently in a water bath at 37° C. and admixed with mycobacterial adjuvant prior to injection into patients. Injections were made intra-dermally at four injection sites into the draining lymph nodes. The minimum interval between doses was two weeks, and most of the doses were given at intervals of four weeks. Prior to the first dose, and prior to some subsequent doses, the patients were tested for delayed-type hypersensitivity (DTH) against the four cell lines listed in the vaccination schedule above (all tests involved 0.8×106 cells with no adjuvant).
Analysis of Immunological Response
(a) T-Cell Proliferation Responses
[0040] To determine if vaccination resulted in a specific expansion of T-cell populations that recognised antigens derived from the vaccinating cell lines we performed a proliferation assay on T-cells following stimulation with lysates of the prostate cell lines. Whole blood was extracted at each visit to the clinic and used in a BrdU (bromodeoxyuridine) based proliferation assay as described below:
Patent BrdU Proliferation Method
Reagents
[0041]
[0000]
RPMI
Life Technologies, Paisely Scotland.
BrdU
Sigma Chemical Co, Poole, Dorset.
PharMlyse
35221E
Pharminogen, Oxford UK
Cytofix/Cytoperm
2090KZ
″
Perm/Wash buffer (×10)
2091KZ
″
FITC Anti-BrdU/Dnase
340649
Becton Dickinson
PerCP Anti-CD3
347344
″
Pe Anti-CD4
30155X
Pharmingen
Pe Anti-CD8
30325X
″
FITC mu-IgG1
349041
Becton Dickinson
PerCP IgG1
349044
″
PE IgG1
340013
″
Method
[0000]
1) Dilute 1 ml blood with 9 ml RPMI+2 mM L-gin+PS+50 uM 2-Me. Do not add serum. Leave overnight at 37° C.
2) On following morning, aliquot 450 ul of diluted blood into wells of a 48-well plate and add 50 ul of stimulator lysate. The lysate is made by freeze-thawing tumour cells (2×106 cell equivalents/ml) ×3 in liquid nitrogen and then storing aliquots frozen until required.
3) Culture cells at 37° C. for 5 days.
4) On the evening of day 5 add 50 ul BrdU @30 ug/ml
5. Aliquot 100 ul of each sample into a 96-well round-bottomed plate.
6) Spin plate and discard supernatant
7) Lyse red cells using 100 ul Pharmlyse for 5 minutes at room temperature
8) Wash ×2 with 50 ul of Cytofix
9) Spin and remove supernatent by flicking
10) Permeabilise with 100 ul Perm wash for 10 mins at RT
11) Add 30 ul of antibody mix comprising antibodies at correct dilution made up to volume with Perm-wash
12) Incubate for 30 mins in the dark at room temperature.
13) Wash ×1 and resuspend in 100 ul 2% paraformaldehyde
14) Add this to 400 ul FACSFlow in cluster tubes ready for analysis
15) Analyse on FACScan, storing 3000 gated CD3 events.
6-Well Plate for Stimulation
[0057]
[0000]
Nil
ConA
1542
LnCap
Du145
Pnt2
PBL1
PBL2
PBL3
PBL4
PBL5
PBL6
96-Well Plate for Antibody Staining
[0058]
[0000]
PBL1
PBL2
PBL3
PBL4
PBL5
PBL6
Nil A
15D
Nil A
15 D
Nil A
15 D
Nil A
15 D
Nil A
15 D
Nil A
15 D
Nil D
15 E
Nil D
15 E
Nil D
15 E
Nil D
15 E
Nil D
15 E
Nil D
15 E
Nil E
Ln D
Nil E
Ln D
Nil E
Ln D
Nil E
Ln D
Nil E
Ln D
Nil E
Ln D
Con D
Ln E
Con D
Ln E
Con D
Ln E
Con D
Ln E
Con D
Ln E
Con D
Ln E
Con E
Du D
Con E
Du D
Con E
Du D
Con E
Du D
Con E
Du D
Con E
Du D
Du E
Du E
Du E
Du E
Du E
Du E
Ph D
Ph D
Ph D
Ph D
Ph D
Ph D
Ph E
Ph E
Ph E
Ph E
Ph E
Ph E
Legend:
[0000]
A: IgG1-FITC (5 ul) IgG1-PE (5 ul) IgG1-PerCP (5 ul) 15 ul MoAb+15 ul
D: BrdU-FITC (5 ul) CD4-PE (5 ul) CD3-PerCP (5 ul) 15 ul MoAb+15 ul
E: BrdU-FITC (5 ul) CD8-PE (5 ul) CD3-PerCP (5 ul) 15 ul MoAb+15 ul
15: NIH1542-CP3TX
Ln: LnCap
D: Du145
Pn: PNT2
Con: ConA lectin (positive control)
Nil: No stimulation
[0068] The results for the proliferation assays are shown in FIGS. 1A , 1 B and 1 C show where a proliferation index for either CD4 or CD8 positive T-cells are plotted against the various cell lysates. The proliferation index being derived by dividing through the percentage of T-cells proliferating by the no-lysate control.
[0069] Results are shown for patient numbers 112, 307 and 406. Results are given for four cell lysates namely, NIH1542, LnCap, DU-145 and PNT-2. Overall, 50% of patients treated mount a specific proliferative response to at least one of the cell lines.
(b) Western Blots Utilising Patients' Serum
[0070] Standardised cell lysates were prepared for a number of prostate cell lines to enable similar quantities of protein to be loaded on a denaturing SDS PAGE gel for Western blot analysis. Each blot was loaded with molecular weight markers, and equal amounts of protein derived from cell lysates of NIH1542, LnCap, DU-145 and PNT-2. The blot was then probed with serum from patients derived from pre-vaccination and following 16 weeks vaccination (four to six doses).
Method
a) Sample Preparation (Prostate Tumor Lines)
[0000]
Wash cell pellets 3 times in PBS
Re-suspend at 1×107 cells/ml of lysis buffer
Pass through 5 cycles of rapid freeze thaw lysis in liquid nitrogen/water bath
Centrifuge at 1500 rpm for 5 min to remove cell debris
Ultracentrifuge at 20,000 rpm for 30 min to remove membrane contaminants
Aliquot at 200 ul and stored at −80° C.
b) Gel Electrophoresis
[0000]
Lysates mixed 1:1 with Laemelli sample buffer and boiled for 5 min
20 ug samples loaded into 4-20% gradient gel wells
Gels run in Bjerrum and Schafer-Nielson transfer buffer (with SDS) at 200 V for 35 min.
c) Western Transfer
[0000]
Gels, nitrocellulose membranes and blotting paper equilibrated in transfer buffer for 15 min
Arrange gel-nitrocellulose sandwich on anode of semi-dry electrophoretic transfer cell: 2 sheets of blotting paper, nitrocellulose membrane, gel, 2 sheets of blotting paper
Apply cathode and run at 25 V for 90 min.
d) Immunological Detection of Proteins
[0000]
Block nitrocellulose membranes overnight at 4° C. with 5% Marvel in PBS/0/05% Tween 20
Rinse membranes twice in PBS/0.05% Tween 20, then wash for 20 min and 2×5 min at RT on a shaking platform
Incubate membranes in 1:20 dilution of clarified patient plasma for 120 min at RT on a shaking platform
Wash as above with an additional 5 min final wash
Incubate membranes in 1:250 dilution of biotin anti-human IgG or IgM for 90 min at RT on a shaking platform
Wash as above with an additional 5 min final wash
Incubate membranes in 1:1000 dilution of streptavidin-horseradish peroxidase conjugate for 60 min at RT on a shaking platform
Wash as above
Incubate membranes in Diaminobenzidine peroxidase substrate for 5 min to allow colour development, stop reaction by rinsing membrane with water
[0092] The results in FIGS. 3A , 3 B and 3 C show for patients 112, 305 and 402 clearly show that vaccination over the period of 16 weeks (four to six doses) can result in an increase in antibody titre against cell line lysates and also cross reactivity against lysates not received in this vaccination regime (other than DTH testing).
(c) Antibody Titre Determination
[0093] Antibody titres were determined by coating ELISA plates with standardised cell line lysates and performing dilution studies on serum from vaccinated patients.
[0000] Method for ELISA with Anti-Lysate IgG.
1. Coat plates with 50 ul/well lysates (@10 ug/ml) using the following dilutions:
[0000]
Lysate
Protein conc
Coating conc
Amount/ml
Amount in 5 mls ul
PNT2
2.5 mg/ml
10 ug/ml
3.89 ul
19.4 ul
1542
4.8 mg/ml
10 ug/ml
2.07 ul
10.3 ul
Du145
2.4 mg/ml
10 ug/ml
4.17 ul
20.8 ul
LnCap
2.4 mg/ml
10 ug/ml
4.12 ul
20.6 ul
2. Cover and incubate overnight @ 4° C.
3. Wash ×2 PBS-Tween. Pound plate on paper towels to dry.
4. Block with PBS/10% FCS (100 ul/well)
5. Cover and incubate @ room temperature (RT) for 1 hour (minimum).
6. Wash ×2 PBS-Tween
7. Add 100 ul PBS-10% FCS to rows 2-8
8. Add 200 ul plasma sample (diluted 1 in 100 in PBS-10% FCS ie. 10 ul plasma added to 999 uls PBS-10% FCS) to row 1 and do serial 100 ul dilutions down the plate as below. Discard extra 100 ul from bottom well. Cover and incubate in fridge overnight.
9. Dilute biotinylated antibody (Pharmingen; IgG 34162D) ie. Final conc 1 mg/ml (ie 20 ml in 10 mls).
10. Cover and incubate @RT for 45 min.
11. Wash ×6 as above.
12. Dilute streptavidin—HRP (Pharmingen, 13047E 0, dilute 1:1000 (ie 10 ml->10 mls).
13. Add 100 ml/well.
14. Incubate 30 min @RT.
15. Wash ×8.
16. Add 100 ml substrate/well. Allow to develop 10-80 min at RT.
17. Colour reaction stopped by adding 100 ml 1M H2SO4.
18. Read OD @ A405 nm.
[0112] The results in FIGS. 3A , 3 B and 3 C show for patients 112, 305 and 402 show antibody titres at baseline (0), 4 weeks, 8 weeks and 16 weeks. The data show that after vaccination with at least four doses, patients can show an increase in antibody titre against cell line lysates and also cross-reactivity against cell lines not received in this vaccination regime (except as DTH doses).
(d) Evaluation of PSA Levels
[0113] PSA levels for patients receiving the vaccine were recorded at entry into the trial and throughout the course of vaccination, using routinely used clinical kits. The PSA values for patients 110, 303 and 404 are shown in FIGS. 4A , 4 B and 4 C show (vertical axis is serum PSA in ng/ml; horizontal axis is time, with the first time point representing the initiation of the vaccination program) and portray a drop or partial stabilization of the PSA values, which in this group of patients normally continues to rise, often exponentially. The result for patient 110 is somewhat confounded by the radiotherapy treatment to alleviate bone pain, although the PSA level had dropped prior to radiotherapy.
Example 2
Use of a Normal Melanocyte in a Murine Melanoma Protection Model
[0114] A normal melanocyte cell line was used in a vaccination protection model of murine melanoma utilising the B16.F10 as the challenge dose. The C57 mice received two vaccinations of either PBS, 5×106 irradiated K1735 allogeneic melanoma cells or 5×106 irradiated Melan P1 autologous normal melanocyte cells on days −14 and −7. Challenge on day 0 was with 1×104 B16.F10 cells and tumour volume measured every three days from day 10 onwards. Animals were sacrificed when the tumour had grown to 1.5×1.5 cm measured across the maximum dimensions of the tumour. FIG. 5 shows that vaccination with Melan1P cells offer some level of protection against this particularly aggressive murine tumour.
[0115] This application claims priority to GB 9827104.2, filed Dec. 10, 1998, which is incorporated by reference in its entirety. | This invention is concerned with agents for the treatment of primary, metastatic and residual cancer in mammals (including humans) by inducing the immune system of the mammal or human afflicted with cancer to mount an attack against the tumour lesion. In particular, the invention pertains to the use of whole-cells, derivatives and portions thereof with or without vaccine adjuvants and/or other accessory factors. More particularly, this disclosure describes the use of particular combinations of whole-cells and derivatives and portions thereof that form the basis of treatment strategy. | 0 |
CROSS-REFERENCE TO RELATED APPLICATION
This application is a continuation-in-part of U.S. patent application Ser. No. 08/675,439, filed Jun. 28, 1996.
BACKGROUND OF THE INVENTION
The Ras family of proteins are important in the signal transduction pathway modulating cell growth. The protein is produced in the ribosome, released into the cytosol, and post-translationally modified. The first step in the series of post-translational modifications is the alkylation of Cys 168 with farnesyl or geranylgeranyl pyrophosphate in a reaction catalyzed by prenyl transferase enzymes such as farnesyl transferase and geranylgeranyl transferase (Hancock, J F, et al., Cell 57:1167-1177 (1989)). Subsequently, the three C-terminal amino acids are cleaved (Gutierrez, L., et al., EMBO J. 8:1093-1098 (1989)), and the terminal Cys is converted to a methyl ester (Clark, S., et al., Proc. Nat'l Acad. Sci. (USA) 85:4643-4647 (1988)). Some forms of Ras are also reversibly palmitoylated on cysteine residues immediately N-terminal to Cys 168 (Buss, J E, et al., Mol. Cell. Biol. 6:116-122 (1986)). It is believed that these modifications increase the hydrophobicity of the C-terminal region of Ras, causing it to localize at the surface of the cell membrane. Localization of Ras to the cell membrane is necessary for signal transduction (Willumsen, B M, et al., Science 310:583-586 (1984)).
Oncogenic forms of Ras are observed in a relatively large number of cancers including over 50 percent of colon cancers and over 90 percent of pancreatic cancers (Bos, J L, Cancer Research 49:4682-4689 (1989)). These observations suggest that intervention in the function of Ras mediated signal transduction may be useful in the treatment of cancer.
Previously, it has been shown that the C-terminal tetrapeptide of Ras has the “CAAX” motif (wherein C is cysteine, A is an aliphatic amino acid, and X is any amino acid). Tetrapeptides having this structure have been shown to be inhibitors of prenyl transferases (Reiss, et al., Cell 62:81-88 (1990)). Poor potency of these early farnesyl transferase inhibitors has prompted the search for new inhibitors with more favorable pharmacokinetic behavior (James, G L, et al., Science 260:1937-1942 (1993); Kohl, N E, et al., Proc. Nat'l Acad. Sci. USA 91:9141-9145 (1994); deSolms, S J, et al., J. Med. Chem. 38:3967-3971 (1995); Nagasu, T, et al., Cancer Research 55:5310-5314 (1995); Lerner, E C, et al., J. Biol. Chem. 270:26802-26806 (1995); Lerner, E C, et al., J. Biol. Chem. 270:26770 (1995); and James, et al., Proc. Natl. Acad. Sci. USA 93:4454 (1996)).
Recently, it has been shown that a prenyl transferase inhibitor can block growth of Ras-dependent tumors in nude mice (Kohl, N E, et al., Proc. Nat'l Acad. Sci. USA 91:9141-9145 (1994)). In addition, it has been shown that over 70 percent of a large sampling of tumor cell lines are inhibited by prenyl transferase inhibitors with selectivity over non-transformed epithelial cells (Sepp-Lorenzino, I, et al., Cancer Research, 55:5302-5309 (1995)). Inhibiting farnesylation has been disclosed as a method of treating hepatitis delta virus infection, (Casey, P, et al., WO 97/31641).
SUMMARY OF THE INVENTION
In one aspect, the invention features a compound of formula I or formula II
wherein
R 1 is N (R 10 ) (R 11 );
R 2 is thio lower alkyl;
each of R 3 and R 5 , independently, is CH 2 or C(O);
R 4 is substituted or unsubstituted thio lower alkyl, wherein said substituent is CH 2 NHC(O)R 13 and said substituent is attached to said thio group;
R 6 is a residue of a natural or synthetic α-amino acid;
R 7 is a residue of a natural or synthetic α-amino acid;
R 8 is OH or lower alkoxy, or, together with R 7 , forms homoserinelactone;
each of R 9 , R 10 and R 11 , independently, is H or lower alkyl;
R 12 is substituted or unsubstituted cycloalkyl, cycloalkyl lower alkyl, aryl, aryl lower alkyl, heterocycle, or heterocycle lower alkyl, wherein said substituent is lower alkyl, aryl, halo, lower alkoxy, or C(O)—R 7 —R 8 ;
R 13 is lower alkyl, aryl, or aryl lower alkyl;
R 18 is H or, together with R 9 , forms CH 2 CH 2 ;
provided if R 4 is unsubstituted thio lower alkyl, the free thio group of R 2 and the free thio group of R 4 may form a disulfide bond;
or a pharmaceutically acceptable salt thereof.
In another aspect, the present invention is directed to a process for preparing a compound of Formula I or Formula II.
In one embodiment, the compound is of formula I where R 6 is —N(R 14 )CH(R 15 )C(O)—, where R 14 is H or lower alkyl, and R 15 is substituted or unsubstituted lower alkyl, aryl, aryl lower alkyl, heterocycle, or heterocycle lower alkyl where said substituent is lower alkyl, halo, or lower alkoxy, or where R 15 , together with NR 14 C attached thereto, form heterocycle; and R 7 is —N(R 16 )CH(R 17 )C(O)— where R 16 is H or lower alkyl, and R 17 is (CH 2 ) m S(O) n CH 3 or substituted or unsubstituted lower alkyl, thio lower alkyl, where said substituent is C(O)N(R 10 )(R 11 ), m is 1-6, n is 0-2, and R 8 is OH or lower alkoxy. In this embodiment, R 2 can be CH 2 SH; R 4 can be C(CH 3 ) 2 SH or CH 2 SH wherein the free thio group of R 2 and the free thio group of R 4 form a disulfide bond; R 15 , together with NR 14 C attached thereto, can form heterocycle; R 16 can be H; and R 17 can be (CH 2 ) 2 S(O) n CH 3 ; furthermore, R 1 can be NH 2 ; R 3 can be CH 2 ; R 5 can be CO; and R 8 can be OH or OCH 3 . In the same embodiment, R 2 can be (CH 2 )SH; R 4 can be C(CH 2 ) 2 SCH 2 NHCOCH 3 or CH 2 SCH 2 NHCOCH 3 ; R 15 , together with NR 14 C attached thereto, can form heterocycle; R 16 can be H, and R 17 can be (CH 2 ) 2 S(O) n CH 3 ; furthermore, R 1 is NH 2 ; R 3 is CH 2 ; R 5 is C(O); and R 8 is OH or OCH 3 .
In another embodiment, the compound is of formula II, wherein R 2 is CH 2 SH; R 4 is C(CH 3 ) 2 SH or CH 2 SH wherein the free thio group of R 2 and the free thio group of R 4 form a disulfide bond; R 12 is substituted or unsubstituted aryl or aryl lower alkyl, and R 18 is H. In this embodiment, R 1 can be NH 2 ; R 3 can be CH 2 ; R 5 can be C(O); R 9 can be H; and R 12 can be substituted or unsubstituted phenyl or benzyl, wherein said substituent is lower alkyl or halo.
In a still further embodiment, R 2 is (CH 2 )SH; R 4 is C(CH 2 ) 2 SCH 2 NHCOCH 3 or CH 2 SCH 2 NHCOCH 3 ; and R 12 is substituted or unsubstituted aryl or aryl lower alkyl. In this embodiment, R 1 can be NH 2 ; R can be CH 2 ; R 5 can be CO; R 9 can be H; and R 12 can be substituted or unsubstituted phenyl or benzyl, wherein said substituent is lower alkyl or halo.
Examples of the present invention include the following:
In another aspect, the invention features a compound of formula III or formula IV
where
Y is CH 2 or C(O);
R 1 , R 2 , R 3 , and R 4 , each is, independently, H, lower alkyl, optionally substituted arylalkyl, optionally substituted alkenyl, (C 1 -C 18 )-aliphatic acyl, or arylacyl;
R 5 and R 6 each is, independently, H or CH 3 ;
R 9 and R 10 each is independently selected from the group consisting of H, lower alkyl, and C 3 -C 6 cycloalkyl;
Ar is optionally substituted aryl or optionally substituted heterocycle;
n is 0 or an integer from 1 to 4;
wherein each substituent is, independently, aryl, heterocycle, halogen, OR 9 , NR 9 R 10 , CN, NO 2 , CF 3 , or lower alkyl, said lower alkyl optionally substituted with C 1 -C 4 alkoxy, NR 9 R 10 , C 3 -C 6 cycloalkyl, or OH;
or a pharmaceutically acceptable salt thereof.
In still another aspect, the present invention is directed to a process for preparing a compound of Formula III or Formula IV.
A preferred group of compounds of Formula III or Formula IV include the following:
In yet another aspect, the invention features a compound of formula V:
wherein
Ar is optionally substituted aryl or optionally substituted heterocycle, wherein each substituent is independently selected from the group consisting of aryl, heterocycle, halogen, OR 9 , N 9 R 10 , CN, NO 2 , CF 3 , and lower alkyl, said lower alkyl optionally substituted with (C 1 -C 4 )-alkoxy, NR 9 R 10 , C 3 -C 6 cycloalkyl, or OH;
R 1 and R 2 each is, independently, CH 2 or C(O);
R 3 and R 4 each is, independently, H or CH 3 ;
R 5 , R 6 , R 7 , and R 8 each is independently selected from the group consisting of H, or an optionally substituted moiety selected from the group consisting of (C 1 -C 8 )-alkyl, alkenyl, alkynyl, aryl, and heterocycle;
wherein said optionally substituted moiety is optionally substituted by one or more substituents independently selected from the group consisting of (C 3 -C 6 )-cycloalkyl, optionally further substituted aryl, and optionally further substituted heterocycle,
wherein said optionally further substituted aryl and heterocycle are optionally substituted by one or more substituents independently selected from the group consisting of (C 1 -C 4 )-alkyl, halogen, (CH 2 ) m OR 9 , and (CH 2 ) m NR 9 R 10 ;
R 9 and R 10 each is, independently, H lower alkyl or (C 3 -C 6 ) cycloalkyl;
R 11 is H or NH 2 ;
m is 0 or an integer from 1 to 4;
n is 0, 1, or 2;
or a pharmaceutically acceptable salt thereof.
In another aspect, the present invention is directed to a process for preparing a compound of Formula V.
A preferred group of compounds of Formula V includes the following:
The compounds of the present invention may have asymmetric centers and occur as racemates, racemic mixtures, and as individual diastereomers, with all possible isomers, including optical isomers, being included in the present invention. For simplicity, where no specific configuration is depicted in a structural formula, it is understood that all enantiomeric forms and mixtures thereof are represented.
As used herein, “lower alkyl” is intended to include saturated aliphatic hydrocarbon groups having 1-6 carbon atoms. Examples of lower alkyl groups include methyl, ethyl, propyl, isopropyl, butyl, isobutyl, sec-butyl, t-butyl, and the like. The term “alkyl” refers to saturated aliphatic hydrocarbon groups having up to 18 carbon atoms. The terms “alkenyl” and “alkynyl” refer to unsaturated aliphatic hydrocarbon groups having 2-18 carbon atoms and from 1 to 5 double or triple bonds. “Lower alkoxy” groups include those groups having 1-6 carbons. Examples of lower alkoxy groups include methoxy, ethoxy, propoxy, isopropoxy, and the like. All alkyl, alkenyl, alkynyl and alkoxy groups may be branched or straight chained, but are noncyclic. The term “cycloalkyl” means a 3-7 carbon ring. Examples of cycloalkyl groups include cyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl, and cycloseptyl. The term “halo” means chloro, bromo, iodo, or fluoro. The terms “heterocycle lower alkyl,” “thio lower alkyl,” “cycloalkyl lower alkyl”, and “lower alkyl,” are substituted, respectively, with one to three heterocycle, thio, cycloalkyl, and aryl groups.
As used herein, “aryl” is intended to include any stable monocyclic, bicyclic, or tricyclic carbon ring(s) of up to 7 members in each ring, wherein at least one ring is aromatic. Examples of aryl groups include phenyl, naphthyl, anthracenyl, biphenyl, tetrahydronaphthyl, indanyl, phenanthrenyl, and the like.
The term heterocycle, as used herein, represents a stable 5- to 7-membered monocyclic or stable 8- to 11-membered bicyclic or stable 11 to 15-membered tricyclic heterocyclic ring which is either saturated or unsaturated, and which consists of carbon atoms and from one to four heteroatoms selected from the group consisting of N, O, and S, and including any bicyclic group in which any of the above-defined heterocyclic rings is fused to a benzene ring. The heterocyclic ring may be attached at any heteroatom or carbon atom which results in the creation of a stable structure. Examples of such heterocyclic elements include, but are not limited to, azepinyl, benzimidazolyl, benzisoxazolyl, benzofurazanyl, benzopyranyl, benzothiopyranyl, benzofuryl, benzothiazolyl, benzothienyl, benzoxazolyl, chromanyl, cinnolinyl, dihydrobenzofuryl, dihydrobenzothienyl, dihydrobenzothiopyranyl, dihydrobenzothio-pyranyl sulfone, furyl, imidazolidinyl, imidazolinyl, imidazolyl, indolinyl, indolyl, isochromanyl, isoindolinyl, isoquinolinyl, isothiazolidinyl, isothiazolyl, isothiazolidinyl, morpholinyl, naphthyridinyl, oxadiazolyl, 2-oxoazepinyl, 2-oxopiperazinyl, 2-oxopiperidinyl, 2-oxopyrrolidinyl, piperidyl, piperazinyl, pyridyl, pyridyl N-oxide, quinoxalinyl, tetrahydrofuryl, tetrahydroisoquinolinyl, tetrahydro-quinolinyl, thiamorpholinyl, thiamorpholinyl sulfoxide, thiazolyl, thiazolinyl, thiazolidinyl, thienofuryl, thienothienyl, thienyl, and the like.
When a group is substituted, it may be substituted one to four times. The various substituents may be attached to carbon atoms or to heteroatoms (e.g., S, N, or O).
As used herein, the term “residue of an α-amino acid” stands for an α-amino acid residue which is either a natural α-amino acid which is found in nature (e.g., cysteinyl, methionyl, phenylalaninyl, leucinyl, etc.) or a synthetic α-amino acid which is not found in nature (e.g., neurleucyl or the residue of 1,2,3,4-tetrahydroisoquinoline-3-carboxylic acid or penicillamine, etc.).
The compounds of this invention can be provided in the form of pharmaceutically acceptable salts. Acceptable salts include, but are not limited to acid addition salts of inorganic acids such as acetate, maleate, fumarate, tartrate, succinate, citrate, lactate, methanesulfonate, p-toluenesulfonate, pamoate, salicylate, oxalate, and stearate. Also within the scope of the present invention, where applicable, are salts formed from bases such as sodium or potassium hydroxide. For further examples of pharmaceutically acceptable salts see, “Pharmaceutical Salts,” J. Pharm. Sci. 66:1 (1977).
In another aspect, the invention features a method of inhibiting prenyl transferases (e.g., farnesyl transferase or geranylgeranyl transferase) in a subject, e.g., a mammal such as a human, by administering to the subject a therapeutically effective amount of a compound of formula I, formula II, formula III, formula IV, or formula V. In particular, the present invention also covers a method of treating restenosis or tissue proliferative diseases (i.e., tumor) in a subject by administering to the subject a therapeutically effective amount of a compound or its salt. Examples of a tissue proliferative disease include both those associated with benign (e.g., non-malignant) cell proliferation such as fibrosis, benign prostatic hyperplasia, atherosclerosis, and restenosis, and those associated with malignant cell proliferation, such as cancer (e.g., ras-mutant tumors). Examples of treatable tumors include breast, colon, pancreas, prostate, lung, ovarian, epidermal, and hematopoietic cancers (Sepp-Lorenzino, I, et al., Cancer Research 55:5302 (1995)).
A therapeutically effective amount of a compound of this invention and a pharmaceutically acceptable carrier substance (e.g., magnesium carbonate, lactose, or a phospholipid with which the therapeutic compound can form a micelle) together form a pharmaceutical composition (e.g., a pill, tablet, capsule, or liquid) for administration (e.g., orally, intravenously, transdermally, or subcutaneously) to a subject in need of the compound. The pill, tablet, or capsule can be coated with a substance capable of protecting the composition from the gastric acid or intestinal enzymes in the subject's stomach for a period of time sufficient to allow the composition to pass undigested into the subject's small intestine.
The compounds of the present invention may be administered in a dosage range of about 0.0001 to 200 mg/kg/day, preferably 0.01 to 100 mg/kg/day. A dose of a compound of the present invention for treating the above-mentioned diseases or disorders varies depending upon the manner of administration, the age and the body weight of the subject, and the condition of the subject to be treated, and ultimately will be decided by the attending physician or veterinarian. Such an amount of the compound as determined by the attending physician or veterinarian is referred to herein as a “therapeutically effective amount.”
Also contemplated within the scope of the invention are a method of preparing the compounds of formula I, formula II, formula III, formula IV, and formula V, and the novel chemical intermediates used in these syntheses as described herein.
Other features and advantages of the present invention will be apparent from the detailed description of the invention and from the claims.
DETAILED DESCRIPTION OF THE INVENTION
It is believed that one skilled in the art can, based on the description herein, utilize the present invention to its fullest extent. The following specific embodiments are, therefore, to be construed as merely illustrative, and not limitative of the remainder of the disclosure in any way whatsoever.
A compound of the present invention can be tested for farnesyl transferase inhibiting activity by testing said compound in a farnesyl transferase in vitro assay, such as the assay described below.
Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. Also, all publications, patent applications, patents, and other references mentioned herein are incorporated by reference.
Farnesyl transferase activity is assayed by [ 3 H] farnesylation of recombinant human H-Ras protein wild type, using microplate and filtration method. Incubation mixture contains, in a total volume of 25 μl: 50 mM Tris HCl (pH 7.5), 5 mM dithiothreitol, 20 μM ZnCl 2 , 40 mM MgCl 2 , 0.6 μM [ 3 H] farnesyl pyrophosphate (22.3 Ci/mmol), 4 μM H-Ras and 10 μg of farnesyl transferase from human brain cytosol. Test compounds are added in adequate solvent and incubations start by addition of farnesyl transferase. After approximately 60 minutes at approximately 37° C., the reaction is stopped by addition of 100 μl of 10% HCl in ethanol and allowed to incubate approximately 15 minutes at approximately 37° C., then 150 μl of absolute ethanol are added and incubation mixture is filtered on Unifilter GF/B microplates and washed 6 times with ethanol. After addition of 50 μl of Microscint 0, plates were counted on a Packard Top Count scintillation counter. Geranylgeranyl transferase activity is assayed by the same method, but using 4 μM human recombinant H-Ras CVLL type, 0.6 μM [ 3 H] geranylgeranyl-pyrophosphate (19.3 Ci/mmmol) and 100 μg of geranylgeranyl transferase from human brain.
The following is a description of the synthesis of compounds 1, 4, 9. Compounds 2,3,5-8, 10-20 can be prepared in an analogous manner by a person of ordinary skill in the art using appropriate starting materials. Compounds 21, 28, 29, and 30 were prepared using the reactions summarized in reaction scheme I. Compound 22 was prepared using the reactions summarized in reaction schemes II and IV. Compounds 25, 26, and 27 were prepared using the reactions summarized in reaction scheme V. Compound 31 may be prepared using the reactions summarized in scheme III. Other compounds of the invention can be prepared in an analogous manner by a person of ordinary skill in the art using appropriate starting materials.
The compounds of the invention were prepared using standard solution phase methodologies, e.g., as described in Greenstein, et al., Chemistry of the Amino Acids, Vols. 1-3 (J. Wiley, New York (1961)); and M. Bodanszky, et al., The Practice of Peptide Synthesis (Springer-Verlag, 1984)). The condensation reactions were carried out in an inert organic solvent, e.g., dimethylformide, dichloromethane, tetrahydrofuran, benzene or acetonitrile, using a suitable mild condensing agent, e.g., 1-(3-dimethylaminopropyl)-3-ethylcarbodiimide-HCl (EDC), 0-benzotriazol-1-yl-N,N,N′,N′-tetramethyluronium hexafluorophosphate (HBTU), and optionally a catalyst, e.g., 1-hydroxybenzotriazole (HOBT). The reaction temperature was maintained below room temperature (−15° C. to room temperature) in order to minimize side reactions. Cyclic disulfide formation was carried out under high dilute condition using using various oxidizing agents (e.g. oxygen, iodine, immobilized oxidizing agent like EKATHIOX™ resin, (Ekagen Corp., Menlo Park, Calif., etc.)), in various solvents (e.g. water, alcohol, acetonitrile, tetrahydrofuran (THF), acetic acid, chloroform, etc.). See, e.g., B. Kamber, et al., Helv. Chim. Acta, 63(96):899 (1980). Compounds where R 8 , together with R 9 , forms CH 2 CH 2 can be made according to the methods of Williams, et al., J. Med. Chem. 39(7):1346 (1996), e.g., by starting with protected cysteine.
2-Alkylpiperazines were synthesized similarly according to the procedure described in Org. Prep. Proc. Int. 1990, 22, 761-768. Replacement of hydroxyl group by protected sulfur were carried out by Mitsunobu reactions. (Synthesis 1981, 1; Tet. Lett. 1981, 3119 etc.) The protected cysteinal was prepared according to the procedure put forth by O. P. Goel, et al., (Org. Syn. 1988, 67, 69-75). The reductive alkylation can be accomplished with various agents, e.g. sodium triacetoxyborohydride, (Na(OAc) 3 BH), sodium cyanoborohydride or pyridine-borane complex, in solvents such as dichloromethane, dichloroethane, methanol or dimethylformamide, etc.
The intermediate and final products were isolated and purified by standard methods, e.g., column chromatography or HPLC.
EXAMPLE 1
Synthesis of N-[2-(R)-amino-3-mercaptopropyl]-L-penicillaminyl-1,2,3,4-tetrahydro-3(s)-isoquinoline Carbonyl Methionine Methylester Cyclic Disulfide (Compound 1)
a) N-t-Butoxycarbonyl-S-trityl-L-cysteinyl-N,O-dimethylamide
To an ice-cooled solution of N-t-butoxycarbonyl-L-cysteine (8.0 g) and N,O-dimethylhydroxylamine hydrochloride (7.1 g) in 80 ml dimethylformide was added 4.2 ml diethylcyanophosphonate and 14.7 ml diisopropylethylamine, and after stirring at 0° C. for about 1 hour, the reaction mixture was allowed to room temperature overnight. Volatile substances were removed in vacuo to dryness, and the residue was partitioned between ethylacetate and water. Ethylacetate layer was washed with aqueous NaHCO 3 , water, and dried (MgSO 4 ). Solvent was evaporated in vacuo to dryness, and the residue was chromatographed on silica gel (165 g) using CHCl 3 as an eluant. Appropriate fractions were pooled, and solvent was removed in vacuo to dryness. White foam 8.08 g TLC (silica gel: CHCl 3 /acetone=9:1 R f =0.58).
b) 2(R)-t-Butoxycarbonylamino-3-triphenylmethylmercaptopropanal
To an ice-cooled solution of N-t-Butoxycarbonyl s-trityl-L-cysteinyl-N,O-dimethylamide (0.85 g) in 20 ml tetrahydrofuran (THF) was added dropwise 3 ml 1.0 M LiAH 4 in THF under nitrogen atmosphere. After the mixture was stirred for about 30 minutes at 0° C., 1M KHSO 4 was slowly added, and the resulting emulsion was filtered through diatomaceous earth pad and further washed with ethylacetate. After drying over anhydrous MgSO 4 , the solvent was removed in vacuo to dryness resulting in 0.7 g of the above-titled compound TLC (silica gel; CHCl 3 /acetone=4:1; R f =0.88).
c) N-t-Butoxycarbonyl-S-acetamidomethylpenicillaminyl-1,2,3,4-tetrahydro-3(S)-isoquinolinecarbonyl-methionine Methylester
To an ice-cooled solution of N-t-butoxycarbonyl-L-1,2,3,4-tetrahydro-3(S)-isoquinoline (2.77 g) and L-methionine methylester hydrochloride (2.0 g), 1-hydroxybenzotriazole (HOBT) (1.37 g) and O-Benzotriazol-1-yl-N,N,N′,N′-tetramethyluronium hexafluorophosphate (HBTU) (3.87 g) in 30 ml dimethylformide was added 4.9 ml diisopropylethylamine (DIEA). After stirring at 0° C. for about 30 minutes, the reaction mixture was allowed to room temperature overnight. Volatile substances were evaporated in vacuo to dryness, and the residue was partitioned between EtOAc and water. EtOAc layer was washed with aqueous NaHCO 3 , water, and dried (MgSO 4 ). Solvent was evaporated in vacuo to dryness. It was treated with 50% trifluoracetic acid in chloroform (40 ml) containing 4.8 ml triethylsilane for about 1 hour, and volatile substances were removed in vacuo to dryness. Trace of trifluoroacetic acid (TFA) was further evaporated with toluene. To the above L-1,2,3,4-tetrahydro-3(S)-isoquinolinecarbonyl methionine methylester TFA salt (2.2 g) in dichloromethane (20 ml) cooled to 0° C. was added 1.2 ml DIEA followed by a solution of HOBT (0.7 g), N-t-butoxycarbonyl-S-acetamidomethyl penicillin (1.6 g) in DMF (3 ml), and EDC (1.2 g). The mixture was stirred at 0° C. for about 30 minutes and then allowed to room temperature overnight. Volatile substances were removed in vacuo to dryness. The residue was partitioned between EtOAc and water. Ethylacetate layer was washed with aqueous NaHCO 3 , water, and then dried (MgSO 4 ). Solvent was evaporated in vacuo to dryness to yield 3.3 g orange solid.
d) L-[S-acetamidomethylpenicillaminyl-1,2,3,4-tetrahydro-3[S]-isoquinolinecarbonyl Methionine Methylester and Its TFA Salt
N-t-Butoxycarbonyl-S-acetamidomethyl-penicillaminyl-1,2,3,4-tetrahydro-3[S]-isoquinolinecarbonyl methionine methylester (3.3 g) was treated with 50% TFA in CH 2 Cl 2 (20 ml) containing 1 ml triethylsilane for about 30 minutes Volatile substances were removed in vacuo to dryness. Trace of TFA was removed by co-evaporation with toluene several times. The TFA salt was dissolved in CHCl 3 (30 ml), treated with excess triethylamine, washed with water, dried (MgSO 4 ), and solvent was evaporated in vacuo to give free base.
e) N-[2(R)-(t-Butoxycarbonyl)amino-3-triphenylmethylmercaptopropyl]-L-[S-acetamidomethyl-penicillaminyl]-1,2,3,4-tetrahydro-3(S)-isoquinolinecarbonyl Methionine Methyl Ester
To a solution of 2(R)-t-butoxycarbonylamino-3-triphenyl methyl-mercapto-propanal (0.7 g) and L-[S-acetamido methylpenicillaminyl-1,2,3,4-tetrahydro-3(s)-isoquinolinecarbonyl methionine methylester (0.43 g) in CH 2 Cl 2 (20 ml) containing 1% acetic acid was added triacetoxysodiumborohydride Na(OAc) 3 BH (360 mg) in one portion. After stirring for about 2 hours, the mixture was washed with water, 5% aqueous NaHCO 3 , water, and then dried (MgSO 4 ). The solvent was evaporated in vacuo to dryness, and the residue was chromatographed on silica gel (50 g) using CHCl 3 /acetone (19:1 to 9:1) as eluants. Appropriate fractions were pooled and solvents were removed in vacuo to dryness resulting in a white foam (390 mg) of the above title compound. TLC (silica gel; CHCl 3 /acetone=4:1; R f =0.4).
f) N-[2(R)-(t-Butoxycarbonyl)amino-3-mercaptopropyl]-L-penicillaminyl]-1,2,3,4-tetrahydro-3(S)-isoquinoline Carbonyl Methionine Methylester Cyclic Disulfide
To a solution of N-[2(R)-(t-butoxycarbonyl)amino-3-triphenylmethylmercaptopropyl]-L-[S-acetamidomethylpenicillaminyl]-1,2,3,4-tetrahydro-3(S)-isoquinoline carbonyl methionine methylester (500 mg) in 50 ml 90% aqueous MeOH was added dropwise a solution of iodine (250 mg) in methanol (MeOH) (10 ml). After stirring for about 1 hour, most of methanol was removed in vacuo to a small volume, diluted with water, and extracted with ethylacetate. The ethylacetate extract was washed with water, aqueous Na 2 S 2 O 3 , water, and then dried (MgSO 4 ). The solvent was evaporated in vacuo to dryness resulting in 400 mg of the above title compound.
g) N-[2-(R)-Amino-3-mercaptopropyl]-L-penicillaminyl-1,2,3,4-tetrahydro-3(S)-isoquinoline Carbonyl Methionine Methylester Cyclic Disulfide
Crude N-[2(R)-(t-butoxycarbonyl)amino-3-mercaptopropyl]-L-penicillaminyl]-1,2,3,4-tetrahydro-3(S)-isoquinoline carbonyl methionine methylester cyclic disulfide (400 mg) was treated with 90% trifluoroacetic acid (TFA) in water TFA/H 2 O (9:1) (10 ml) for about 30 minutes Volatile substances were removed in vacuo to dryness, and a trace of TFA was evaporated with toluene several times and triturated with hexane, decanted, and then dried. Crude product was subjected to preparative high performance liquid chromatography (HPLC) using C 18 column and 0.1% TFA and CH 3 CN as mobile phase. Appropriate fractions were pooled, and solvents were removed giving the above title compound as a white solid (78 mg). M/e=541.1.
Example 2
Synthesis of N-[2-(R)-Amino-3-mercaptopropyl]-L-[s-acetamidomethyl-penicillaminyl]-1,2,3,4-tetrahydro-3(S)-isoquinoline Carbonyl Methionine (Compound 4)
To a solution of N-[2(R)-(t-butoxycarbonyl)-amino-3-triphenylmethylmercaptopropyl]-L-[s-acetamidomethyl penicillaminyl]-1,2,3,4-tetrahydro-3(S)-isoquinolinecarbonyl methionine methylester (Example I e))(500 mg) in 10 MeOH (50 ml) was added 2 ml 2 N-NaOH. After 30 minutes, most of MeOH was removed in vacuo to a small volume, diluted with water, acidified with 5% aqueous citric acid, and extracted with ethylacetate. The ethylacetate extract was then dried (MgSO 4 ). Solvent was evaporated in vacuo to dryness. The residue was treated with 50% TFA in CH 2 Cl 2 containing triethylsilane (Et 3 SiH) (0.5 ml) for about 40 minutes Volatile substances were removed in dryness, and a trace of TFA was evaporated with toluene and then dried. Crude product was purified by preparative HPLC giving the above titled compound (100 mg) as a white solid. M/e=600.2
Example 3
Synthesis of N-[2-(R)-Amino-3-mercaptopropyl]-L-penicillaminyl]-2,3-dimethylanilide Cyclic Disulfide (Compound 9)
a) [N-t-Butoxycarbonyl-S-acetamidomethyl]penicillaminyl-2,3-dimethylanilide
To an ice-cooled solution of N-[t-butoxycarbonyl)-S-acetamidomethyl penicillamine (Bachem California, Torrance, Calif.) (0.64 g), 2,3-dimethylaniline (0.25 g), hydroxybenzotriazole (0.41 g) in dimethylformide (DMF)/CH 2 Cl 2 (1:1, 20 ml) was added 1-(3-dimethylaminopropyl)-3-ethylcarbodiimide (EDC) (0.57 g). The mixture was stirred at 0-5° C. for about 30 minutes and then the temperature was slowly allowed to room temperature overnight. After evaporation of the solvents, the residue was partitioned between ethyl acetate (EtOAc) and water. EtOAc extract was washed with aqueous NaHCO 3 , water, and then dried (MgSO 4 ). The solvent was evaporated in vacuo to dryness. The residue was chromatographed on silica gel (40 g) using CHCl 3 /acetone=19:1 as eluants, appropriate fractions were pooled, and solvents were removed in vacuo to dryness giving 350 mg of the above titled compound. TLC (silica gel: CHCl 3 /acetone=4:1, R f —0.77).
b) L-[S-acetamidomethylpenicillaminyl-2,3-dimethyl Anilide TFA Salt
[N-t-butoxycarbonyl-S-acetamidomethyl]-penicillaminyl-2,3-dimethylanilide was treated with 50% TFA in CH 2 Cl 2 (20 ml) for about 30 minutes Volatile substances were removed in vacuo to dryness. Trace of TFA was removed by co-evaporation with toluene several times. The TFA salt was dissolved in CHCl 3 (30 ml), treated with excess triethylamine, washed with water, dried (MgSO 4 ), and solvent was evaporated in vacuo to give free base.
c) N-[2(R)-(t-Butoxycarbonyl)amino-3-triphenylmethylmercaptopropyl]-L-[S-acetamidomethylpenicillaminyl-2,3-dimethylamilide
To a stirred solution of 2(R)-t-butoxycarbonylamino-3-triphenylmethylmercaptopropanal (0.5 g; Example 1b) and L-[S-acetamidomethylpenicillaminyl-2,3-dimethylanilide TFA salt (0.3 g) in MeOH containing 1% acetic acid (HOAc) (10 ml) was added portionwise NaCNBH 3 (100 mg). The mixture was stirred at room temperature overnight. Most of the solvent was evaporated in vacuo to a small volume, which was partitioned between EtOAc and water. EtOAc layer was further washed with aqueous NaHCO 3 , water, and then dried (MgSO 4 ). After evaporation of solvent, the residue was chromatographed on silica gel (30 g) using CHCl 3 -acetone (19:1 to 9:1) as eluants. Appropriate fractions were pooled, and solvents were evaporated in vacuo to dryness giving 360 mg of the above titled compound. TLC (silica gel: CHCl 3 /acetone=9:1, R f =0.13.
d) N-[2-(R)-Amino-3-mercaptopropyl]-L-penicillaminyl]-2,3-dimethylanilide Cyclic Disulfide
To a stirred solution of N-[2(R)-(t-butoxycarbonyl)amino-3-triphenylmethylmercaptopropyl]-L-[S-acetamidomethyl penicillaminyl]-2,3-dimethylamilide (350 mg) in 50 ml 90% MeOH in water was added a solution of iodine (250 mg) in MeOH (5 ml). After 1 hour, most of the solvent was evaporated in vacuo to a small volume, diluted with water, extracted with EtOAc. EtoAc layer was washed with aqueous Na 2 S 2O 3 , water, then dried (MgSO 4 ). Solvent was removed in vacuo to dryness (220 mg), treated with 90% aqueous TFA (ml) for about 30 minutes, and volatile substances were removed in vacuo to dryness. Crude product was purified by preparative HPLC giving 62 mg of the above titled compound as a white solid. M/e=340.2.
Example 4
Synthesis of 1-[2(R)-Amino-3-mercaptopropyl]-2(S)-2-mercaptoethyl)-4-(1-naphthoyl)-piperazine-1,2-cyclodisulfide, (Compound 28),
1-[2(R)-Amino-3-mercaptopropyl]-2(S)-2-mercaptoethyl)-4-(1-naphthoyl)-piperazine, (Compound 30), and
Bis-1,1′-2,2′-[2(R)-amino-3-mercaptopropyl]-2(S)-[2-mercaptoethyl)-4-(1-naphthoyl)-piperazine-tetrasulfide, (Compound 29)
a) Synthesis of 1-Benzyl-3(S)-benzyloxycarbonylmethyl piperazine-2,5-dione
To an ice-cooled solution of BOC-aspartic acid β-benzyl ester (10 g), hydroxybenzotriazole (HOBT, 4.2 g), and N-benzylglycine ethyl ester (6.4 g) in 80 ml CH 2 Cl 2 was added a cold solution of dicyclohexylcarbodiimide (DCC, 7.1 g) in 20 ml CH 2 Cl 2 . The reaction was stirred for about 1 hour at 0-5° C., then overnight at room temperature. The precipitate was filtered off and the filtrate was evaporated in vacuo to dryness. The residue was partitioned between ethyl acetate and water. The organic layer was washed with 100 ml aqueous NaHCO 3 , water, then dried (MgSO 4 ). Solvent was removed in vacuo to dryness to give 16 g. TLC (silica gel: CHCl 3 /acetone=9:1, R f =0.55).
This was treated with 50% trifluoroacetic acid in CHCl 3 (40 ml) for about 1 hour and the volatile substances were removed in vacuo to dryness. The residue was partitioned between ethyl acetate and saturated aqueous NaHCO 3 . The organic layer was then dried (MgSO 4 ) and the solvent was evaporated in vacuo to give 10 g. TLC (silica gel, CHCl 3 /acetone=9:1, R f =0.14).
b) Synthesis of 4-Benzyl-1-tert-butoxycarbonyl-2(S)-(2-hydroxyethyl) piperazine
To an ice-cooled solution of the product from Step A (9.73 g) in 200 ml tetrahydrofuran (THF) was added portion wise a 50% mineral dispersion of lithium aluminum hydride (12.5 g) under a nitrogen atmosphere. The reaction mixture was refluxed overnight. After cooling in an ice bath, saturated aqueous Na 2 SO 4 was added dropwise to decompose excess LAH and the white slurry in THF was filtered through a diatomaceous earth pad. The filtrate was concentrated in vacuo to dryness and the residue was dissolved in dichloromethane (55 mg), treated with di-tert-butyl dicarbonate (5.9 g), and stirred for about 1 hour. Aqueous saturated NaHCO 3 (25 ml) was added and stirred for about 2 hours. The organic layer was washed with saturated sodium chloride and dried (MgSO 4 ). After evaporation of solvent, the residue was chromatographed on silica gel (160 g) using CHCl 3 /MeOH (19:1) as eluent. Appropriate fractions were pooled, and solvents were removed in vacuo to dryness, to give 8.7 g of a glass. TLC (silica gel: CHCl 3 /MeOH=9:1, R f =0.56).
c) Synthesis of 1-tert-Butoxycarbonyl-2-(S)-(2-hydroxyethyl) piperazine
The product from Step B (8.7 g) was dissolved in ethanol (35 ml) treated with Pd(OH) 2 -charcoal (0.8 g) and acetic acid (3 ml). Hydrogenation was carried out under 30 p.s.i. overnight. The reaction mixture was filtered through a diatomaceous earth pad and the solvent was removed in vacuo to dryness.
d) Synthesis of 1-tert-Butoxycarbonyl-2(S)-(2-hydroxyethyl)-4-(1-naphthoyl) piperazine
To a solution of the product from Step C (8.4 g) in acetonitrile (40 ml) was added 110 ml 1N aqueous NaOH followed by a solution of 1-naphthoyl chloride (5.14 g) in acetonitrile (20 ml). After about 3 hours stirring, most of the acetonitrile was removed in vacuo and the remaining mixture was extracted with chloroform. It was dried (MgSO 4 ) and the solvent was removed in vacuo to dryness, to give 8.12 g. of product. TLC (silica gel: CHCl 3 /MeOH=9:1, R f =0.64).
e) Synthesis of 1-tert-Butoxycarbonyl-2(S)-(2-triphenylmethylthioethyl)-4-(1-naphthoyl)piperazine
To an ice-cooled solution of triphenylphosphine (0.53 g) in 5 ml dry THF was added dropwise a solution of diethylazodicarboxylate (DEAD, 0.25 g) in 2 ml THF. After stirring at 0-5° C. for about 30 minutes, a solution of the product from Step D (0.4 g) and triphenylmercaptan (0.55 g) in 10 ml THF was added dropwise. The mixture was stirred at 0-5° C. for about 1 hour and room temperature for about 1 hour. The solvent was evaporated in vacuo to dryness and the residue was chromatographed on silica gel (40 g) using CHCl 3 as eluent. Appropriate fractions were pooled and the solvent was removed in vacuo to dryness, to give a pale yellow foam 420 mg. Mass Spec (Electrospray) 665.2 (643+23(sodium)). TLC (silica gel: CHCl 3 /acetone=9:1 R f =0.53)
f) Synthesis of 2(S)-(2-Triphenylmethylthioethyl)-4-(1-naphthoyl) piperazine
To a stirred solution of the product from Step E (2.2 g) in 30 ml CH 2 Cl 2 was added 10 ml trifluoroacetic acid (TFA). The mixture was stirred for about 30 minutes. Volatile substances were removed in vacuo to dryness. The residue was dissolved in CHCl 3 (50 ml) and treated with excess triethylamine (4 ml). The mixture was washed with water, then dried (MgSO 4 ) and volatile substances were removed in vacuo to dryness, to give a pale yellow glass, 2.1 g; TLC (silica gel; CHCl 3 /MeOH=9:1, R f =0.63)
g) Synthesis of 1-[2(R)-N-tert-Butoxycarbonylamino-3-triphenyl methylthiopropyl]-2(S)-(2-triphenylmethylthioethyl)-4-(1-naphthoyl)-piperazine
To a solution of the product from Step F (0.9 g) and 2(R)-N-tert-butoxycarbonylamino-3-triphenylmethylthiopropanal (1.2 g) prepared according to the procedure of O. P. Goel, et al., (Org. Syn. 1988, 67, 69-75), in CH 2 Cl 2 (20 ml) containing 1% acetic acid, was added 4 g of molecular sieves 4 Å followed by portion wise addition of Na(OAc) 3 BH (1 g) over a 30 minutes period. After stirring for about 2 hours, the mixture was filtered and the filtrate was washed with water, 5% aqueous NaHCO 3 , water, and then dried (MgSO 4 ). The solvent was evaporated in vacuo to dryness, and the residue was chromatographed on silica gel (60 g) using CHCl 3 as an eluent. Appropriate fractions were pooled and solvent was removed in vacuo to dryness, to give 0.6 g white foam. TLC (silica gel, CHCl 3 /acetone=9:1; R f =0.55); Mass Spec (Electro Spray) 974.3.
h) Synthesis of 1-[2(R)-amino-3-mercaptopropyl]-2(S)-2-mercaptoethyl)-4-(1-naphthoyl)-piperazine-1,2-cyclodisulfide, (Compound 28), and
Bis-1,1′-2,2′-[2(R)-Amino-3-mercaptopropyl]-2(S)-[2-mercaptoethyl)-4-(l-naphthoyl)-piperazine-tetrasulfide, (Compound 29)
To a stirred solution of the product from step g (0.7 g) in CHCl 3 /CH 3 OH (1:3, 60 ml) was added a solution of iodine in methanol (0.2 g in 5 ml). After stirring for about 40 minutes most of the solvents were removed in vacuo to dryness and the residue was partitioned between ethyl acetate (30 ml) and 5% aqueous Na 2 S 2 O 3 . The organic layer was washed with water, then dried (MgSO 4 ). After evaporation of solvent the residue was treated with 50% trifluoroacetic acid in dichloromethane (10 ml) for about 30 minutes. Volatile substances were removed in vacuo to dryness and the residue was triturated with ether and filtered.
The crude product was subjected to preparative high performance liquid chromatography (HPLC) using a C 18 column and 0.1% aqueous TFA and CH 3 CN as the mobile phase. Earlier fractions (retention=5 minutes, CH 3 CN/0.1% aqueous TFA=50:50, elution rate=1 ml/min) gave the white solid 1,2 cyclodisulfide; Mass. Spec. (Electrospray)=388.1. Later fractions (retention time=7.2 minutes using the same isocratic conditions) gave the dimer; Mass Spec. (Electrospray)=775.1 The ratio of cyclic disulfide and dimeric tetrasulfide was about 4 to 1.
Example 5
Alternative Cyclization of compound 30 Using Immobilized Oxidizing Resin (EKATHIOX™ Resin) or Air
a) Synthesis of 1-[2(R)-Amino-3-mercaptopropyl]-2(S)-2-mercaptoethyl)-4-(1-naphthoyl)-piperazine (Compound 30)
The product from Step G (450 mg) was treated for about 30 minutes with 50% TFA in CH 2 Cl 2 (10 ml) containing 1 ml triethylsilane. Volatile substances were then removed in vacuo to dryness. The residue was triturated with ether, filtered, then dried, resulting in 280 mg of 1-[2(R)-amino-3-mercaptopropyl]-2(S)-(2-mercaptoethyl)-4-(1-naphthoyl)-piperazine, (Compound 30). Mass spec (electrospray) 390.3
b) Cyclization of 1-[2(R)-Amino-3-mercaptopropyl]-2(S)-2-mercaptoethyl)-4-(l-naphthoyl)-piperazine (Compound 30) to form 1-[2(R)-Amino-3-mercaptopropyl]-2(S)-2-mercaptoethyl)-4-(1-naphthoyl)-piperazine-1,2-cyclodisulfide (Compound 28)
100 mg of the product from Step a) was dissolved in 10 ml aqueous CH 3 CN (H 2 O/CH 3 CN=7.3), and treated with 3 g of EKATHIOX™ resin (0.34 mmoles/gm). The mixture was stirred at room temperature for about 6 hours. The mixture was then filtered, the resin washed with aqueous methanol (1:3), and most of the organic solvent was removed in vacuo to a small volume. The concentrate was subjected to preparative HPLC using 0.1% aqueous TFA and CH 3 CN as mobile phase. Appropriate fractions were pooled and most of the solvents removed in vacuo to small volume. The concentrate was then lyophilized.
Alternatively, the solution of 1-[2(R)-amino-3-mercaptopropyl]-2(S)-(2-mercaptoethyl)-4-(1-naphthoyl)-piperazine (Compound 30) in aqueous CH 3 CN was stirred with air in pH 6-8 range. In both instances the reaction mixture showed a distribution of the cyclic disulfide and the tetrasulfide dimer in the ratio of about 4 to 1.
Other Embodiments
It is to be understood that while the invention has been described in conjunction with the detailed description thereof, that the foregoing description is intended to illustrate and not limit the scope of the invention, which is defined by the scope of the appended claims. Other aspects, advantages, and modifications are within the claims. | A family of compounds capable of inhibiting the activity of prenyl transferases. The compounds are covered by the four following formulas
Each of the R groups is defined in the disclosure. | 2 |
This is a divisional application of application Ser. No. 09/566,136, filed on May 5, 2000, now U.S. Pat. No. 6,474,313, the disclosure of which is incorporated by reference in its entirety herein.
CROSS REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of the earlier filing date of U.S. Provisional Application No. 60/166,404, filed Nov. 19, 1999, which is incorporated by reference herein in its entirety.
FIELD OF INVENTION
The present invention relates to an integrated pressure management system that manages pressure and detects leaks in a fuel system. The present invention also relates to an integrated pressure management system that performs a leak diagnostic for the headspace in a fuel tank, a canister that collects volatile fuel vapors from the headspace, a purge valve, and all associated hoses.
BACKGROUND OF INVENTION
In a conventional pressure management system for a vehicle, fuel vapor that escapes from a fuel tank is stored in a canister. If there is a leak in the fuel tank, canister or any other component of the vapor handling system, some fuel vapor could exit through the leak to escape into the atmosphere instead of being stored in the canister. Thus, it is desirable to detect leaks.
In such conventional pressure management systems, excess fuel vapor accumulates immediately after engine shutdown, thereby creating a positive pressure in the fuel vapor management system. Thus, it is desirable to vent, or “blow-off,” through the canister, this excess fuel vapor and to facilitate vacuum generation in the fuel vapor management system. Similarly, it is desirable to relieve positive pressure during tank refueling by allowing air to exit the tank at high flow rates. This is commonly referred to as onboard refueling vapor recovery (ORVR).
SUMMARY OF THE INVENTION
According to the present invention, a sensor or switch signals that a predetermined pressure exists. In particular, the sensor/switch signals that a predetermined vacuum exists. As it is used herein, “pressure” is measured relative to the ambient atmospheric pressure. Thus, positive pressure refers to pressure greater than the ambient atmospheric pressure and negative pressure, or “vacuum,” refers to pressure less than the ambient atmospheric pressure.
The present invention is achieved by providing a volatile fuel vapor collection system. This system comprises an integrated pressure management apparatus, a collection canister in fluid communication with the integrated pressure management apparatus; and a connection establishing the fluid communication between the integrated pressure management apparatus and the collection canister. The integrated pressure management apparatus includes a housing defining an interior chamber, the housing including first and second ports communicating with the interior chamber; a pressure operable device separating the chamber into a first portion and a second portion, the first portion communicating with the first port, the second portion communicating with the second port, the pressure operable device permitting fluid communication between the first and second ports in a first configuration and preventing fluid communication between the first and second ports in a second configuration; and a signal chamber in fluid communication with the first portion of the interior chamber, the pressure operable device further separating the signal chamber from the second portion of the interior chamber.
The present invention is also achieved by a method of assembling a volatile fuel vapor collection system. The method comprises providing collection canister having a first one of a male and female members; providing an integrated pressure management apparatus having a second one of the male and female members; and matingly engaging the male and female members with respect to one another. The integrated pressure management apparatus has a pressure operable device separating an interior chamber into a first portion and a second portion, the first portion communicating with the collection canister, the second portion communicating with a vent, the pressure operable device permitting fluid communication between the collection chamber and the vent in a first configuration and preventing fluid communication between the collection chamber and the vent in a second configuration.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated herein and constitute part of this specification, illustrate the present invention, and, together with the general description given above and the detailed description given below, serve to explain features of the invention. Like reference numerals are used to identify similar features.
FIG. 1 is a schematic illustration showing the operation of an apparatus according to the present invention.
FIG. 2 is a cross-sectional view of a first embodiment of the apparatus according to the present invention
FIG. 3 is a cross-sectional view of a second embodiment of the apparatus according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, a fuel system 10 , e.g., for an engine (not shown), includes a fuel tank 12 , a vacuum source 14 such as an intake manifold of the engine, a purge valve 16 , a charcoal canister 18 , and an integrated pressure management system (IPMA) 20 .
The IPMA 20 performs a plurality of functions including signaling 22 that a first predetermined pressure (vacuum) level exists, relieving pressure 24 at a value below the first predetermined pressure level, relieving pressure 26 above a second pressure level, and controllably connecting 28 the charcoal canister 18 to the ambient atmospheric pressure A.
In the course of cooling that is experienced by the fuel system 10 , e.g., after the engine is turned off, a vacuum is created in the tank 12 and charcoal canister 18 . The existence of a vacuum at the first predetermined pressure level indicates that the integrity of the fuel system 10 is satisfactory. Thus, signaling 22 is used for indicating the integrity of the fuel system 10 , i.e., that there are no leaks. Subsequently relieving pressure 24 at a pressure level below the first predetermined pressure level protects the integrity of the fuel tank 12 , i.e., prevents it from collapsing due to vacuum in the fuel system 10 . Relieving pressure 24 also prevents “dirty” air from being drawn into the tank 12 .
Immediately after the engine is turned off, relieving pressure 26 allows excess pressure due to fuel vaporization to blow off, thereby facilitating the desired vacuum generation that occurs during cooling. During blow off, air within the fuel system 10 is released while fuel molecules are retained. Similarly, in the course of refueling the fuel tank 12 , relieving pressure 26 allows air to exit the fuel tank 12 at high flow.
While the engine is turned on, controllably connecting 28 the canister 18 to the ambient air A allows confirmation of the purge flow and allows confirmation of the signaling 22 performance. While the engine is turned off, controllably connecting 28 allows a computer for the engine to monitor the vacuum generated during cooling.
FIG. 2, shows a first embodiment of the IPMA 20 mounted on the charcoal canister 18 . The IPMA 20 includes a housing 30 that can be mounted to the body of the charcoal canister 18 by a “bayonet” style attachment 32 . A seal 34 is interposed between the charcoal canister 18 and the IPMA 20 . This attachment 32 , in combination with a snap finger 33 , allows the IPMA 20 to be readily serviced in the field. Of course, different styles of attachments between the IPMA 20 and the body 18 can be substituted for the illustrated bayonet attachment 32 , e.g., a threaded attachment, an interlocking telescopic attachment, etc. Alternatively, the body 18 and the housing 30 can be integrally formed from a common homogenous material, can be permanently bonded together (e.g., using an adhesive), or the body 18 and the housing 30 can be interconnected via an intermediate member such as a pipe or a flexible hose.
The housing 30 can be an assembly of a main housing piece 30 a and housing piece covers 30 b and 30 c . Although two housing piece covers 30 b , 30 c have been illustrated, it is desirable to minimize the number of housing pieces to reduce the number of potential leak points, i.e., between housing pieces, which must be sealed. Minimizing the number of housing piece covers depends largely on the fluid flow path configuration through the main housing piece 30 a and the manufacturing efficiency of incorporating the necessary components of the IPMA 20 via the ports of the flow path. Additional features of the housing 30 and the incorporation of components therein will be further described below.
Signaling 22 occurs when vacuum at the first predetermined pressure level is present in the charcoal canister 18 . A pressure operable device 36 separates an interior chamber in the housing 30 . The pressure operable device 36 , which includes a diaphragm 38 that is operatively interconnected to a valve 40 , separates the interior chamber of the housing 30 into an upper portion 42 and a lower portion 44 . The upper portion 42 is in fluid communication with the ambient atmospheric pressure through a first port 46 . The lower portion 44 is in fluid communication with a second port 48 between housing 30 the charcoal canister 18 . The lower portion 44 is also in fluid communicating with a separate portion 44 a via first and second signal passageways 50 , 52 . Orienting the opening of the first signal passageway toward the charcoal canister 18 yields unexpected advantages in providing fluid communication between the portions 44 , 44 a . Sealing between the housing pieces 30 a , 30 b for the second signal passageway 52 can be provided by a protrusion 38 a of the diaphragm 38 that is penetrated by the second signal passageway 52 . A branch 52 a provides fluid communication, over the seal bead of the diaphragm 38 , with the separate portion 44 a . A rubber plug 50 a is installed after the housing portion 30 a is molded. The force created as a result of vacuum in the separate portion 44 a causes the diaphragm 38 to be displaced toward the housing part 30 b . This displacement is opposed by a resilient element 54 , e.g., a leaf spring. The bias of the resilient element 54 can be adjusted by a calibrating screw 56 such that a desired level of vacuum, e.g., one inch of water, will depress a switch 58 that can be mounted on a printed circuit board 60 . In turn, the printed circuit board is electrically connected via an intermediate lead frame 62 to an outlet terminal 64 supported by the housing part 30 c . An O-ring 66 seals the housing part 30 c with respect to the housing part 30 a . As vacuum is released, i.e., the pressure in the portions 44 , 44 a rises, the resilient element 54 pushes the diaphragm 38 away from the switch 58 , whereby the switch 58 resets.
Pressure relieving 24 occurs as vacuum in the portions 44 , 44 a increases, i.e., the pressure decreases below the calibration level for actuating the switch 58 . Vacuum in the charcoal canister 18 and the lower portion 44 will continually act on the valve 40 inasmuch as the upper portion 42 is always at or near the ambient atmospheric pressure A. At some value of vacuum below the first predetermined level, e.g., six inches of water, this vacuum will overcome the opposing force of a second resilient element 68 and displace the valve 40 away from a lip seal 70 . This displacement will open the valve 40 from its closed configuration, thus allowing ambient air to be drawn through the upper portion 42 into the lower the portion 44 . That is to say, in an open configuration of the valve 40 , the first and second ports 46 , 48 are in fluid communication. In this way, vacuum in the fuel system 10 can be regulated.
Controllably connecting 28 to similarly displace the valve 40 from its closed configuration to its open configuration can be provided by a solenoid 72 . At rest, the second resilient element 68 displaces the valve 40 to its closed configuration. A ferrous armature 74 , which can be fixed to the valve 40 , can have a tapered tip that creates higher flux densities and therefore higher pull-in forces. A coil 76 surrounds a solid ferrous core 78 that is isolated from the charcoal canister 18 by an O-ring 80 . The flux path is completed by a ferrous strap 82 that serves to focus the flux back towards the armature 74 . When the coil 76 is energized, the resultant flux pulls the valve 40 toward the core 78 . The armature 74 can be prevented from touching the core 78 by a tube 84 that sits inside the second resilient element 68 , thereby preventing magnetic lock-up. Since very little electrical power is required for the solenoid 72 to maintain the valve 40 in its open configuration, the power can be reduced to as little as 10% of the original power by pulse-width modulation. When electrical power is removed from the coil 76 , the second resilient element 68 pushes the armature 74 and the valve 40 to the normally closed configuration of the valve 40 .
Relieving pressure 26 is provided when there is a positive pressure in the lower portion 44 , e.g., when the tank 12 is being refueled. Specifically, the valve 40 is displaced to its open configuration to provide a very low restriction path for escaping air from the tank 12 . When the charcoal canister 18 , and hence the lower portions 44 , experience positive pressure above ambient atmospheric pressure, the first and second signal passageways 50 , 52 communicate this positive pressure to the separate portion 44 a . In turn, this positive pressure displaces the diaphragm 38 downward toward the valve 40 . A diaphragm pin 39 transfers the displacement of the diaphragm 38 to the valve 40 , thereby displacing the valve 40 to its open configuration with respect to the lip seal 70 . Thus, pressure in the charcoal canister 18 due to refueling is allowed to escape through the lower portion 44 , past the lip seal 70 , through the upper portion 42 , and through the second port 46 .
Relieving pressure 26 is also useful for regulating the pressure in fuel tank 12 during any situation in which the engine is turned off. By limiting the amount of positive pressure in the fuel tank 12 , the cool-down vacuum effect will take place sooner.
FIG. 3 shows a second embodiment of the present invention that is substantially similar to the first embodiment shown in FIG. 2, except that the first and second signal passageways 50 , 52 have been eliminated, and the intermediate lead frame 62 penetrates a protrusion 38 b of the diaphragm 38 , similar to the penetration of protrusion 38 a by the second signal passageway 52 , as shown in FIG. 2 . The signal from the lower portion 44 is communicated to the separate portion 44 a via a path that extends through spaces between the solenoid 72 and the housing 30 , through spaces between the intermediate lead frame 62 and the housing 30 , and through the penetration in the protrusion 38 b.
The present invention has many advantages, including:
providing relief for positive pressure above a first predetermined pressure value, and providing relief for vacuum below a second predetermined pressure value.
vacuum monitoring with the present invention in its open configuration during natural cooling, e.g., after the engine is turned off, provides a leak detection diagnostic.
driving the present invention into its open configuration while the engine is on confirms purge flow and switch/sensor function.
vacuum relief provides fail-safe operation of the purge flow system in the event that the solenoid fails with the valve in a closed configuration.
integrally packaging the sensor/switch, the valve, and the solenoid in a single unit reduces the number of electrical connectors and improves system integrity since there are fewer leak points, i.e., possible openings in the system.
While the invention has been disclosed with reference to certain preferred embodiments, numerous modifications, alterations, and changes to the described embodiments are possible without departing from the sphere and scope of the invention, as defined in the appended claims and their equivalents thereof. Accordingly, it is intended that the invention not be limited to the described embodiments, but that it have the full scope defined by the language of the following claims. | An integrated pressure management system manages pressure and detects leaks in a fuel system. The integrated pressure management system also performs a leak diagnostic for the headspace in a fuel tank, a canister that collects volatile fuel vapors from the headspace, a purge valve, and all associated hoses and connections. | 5 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit under 35 USC 119(e) to U.S. Application Ser. No. 60/376,028, filed Apr. 26, 2002.
TECHNICAL FIELD
[0002] The present invention relates to the delivery of fragrances to skin and/or hair. In a first aspect, the invention concerns compositions achieving controlled delivery of fragrances. In a second and third aspect, the invention concerns personal care products comprising substrates and compositions achieving controlled delivery of fragrances.
BACKGROUND OF THE INVENTION
[0003] Humans have applied scents and fragrances to their skins since ancient times. Originally, these aesthetically pleasing materials were commonly isolated in raw form as gums, resins or essential oils from their natural sources, such as the bark, roots, leaves and fruit of indigenous plants. These gums, resins and oils were directly applied to the body or were diluted with water or other solvent, including, in some cases, wine, then applied by means of the delivery vehicle. With the advent of modern chemistry, the individual components responsible for the odour properties of these resins, gums and oils were isolated and subsequently characterised, enabling the manufacture of “perfumes vehicles”, such as fine fragrances and aftershave lotions.
[0004] Traditional perfumes may comprise perfume oils derived from the sources discussed above and these oils may have a mixture of boiling points varying from low to high. It is self-evident that the highly volatile (low boiling), so-called “top note” constituents are short-lived once deposited onto a warm surface, such as skin. As a result, if a fragrance were entirely composed of such materials, it would not be very durable. In order to counter this and achieve increased fragrance substantivity and longevity, traditional perfumes tended to comprise high levels of lower volatility, so-called “middle note” and “base note” fragrance oils. This, however, has certain disadvantages: a consumer who tests a scent in a store often devotes only a short period of time to the evaluation, during which mainly the top notes of the scent will be in evidence, whereas, having purchased the product, that consumer may then be disappointed with the residual middle and base notes which were less in evidence during their test. In addition, the high volatility of top notes and their corresponding low longevity mean that they are traditionally included at low levels (since they are short lived)—a de facto restriction on the freedom of the perfumer to formulate a fragrance.
[0005] To counter these disadvantages of traditional perfumes, it has been proposed to generate complexes (hereafter “fragrance-releasing complexes”) of perfumes and other materials (hereafter “entrapment materials”), which depress the volatility of the fragrances and allow a more controlled release over time—reference is made to WO 99/21532. The production of such non-volatile complexes allows the perfume to be retained on skin/hair until such times as its release is triggered. Entrapment materials which have been proposed for complex formation in the prior art are discussed hereinbelow. The “trigger” referred to may be a single factor such as externally applied moisture or pH change, or, in the case of skin, a combination of factors such as sweat and its components—for example urea, lactic acid and moisture as well as sebum components, such as cholesterol.
[0006] At least in theory, the use of fragrance-releasing complexes allows the possibility of selectively retaining perfumes of a given volatility, such as the elusive top-note fragrances, thereby reducing or avoiding some of the disadvantages discussed in the above paragraphs. This would open up a world of new possibilities: not only could fragrances be designed to have longer lasting top notes, but the evolution of a fragrance post application could be changed to give unique character combinations during the so-called “dry down”, i.e. a uniquely changing character with time.
[0007] In practice, however, retention, particularly of the top-note scents, is not easy to achieve. While not wishing to be bound by any theory, there appear to be a number of reasons why this is so. In the first place, entrapment materials do not tend to differentiate between top, middle and bottom note fragrances, so that, in a given fragrance, all notes will be complexed. Put another way, increased perfume oil volatility does not appear to equate in any significant way to increased ability to complex. Rather, it would appear that, if all other factors are equal, the degree of complexation of a perfume raw material of given volatility is roughly proportional to its proportion in the mixture. To counteract this effect, it would, of course, be possible to increase the amount of top note oils present, but that could radically alter the oil balance, thereby changing the entire nature of the fragrance. It would also place significant restrictions on perfumers as to what they could put into their fragrances, similarly to the way that, in the past, the high volatility of top notes has lead to inclusion of low levels of top notes in fragrances. A second factor which may limit the capture and retention of top note fragrance oils by entrapment materials may be the presence in many traditional fragrances of certain non-aqueous solvents, such as certain alcohols, which may interfere with the entrapment materials.
[0008] Ideally, the present invention will achieve improved fragrance retention by fragrance-releasing complexes.
[0009] Ideally, the present invention will also selectively improve capture and retention of top note fragrances within fragrance-releasing complexes.
[0010] Ideally, the present invention will also provide personal care articles comprising compositions which achieve the above objectives.
SUMMARY OF THE INVENTION
[0011] According to a first aspect of the invention, a composition is provided comprising a fragrance-releasing complex of an entrapment material and a fragrance; and an encapsulation material, wherein the weight ratio of fragrance-releasing complex to encapsulation material is greater than 1.
[0012] As used herein, the term “encapsulation material” includes any material which is capable of coating the fragrance releasing complex to retain the fragrance in the complexed state.
[0013] As used herein, the term “fragrance-releasing complex” includes fragrance which is reversibly associated with an entrapment material.
[0014] As used herein, the term “entrapment material” includes any material which, when associated with a fragrance, has the effect of suppressing the volatility of that fragrance and delaying its evaporation.
[0015] As used herein, the term “associated” includes chemical and physical linkage. The term “chemical linkage” includes covalent, ionic, hydrogen and other types of chemical bond; the term “physical linkage” includes linkage by Van der Waals force and other types of physical bond.
[0016] The word “reversibly” used to qualify “associated” includes associations which can be broken down so that the fragrance is released from the entrapment material; breakdown is effected by a “trigger” as discussed above.
[0017] As used herein the term “fragrance” includes mixtures of perfume raw materials (PRMs) that are used to impart an overall pleasant odour profile to a composition, particularly a cosmetic composition. A wide variety of chemicals are useful as PRMs, including materials such as aldehydes, ketones and esters, which may be synthetic or may be derived from naturally occurring plant or animal sources. Lists of PRMs can be found in Journals used by those in the art such as “Perfume and Flavourist” or “Journal of Essential Oil Research”. As used herein, the term “perfume raw material” includes oil which is liquid at a temperature of 25° C. and 1 atmosphere pressure, has a ClogP value greater than about 0.1, preferably greater than about 0.5 and more preferably greater than about 1.0.
[0018] As used herein, the term “ClogP” means the logarithm to base 10 of the octanol/water partition coefficient (P). The octanol/water partition coefficient of a PRM is the ratio between its equilibrium concentrations in octanol and water. Given that this measure is a ratio of the equilibrium concentration of a PRM in a non-polar solvent (octanol) with its concentration in a polar solvent (water), ClogP is also a measure of the hydrophobicity of a material—the higher the ClogP value, the more hydrophobic the material. ClogP values can be readily calculated from a program called “CLOGP” which is available from Daylight Chemical Information Systems Inc., Irvine, Calif., USA. Octanol/water partition coefficients are described in more detail in U.S. Pat. No. 5,578,563.
[0019] In a further advantageous aspect, the weight ratio of fragrance-releasing complex to encapsulation material within the composition according to the invention is in the range 1:0.1 to 1:0.9; preferably it is in the range 1:0.2 to 1:0.8 and more preferably, it is in the range 1:0.35 to 1:0.71.
[0020] The encapsulation material according to the invention may comprise a non-ionic surfactant. Preferably, the non-ionic surfactant comprises block copolymers of ethylene oxide and propylene oxide, polyalkylene oxide siloxanes, partially or fully hydrogenated polyoxyethylene castor oil ethers or polyoxyethylene hardened castor oil ethers, sorbitan esters of long chain fatty acids, polyethoxylated fatty alcohol surfactants, glycerol mono-fatty acid esters, fatty acid esters of polyethylene glycol, fluorocarbon surfactants and mixtures thereof. Advantageously, the non-ionic surfactant has a molecular weight above 400.
[0021] The entrapment material according to the invention may comprise capsules, microcapsules, nanocapsules, liposomes, film-formers, cyclic oligosaccharides, materials capable of transforming fragrances into pro-perfumes and mixtures thereof.
[0022] The fragrance comprised within the fragrance-releasing complex may be a first fragrance and may advantageously comprise perfume raw materials, at least 80% of which, preferably at least 90% of which, have a boiling point of less than or equal to 300° C.
[0023] More advantageously, the first fragrance comprises perfume raw materials at least 50% of which, preferably at least 60% of which, more preferably at least 75% of which have a ClogP value of greater than or equal to 3.
[0024] Even more advantageously, the first fragrance comprises perfume raw materials having a molecular weight of less than 200.
[0025] The composition according to the invention may also comprise a second fragrance. Advantageously, the second fragrance comprises perfume raw materials, at least 80% of which, preferably at least 90% of which have a boiling point above 300° C.
[0026] More advantageously, the second fragrance comprises perfume raw materials having a molecular weight of 200 or more.
[0027] The composition according to the invention advantageously comprises at least 50% wt, preferably at least 70% wt and more preferably 75 to 90% wt water. In such a case, the composition may also comprise less than 20% wt, preferably between 5 and 15% wt of a volatile, non-aqueous solvent.
[0028] According to a second aspect of the invention, a personal care article is provided comprising a substrate and a composition as defined above. Preferably, the weight ratio of substrate to composition is in the range 1:0.1 to 1:10. More preferably, it is in the range 1:5 to 1:3.1.
[0029] According to a third aspect of the invention, a personal care article is provided comprising a substrate and a composition, the composition comprising a fragrance-releasing complex and more than 50% wt water, preferably between 80 and 90% wt water.
[0030] The substrate comprised within the personal care article according to the second or third aspect of the invention may advantageously be a nonwoven; more advantageously, the personal care article according to the second or third aspects of the invention may be packaged as a wet wipe in packaging that retains moisture.
DETAILED DESCRIPTION
[0031] Unless otherwise indicated, all percentages of compositions referred to herein are weight percentages and all ratios are weight ratios.
[0032] Unless otherwise indicated, all boiling points referred to herein are determined at standard pressure of 760 mm Hg.
[0033] Unless otherwise indicated, all molecular weights are weight average molecular weights.
[0034] Unless otherwise indicated, the content of all literature sources referred to within this text are incorporated herein in full by reference.
[0035] Except where specific examples of actual measured values are presented, numerical values referred to herein should be considered to be qualified by the word “about”.
[0036] The composition according to the invention may comprise from 0.01 to 10% wt of entrapment material, preferably from 0.01 to 5% wt and more preferably from 0.1 to 2.5% wt entrapment material.
[0037] Entrapment materials which may be used according to the invention include polymers; capsules, microcapsules and nanocapsules; liposomes; film formers; cyclic oligosaccharides; materials capable of transforming the fragrances into so-called pro-perfumes and mixtures of these. Preferred are materials capable of transforming fragrances into pro-perfumes, cyclic oligosaccharides and mixtures thereof. Highly preferred are cyclic oligosaccharides and mixtures thereof.
[0038] The entrapment material according to the present invention may comprise capsules, micro-capsules or nanocapsules. These materials can be used to control release of fragrance oils, by physically surrounding and entrapping small fragrance oil droplets within a resistant wall. The droplet may then be released when it encounters a trigger in the form of a release agent, for example a dissolution solvent such as water. The water may, for example, be supplied in the form of moisture transpired through the skin. Capsules, microcapsules and nanocapsules are known in the art, for example DE-A-1 268 316, U.S. Pat. Nos. 3,539,465 and 3,455,838.
[0039] Moisture sensitive capsules, micro-capsules and nanocapsules preferably comprise a polysaccharide polymer. Examples of suitable polymers are dextrins, especially low-viscosity dextrins including maltodextrins. A preferred example of a low viscosity dextrin is one which, as a 50% dispersion in water has a viscosity at 25° C., using a Brookfield Viscometer fitted with an “A” type T-Bar rotating at 20 rpm in helical mode, of 330±20 mpa.s. This dextrin is known as Encapsul 855 and is available from National Starch and Chemicals Ltd. A further example of a polysaccharide that can be used to form the moisture sensitive capsules is gum acacia.
[0040] The entrapment material may comprise cyclic oligosaccharides. As used herein, the term “cyclic oligosaccharide” means a cyclic structure comprising six or more saccharide units. Preferred for use herein are cyclic oligosaccharides having six, seven or eight saccharide units and mixtures thereof, more preferably six or seven saccharide units and mixtures thereof and even more preferably seven saccharide units and mixtures thereof. It is common in the art to abbreviate six, seven and eight membered cyclic oligosaccharides to α, β and γ respectively.
[0041] The cyclic oligosaccharides for use herein may comprise any suitable saccharide or mixtures of saccharides. Examples of suitable saccharides include, but are not limited to, glucose, fructose, mannose, galactose, maltose and mixtures thereof. It is preferred to use the cyclic oligosaccharides of glucose.
[0042] The preferred cyclic oligosaccharides for use herein are α-cyclodextrins or β-cyclodextrins, or mixtures thereof, and the most preferred cyclic oligosaccharides for use herein are β-cyclodextrins. These cyclic molecules are capable of releasably entrapping “guest” molecules in their internal cavities, typically in the ratio of cyclodextrin molecule to guest molecule of 1:1, though the ratio may also be higher or lower, depending on the sizes of the cavity and the guest molecule.
[0043] The cyclic oligosaccharide, or mixture of cyclic oligosaccharides, for use herein may be substituted by any suitable substituent or mixture of substituents. Suitable substituents include, but are not limited to, alkyl groups, hydroxyalkyl groups, dihydroxyalkyl groups, (hydroxyalkyl)alkylenyl bridging groups such as cyclodextrin glycerol ethers, aryl groups, maltosyl groups, allyl groups, benzyl groups, alkanoyl groups, cationic cyclodextrins such as those containing 2-hydroxy-3-(dimethylamino) propyl ether, quaternary ammonium groups, anionic cyclodextrins such as carboxyalkyl groups, sulphobutylether groups, sulphate groups, and succinylates; amphoteric cyclodextrins; and mixtures thereof. The substituents may be saturated or unsaturated, straight or branched chain moieties. Preferred substituents include saturated and straight chain alkyl groups, hydroxyalkyl groups and mixtures thereof. Preferred alkyl and hydroxyalkyl substituents are selected from C 1 -C 8 alkyl or hydroxyalkyl groups or mixtures thereof, more preferred alkyl and hydroxyalkyl substituents are selected from C 1 -C 6 alkyl or hydroxyalkyl groups or mixtures thereof, even more preferred alkyl and hydroxyalkyl substituents are selected from C 1 -C 4 alkyl or hydroxyalkyl groups and mixtures thereof. Especially preferred alkyl and hydroxyalkyl substituents are propyl, hydroxypropyl, ethyl and methyl, more especially hydroxypropyl and methyl and even more preferably methyl.
[0044] Preferred cyclic oligosaccharides for use in the present invention are unsubstituted, or are substituted by only saturated straight chain alkyl, or hydroxyalkyl, substituents. Therefore, preferred examples of cyclic oligosaccharides for use herein are α-cyclodextrin, β-cyclodextrin, methyl-α-cyclodextrin, methyl-β-cyclodextrin, hydroxypropyl-α-cyclodextrin and hydroxypropyl-β-cyclodextrin, or mixtures thereof. More preferred examples of cyclic oligosaccharides for use herein are methyl-α-cyclodextrin and methyl-β-cyclodextrin. These are available from Wacker-Chemie GmbH, Hanns-Seidel-Platz 4, München, Germany under the tradenames Alpha W6 M and Beta W7 M respectively. Most preferred is methyl-β-cyclodextrin.
[0045] Methods of modifying cyclic oligosaccharides are well known in the art. For example, see “ Methods of Selective Modifications of Cyclodextrins” Chemical Reviews (1998) Vol. 98, No. 5, pp 1977-1996, Khan et al and U.S. Pat. No. 5,710,268.
[0046] In addition to identifying the preferred substituents themselves (as outlined above), it is also preferred that the cyclic oligosaccharides have an average degree of substitution of between 1.6 and 2.8, wherein the term “degree of substitution” means the average number of substituents per saccharide unit. More preferably, the cyclic oligosaccharides for use herein have an average degree of substitution of from about 1.7 to about 2.0. The average number of substituents can be determined using common Nuclear Magnetic Resonance techniques known in the art.
[0047] The cyclic oligosaccharides are preferably soluble in both water and ethanol. As used herein, “soluble” means at least about 0.1 g of solute dissolves in 100 ml of solvent, at 25° C. and 1 atm of pressure. Preferably, the cyclic oligosaccharides for use herein have a solubility of at least about 1 g/100 ml, at 25° C. and 1 atm of pressure.
[0048] The entrapment material according to the invention may comprise material capable of transforming fragrances into so-called pro-perfumes or profragrances. Pro-perfumes are fragrances which have been reversibly modified to suppress the volatility of that fragrance and delay its evaporation. Pro-fragrances may be synthesised from a given fragrance by conversion of that fragrance into a chemical species or reactive chemical form which releases the fragrance when the pro-fragrance is subjected to the proper conditions triggering breakdown, for example by hydrolysis. Synthesis may comprise reacting the fragrance with more than one type of entrapment material. These entrapment materials may comprise any one or more of a number of chemical groups such as acetal, ketal, orthoester or orthocarbonates. Depending on the pro-fragrance chosen, the trigger may range from contact with the acid mantle of the human skin or enzymes in the human skin to a shift in reaction equilibrium, a pH change or exposure to light. Once released, the fragrance has its original characteristics. Non-limiting examples of entrapment materials (and corresponding pro-perfumes) which may be included in compositions according to the present invention are described in WO 98/47477, WO 99/43667, WO 98/07405 and WO 98/47478.
[0049] Complexes between fragrance and entrapement materials may be formed by kneading the two materials together or, alternatively, they may be formed as solutions in suitable solvents. The solvent may be water or another appropriate solvent, though reference is made to the limitations concerning volatile, non-aqueous solvents, discussed below. Preferably, the solvent is water and the complex is formed by bringing together appropriate amounts of perfume and entrapment material in the solvent.
[0050] The presence of encapsulation material in the ratio range according to the invention acts to retain fragrance in the complexed state, especially in the preferred ranges. Without wishing to be bound by any theory, it is believed that this has at least two reasons: in the first place, the encapsulation material coats the complex to form a physical barrier which prevents fragrance from leaving the complex or other materials from displacing the fragrance; secondly, the encapsulation material may also serve to prevent other materials from displacing the fragrance by solubilising those materials. The encapsulation material may be used to retain top note fragrances in the complexed state, though the effect is not limited to retention of top notes.
[0051] The encapsulation material must be capable of removal to expose the fragrance-releasing complex to appropriate triggers to activate fragrance release. Removal may be achieved by means of external influences—in the case of non-ionic surfactants, the combination of the presence of moisture found on the surface of human skin and/or friction may be employed to expose the fragrance-releasing complex to appropriate triggers.
[0052] The composition according to the invention may comprise from 0.01 to 10% wt encapsulation material, preferably from 0.01 to 4% wt and more preferably from 0.1 to 1% wt encapsulation material.
[0053] Nonlimiting examples of encapsulation materials which may be used in compositions according to the invention include non-ionic surfactants.
[0054] Nonlimiting examples of nonionic surfactants include block copolymers of ethylene oxide and propylene oxide. Suitable block polyoxyethylene-polyoxypropylene polymeric surfactants include those based on ethylene glycol, propylene glycol, glycerol, trimethylolpropane and ethylenediamine as the initial reactive hydrogen compound. Certain of the block polymer surfactant compounds designated Pluronic® and Tetronic® by the BASF-Wyandotte Corp., Wyandotte, Mich., are readily available. Nonlimiting examples of compatible surfactants of this type include Pluronic Surfactants with the general formula H(EO) n (PO) m (EO) n H, wherein EO is an ethylene oxide group, PO is a propylene oxide group, and n and m are numbers that indicate the average number of the groups in the surfactants. Typical examples suitable Pluronic surfactants are:
Name Average MW Average n Average m L-101 3,800 4 59 L-81 2,750 3 42 L-44 2,200 10 23 L-43 1,850 6 22 F-38 4,700 43 16 P-84 4,200 19 43, and mixtures thereof.
[0055] Suitable Tetronic Surfactants may have the general formula:
[0056] wherein EO, PO, n, and m have the same meanings as above. Typical examples of suitable Tetronic surfactants are:
Name Average MW Average n Average m 901 4,700 3 18 908 25,000 114 22, and mixtures thereof.
[0057] “Reverse” Pluronic and Tetronic surfactants have the following general formulas:
[0058] Reverse Pluronic Surfactants H(PO) m (EO) n (PO) m H
[0059] Reverse Tetronic Surfactants
[0060] wherein EO, PO, n, and m have the same meanings as above. Typical examples of suitable Reverse Pluronic and Reverse Tetronic surfactants are: Reverse Pluronic surfactants are:
Name Average MW Average n Average m 10 R5 1,950 8 22 25 R1 2,700 21 6
[0061] Reverse Tetronic surfactants
Name Average MW Average n Average m 130 R2 7,740 9 26 70 R2 3,870 4 13 and mixtures thereof.
[0062] Another class of nonionic surfactants which may be included in compositions according to the invention are the polyalkyleneoxide polysiloxanes such as those having a dimethyl polysiloxane hydrophobic moiety and one or more hydrophilic polyalkylene side chains and have the general formula:
R 1 —(CH 3 ) 2 SiO—[(CH 3 ) 2 SiO] a —[(CH 3 )(R 1 )SiO] b —Si(CH 3 ) 2 —R 1
[0063] wherein a+b are from about 1 to about 50, preferably from about 3 to about 30, more preferably from about 10 to about 25, and each R 1 is the same or different and is selected from the group consisting of methyl and a poly(ethyleneoxide/propyleneoxide) copolymer group having the general formula:
—(CH 2 ) n O(C 2 H 4 O) c (C 3 H 6 O) d R 2
[0064] with at least one R 1 being a poly(ethyleneoxide/propyleneoxide) copolymer group, and wherein n is 3 or 4, preferably 3; total c (for all polyalkyleneoxy side groups) has a value of from 1 to about 100, preferably from about 6 to about 100; total d is from 0 to about 14, preferably from 0 to about 3; and more preferably d is 0; total c+d has a value of from about 5 to about 150, preferably from about 9 to about 100 and each R 2 is the same or different and is selected from the group consisting of hydrogen, an alkyl having 1 to 4 carbon atoms, and an acetyl group, preferably hydrogen and methyl group.
[0065] Examples of this type of surfactants are the Silwet® surfactants which are available OSi Specialties, Inc., Danbury, Conn. Representative Silwet surfactants are as follows.
Name Average MW Average a + b Average total c L-7608 600 1 9 L-7607 1,000 2 17 L-77 600 1 9 L-7605 6,000 20 99 L-7604 4,000 21 53 L-7600 4,000 11 68 L-7657 5,000 20 76 L-7602 3,000 20 29
[0066] The molecular weight of the polyalkyleneoxy group (R 1 ) is less than or equal to about 10,000. Preferably, the molecular weight of the polyalkyleneoxy group is less than or equal to about 8,000, and most preferably ranges from about 300 to about 5,000. Thus, the values of c and d can be those numbers which provide molecular weights within these ranges. However, the number of ethyleneoxy units (—C 2 H 4 O) in the polyether chain (R 1 ) must be sufficient to render the polyalkyleneoxide polysiloxane water dispersible or water soluble. If propyleneoxy groups are present in the polyalkylenoxy chain, they can be distributed randomly in the chain or exist as blocks. Preferred Silwet surfactants are L-7600, L-7602, L-7604, L-7605, L-7657, and mixtures thereof.
[0067] The preparation of polyalkyleneoxide polysiloxanes is well known in the art. Polyalkyleneoxide polysiloxanes of the present invention can be prepared according to the procedure set forth in U.S. Pat. No. 3,299,112. Typically, polyalkyleneoxide polysiloxanes of the surfactant blend of the present invention are readily prepared by an addition reaction between a hydrosiloxane (i.e., a siloxane containing silicon-bonded hydrogen) and an alkenyl ether (e.g., a vinyl, allyl, or methallyl ether) of an alkoxy or hydroxy end-blocked polyalkylene oxide). The reaction conditions employed in addition reactions of this type are well known in the art and in general involve heating the reactants (e.g., at a temperature of from about 85° C. to 110° C.) in the presence of a platinum catalyst (e.g., chloroplatinic acid) and a solvent (e.g., toluene).
[0068] Another class of non-ionic surfactants which may be used in compostions according to the invention include polyoxyethylene castor oil ethers or polyoxyethylene hardened castor oil ethers or mixtures thereof, which are either partially or fully hydrogenated. These ethoxylates have the following general formulae:
[0069] These ethoxylates can be used alone or in any mixture thereof. The average ethylene oxide addition mole number (i.e., l+m+n+x+y+z in the above formula) of these ethoxylates is generally from about 7 to about 100, and preferably from about 20 to about 80. Castor oil surfactants are commerically available from Nikko under the trade names HCO 40 and HCO 60 and from BASF under the trade names Cremphor™ RH 40, RH 60, and CO 60.
[0070] Another class of non-ionic surfactants which may be used in compostions according to the invention include sorbitan esters of long-chain fatty acids, such as those having long-chain fatty acid residues with 14 to 18 carbon atoms, preferably 16 to 18 carbon atoms. Furthermore, the esterification degree of the sorbitan polyesters of long-chain fatty acids is preferably 2.5 to 3.5, more preferably 2.8 to 3.2. Typical examples of these sorbitan polyesters of long-chain fatty acids are sorbitan tripalmitate, sorbitan trioleate, and sorbitan tallow fatty acid triesters.
[0071] Other suitable sorbitan ester surfactants include sorbitan fatty acid esters, particularly the mono-and tri-esters of the formula:
[0072] wherein R 1 is H or
[0073] and w is from about 10 to about 16.
[0074] Further suitable sorbitan ester surfactants include polyethoxylated sorbitan fatty acid esters, particularly those of the formula:
[0075] wherein R 1 is H or
[0076] u is from about 10 to about 16 and average (w+x+y+z) is from about 2 to about 20. Preferably, u is 16 and average (w+x+y+z) is from about 2 to about 4.
[0077] Another class of non-ionic surfactants which may be used in compostions according to the invention include polyethoxylated fatty alcohol surfactants such as those having the formula:
CH 3 —(CH 2 ) x —(CH═CH) y —(CH 2 ) z —(OCH 2 CH 2 ) w —OH
[0078] wherein w is from about 0 to about 100, preferably from about 0 to about 80; y is 0 or 1; x is from about 1 to about 10; z is from about 1 to about 10; x+z+y=11 to 25, preferably 11 to 23.
[0079] Branched (polyethoxylated) fatty alcohols having the following formula may also be incorporated into the present compositions:
R—(OCH 2 CH 2 ) w —OH
[0080] wherein R is a branched alkyl group of from about 10 to about 26 carbon atoms and w is as specified above.
[0081] Another class of non-ionic surfactants which may be used in compostions according to the invention include glycerol mono-fatty acid esters, particularly glycerol mono-stearate, oleate, palmitate or laurate.
[0082] Another class of non-ionic surfactants which may be used in compostions according to the invention include fatty acid esters of polyethylene glycol, particularly those of the following formula:
R 1 —(OCH 2 CH 2 ) w —OH
-or-
R 1 —(OCH 2 CH 2 ) w —OR 1
[0083] wherein R 1 is a stearoyl, lauroyl, oleoyl or palmitoyl residue; w is from about 2 to about 20, preferably from about 2 to about 8.
[0084] A further class of non-ionic surfactants which may be used in compostions according to the invention include fluorocarbon surfactants. Fluorocarbon surfactants are a class of surfactants wherein the hydrophobic part of the amphiphile comprises at least in part some portion of a carbon-based linear or cyclic moiety having fluorines attached to the carbon where typically hydrogens would be attached to the carbons together with a hydrophilic head group. Some typical nonlimiting fluorocarbon surfactants include fluorinated alkyl polyoxyalkylene, and fluorinated alkyl esters as well as ionic surfactants. Representative structures for these compounds are given below:
[0085] (1) R f R(R 1 O) x R 2
[0086] (2) R f R—OC(O)R 3
[0087] (3) R f R—Y—Z
[0088] (4) R f RZ
[0089] wherein R f contains from about 6 to about 18 carbons each having from about 0 to about 3 fluorines attached. R is either an alkyl or alkylene oxide group which, when present, has from about 1 to about 10 carbons and R 1 represents an alkylene radical having from about 1 to about 4 carbons. R 2 is either a hydrogen or a small alkyl capping group having from about 1 to about 3 carbons. R 3 represents a hydrocarbon moiety comprising from about 2 to about 22 including the carbon on the ester group. This hydrocarbon can be linear, branched or cyclic saturated or unsaturated and contained moieties based on oxygen, nitrogen, and sulfur including, but not limited to ethers, alcohols, esters, carboxylates, amides, amines, thio-esters, and thiols; these oxygen, nitrogen, and sulfur moieties can either interrupt the hydrocabon chain or be pendant on the hydrocarbon chain. In structure 3, Y represents a hydrocarbon group that can be an alkyl, pyridine group, amidopropyl, etc. that acts as a linking group between the fluorinated chain and the hydrophilic head group. In structures 3 and 4, Z represents a cationic, anionic, and amphoteric hydrophilic head groups including, but not limited to carboxylates, sulfates, sulfonates, quaternary ammonium groups, and betaines. Nonlimiting commercially available examples of these structures include Zonyl® 9075, FSO, FSN, FS-300, FS-310, FSN-100, FSO-100, FTS, TBC from DuPont and Fluorad™ surfactants FC-430, FC-431, FC-740, FC-99, FC-120, FC-754, FC170C, and FC-171 from the 3M™ company in St. Paul, Minn.
[0090] Advantageously, the non-ionic surfactants employed according to the invention have a molecular weight above 400. Below this value, there is a risk that these molecules may act as so-called “molecular wedges” which not only coat the complex, but may also enter the entrapment material and block entry or exit to the fragrances. In other words, entrapment may either be prevented or, where it has occurred, it may cease to be reversible, or release may no longer be controllable. More preferably, the molecular weight is in the range 400 to 20,000.
[0091] The first fragrance according to the invention may comprise perfume raw materials of high, medium or low volatility, but preferably of high volatility. These highly volatile fragrances essentially correspond to the “top notes”. More preferably, at least 80%, more preferably still at least 90%, of the perfume raw materials have a boiling point of less than 300° C.
[0092] Advantageously, the first fragrance is highly hydrophobic, being comprised of perfume raw materials, at least 50%, preferably at least 60%, more preferably at least 75% of which have a ClogP value of at least 3. The ability to complex with entrapment materials, particularly cyclodextrins, appears to increase with the degree of hydrophobicity so that in a kinetic race between fragrances of different polarity, it appears that, when all other parameters are equal, hydrophobic molecules are the more likely to complex than hydrophilic ones. Advantageously, the top note fragrances will therefore comprise PRMs, at least 50% of which have a ClogP of at least 3.
[0093] In addition, it is advantageous if the fragrance is comprised of perfume raw materials which have a molecular weight of less than 200. Without wishing to be bound by theory, it appears that, above this threshold, the likelihood of complexation decreases, so that this represents another factor which may assist in preferential complexation of a given molecular species.
[0094] Examples of PRMs having a ClogP of at least 3 and with molecular weights of less than 200 include but are not limited to: citronellol, Ethyl cinnamate, 2,4,6-Trimethylbenzaldehyde, 2,6-Dimethyl-2-heptanol, Diisobutylcarbinol, Ethyl salicylate, Phenethyl isobutyrate, Ethyl hexyl ketone, Propyl amyl ketone, Dibutyl ketone, Heptyl methyl ketone, 4,5-Dihydrotoluene, Caprylic aldehyde, Citral, Geranial, Isopropyl benzoate, Cyclohexanepropionic acid, Campholene aldehyde, Caprylic acid, Caprylic alcohol, Cuminaldehyde, 1-Ethyl-4-nitrobenzene, Heptyl formate, 4-Isopropylphenol, 2-Isopropylphenol, 3-Isopropylphenol, Allyl disulfide, 4-Methyl-1-phenyl-2-pentanone, 2-Propylfuran, Allyl caproate, Styrene, Isoeugenyl methyl ether, Indonaphthene, Diethyl suberate, L-Menthone, Menthone racemic, p-Cresyl isobutyrate, Butyl butyrate, Ethyl hexanoate, Propyl valerate, n-Pentyl propanoate, Hexyl acetate, Methyl heptanoate, trans-3,3,5-Trimethylcyclohexanol, 3,3,5-Trimethylcyclohexanol, Ethyl p-anisate, 2-Ethyl-1-hexanol, Benzyl isobutyrate, 2,5-Dimethylthiophene, Isobutyl 2-butenoate, Caprylnitrile, gamma-Nonalactone, Nerol, trans-Geraniol, 1-Vinylheptanol, Eucalyptol, 4-Terpinenol, Dihydrocarveol, Ethyl 2-methoxybenzoate, Ethyl cyclohexanecarboxylate, 2-Ethylhexanal, Ethyl amyl carbinol, 2-Octanol, 2-Octanol, Ethyl methylphenylglycidate, Diisobutyl ketone, Coumarone, Propyl isovalerate, Isobutyl butanoate, Isopentyl propanoate, 2-Ethylbutyl acetate, 6-Methyl-tetrahydroquinoline, Eugenyl methyl ether, Ethyl dihydrocinnamate, 3,5-Dimethoxytoluene, Toluene, Ethyl benzoate, n-Butyrophenone, alpha-Terpineol, Methyl 2-methylbenzoate, Methyl 4-methylbenzoate, Methyl 3, methylbenzoate, sec.Butyl n-butyrate, 1,4-Cineole, Fenchyl alcohol, Pinanol, cis-2-Pinanol, 2,4, Dimethylacetophenone, Isoeugenol, Safrole, Methyl 2-octynoate, o-Methylanisole, p-Cresyl methyl ether, Ethyl anthranilate, Linalool, Phenyl butyrate, Ethylene glycol dibutyrate, Diethyl phthalate, Phenyl mercaptan, Cumic alcohol, m-Toluquinoline, 6-Methylquinoline, Lepidine, 2-Ethylbenzaldehyde, 4-Ethylbenzaldehyde, o-Ethylphenol, p-Ethylphenol, m-Ethylphenol, (+)-Pulegone, 2,4-Dimethylbenzaldehyde, Isoxylaldehyde, Ethyl sorbate, Benzyl propionate, 1,3-Dimethylbutyl acetate, Isobutyl isobutanoate, 2,6-Xylenol, 2,4-Xylenol, 2,5-Xylenol, 3,5-Xylenol, Methyl cinnamate, Hexyl methyl ether, Benzyl ethyl ether, Methyl salicylate, Butyl propyl ketone, Ethyl amyl ketone, Hexyl methyl ketone, 2,3-Xylenol, 3,4, Xylenol.
[0095] Compositions according to the invention may also comprise a second fragrance. Advantageously, the second fragrance comprises PRMs at least 80% of which, preferably at least 90% of which have a boiling point of more than 300° C.—these fragrances essentially correspond to the “middle notes” and “base notes”.
[0096] With reference to the foregoing discussion, it is also preferred that the molecular weights of the perfume raw materials comprised within the second fragrance are 200 or more.
[0097] Fulfilment of this condition may have the effect that the second fragrance is less likely to form complexes with the encapsulation material than the first fragrance. In the case that the first fragrance comprises “top notes”, this may allow preferential entrapment and delayed release of the highly volatile fragrance.
[0098] Examples of PRMs corresponding to middles and base notes which have molecular weights of 200 or more include, but are not limited to: sandalore, Sorbitol, (S)-2-Aminopentanedioic acid, DL-Tartaric acid, Triethanolamine, (S)-alpha-Aminobenzenepropanoic acid, Adipic acid, Acetanilide, Coumarin, p-Hydroxybenzaldehyde, Azelaic acid, Methyl beta-naphthyl ketone.
[0099] Certain embodiments of the composition according to the present invention advantageously comprise at least 50% wt water. Preferably, they comprise at least 70% wt water, more preferably between 75 and 90% wt water.
[0100] Compositions according to the invention may comprise a volatile, non-aqueous solvent which has the ability to impart a refreshing skin-feel to a fragrance. On the other hand, as stated above, certain solvents such as alcohols may interfere with the entrapment materials. This effect may be suppressed when the volatile solvent is comprised within an aqueous solution at levels of less than 20% wt and preferably between 5 and 15% wt.
[0101] As used herein, the term “volatile non-aqueous solvent” includes solvents having a boiling point under 1 atm, of less than about 100° C., preferably less than about 90° C., more preferably less than about 80° C.
[0102] The volatile solvents for use herein will be safe for use on a wide range of substrates, especially human or animal skin or hair. Suitable volatile solvents for inclusion according to the invention include C 3 -C 14 saturated and unsaturated, straight or branched chain hydrocarbons such as cyclohexane, hexane, heptane, isooctane, isopentane, pentane; ethers such as dimethyl ether, diethyl ether; straight or branched chain alcohols and diols such as methanol, ethanol, propanol, isopropanol; aldehydes and ketones such as acetone; propellants, and mixtures thereof. Preferred volatile solvents are C 1 -C 4 alcohols and mixtures thereof. More preferred for use herein are C 1 -C 4 straight chain or branched chain alcohols for example methanol, ethanol, propanol, isopropanol and butanol and mixtures thereof, and most preferred for use herein is ethanol.
[0103] According to the second aspect of the invention, a personal care article is provided comprising a substrate and a composition as defined above.
[0104] The weight ratio of substrate:composition according to the first aspect of the invention may be in the range 1:0.1 to 1:10, is preferably in the range 1:0.2 to 1:8.0 and is more preferably 1:3.1.
[0105] The composition according to the first aspect of the invention may be introduced onto or into the substrate by any method known to those skilled in the art, such as by dipping the substrate into the composition, spraying the composition onto or into the substrate or pumping the compositon into the substrate.
[0106] Substrates which may be incorporated into personal cleansing articles according to the invention are preferably water insoluble and may comprise woven, nonwoven, hydroentangled and air entangled material, natural or synthetic sponge, polymeric netted meshes, or mixtures of these materials. Preferably, the substrate comprises nonwoven material.
[0107] The substrate may comprise natural materials, synthetic materials or a mixture of the two.
[0108] Included within the term “natural materials” are those directly derived from plants, animals and insects and those which comprise products of plants, animals, and insects. Included within the term “synthetic materials” are those obtained primarily from man-made materials or from natural materials which have been further altered.
[0109] In making a nonwoven substrate, the conventional starting material usually comprises fibrous synthetic or natural textile-length fibers, or mixtures thereof. Nonlimiting examples of natural materials useful in the present invention include silk fibers, keratin fibers and cellulosic fibers. Nonlimiting examples of keratin fibers include those selected from the group consisting of wool fibers, camel hair fibers, and the like. Nonlimiting examples of cellulosic fibers include those selected from the group consisting of wood pulp fibers, cotton fibers, hemp fibers, jute fibers, flax fibers, and mixtures thereof. Nonlimiting examples of synthetic materials useful in the present invention include those selected from the group consisting of acetate fibers, acrylic fibers, cellulose ester fibers, modacrylic fibers, polyamide fibers, polyester fibers, polyolefin fibers, polyvinyl alcohol fibers, rayon fibers, polyurethane foam, and mixtures thereof. Examples of some of these synthetic materials include acrylics such as acrilan, creslan, and the acrylonitrile-based fiber, orlon; cellulose ester fibers such as cellulose acetate, amel, and acele; polyamides such as nylons (e.g., nylon 6, nylon 66, nylon 610, and the like); polyesters such as fortrel, kodel, and the polyethylene terephthalate fiber, dacron; polyolefins such as polypropylene, polyethylene; polyvinyl acetate fibers; polyurethane foams and mixtures thereof. These and other suitable fibers and the nonwoven materials prepared therefrom are generally described in Riedel, “Nonwoven Bonding Methods and Materials,” Nonwoven World (1987); the Encyclopedia Americana, vol. 11, pp. 147-153, and vol. 26, pp. 566-581 (1984); U.S. Pat. Nos. 4,891,227 and 4,891,228. Nonwoven substrates made from natural materials consist of webs or sheets most commonly formed on a fine wire screen from a liquid suspension of the fibers. See C. A. Hampel et al., The Encyclopedia of Chemistry, third edition, 1973, pp.793-795 (1973); The Encyclopedia Americana, vol. 21, pp. 376-383 (1984); and G. A. Smook, Handbook of Pulp and Paper Technologies, Technical Association for the Pulp and Paper Industry (1986).
[0110] Methods of making nonwoven substrates are well known in the art. Generally, these nonwoven substrates can be made by air-laying, water-laying, meltblowing, coforming, spinbonding, or carding processes in which the fibers or filaments are first cut to desired lengths from long strands, passed into a water or air stream, and then deposited onto a screen through which the fiber-laden air or water is passed. The resulting layer, regardless of its method of production or composition, is then subjected to at least one of several types of bonding operations to anchor the individual fibers together to form a self-sustaining web. In the present invention the nonwoven layer can be prepared by a variety of processes including hydroentanglement, thermally bonding or thermo-bonding, and combinations of these processes. Moreover, the substrates of the present invention can consist of a single layer or multiple layers. In addition, a multilayered substrate can include films and other nonfibrous materials.
[0111] The substrate can be made into a wide variety of shapes and forms including flat pads, thick pads, thin sheets, ball-shaped implements, irregularly shaped implements, and having sizes ranging from a surface area of 6.25 cm 2 (a square inch) to about hundreds of square centimetres. The exact size will depend upon the desired use and product characteristics. Especially convenient are square, circular, rectangular, or oval pads having a surface area of from about 6.25 cm 2 (1 in 2 ) to about 900 cm 2 .
[0112] According to the third aspect of the invention, a personal care article is provided comprising a substrate, as defined hereinabove, and a composition, the composition comprising a fragrance-releasing complex, as defined hereinabove, and more than 50% wt water, preferably between 80 and 90% wt water.
[0113] Advantageously, the personal care articles according to the second and third aspects of the invention may be packaged as wet wipes in water-proof packaging.
[0114] The compositions and personal care articles according to the present invention may comprise a wide range of optional ingredients, such as active ingredients, sunscreens, surfactants and other materials.
[0115] The compositions and personal care articles of the present invention can comprise a safe and effective amount of one or more active ingredients or pharmaceutically-acceptable salts thereof. The term “safe and effective amount” as used herein, means an amount of an active ingredient high enough to modify the condition to be treated or to deliver the desired skin benefit, but low enough to avoid serious side effects, at a reasonable benefit to risk ratio within the scope of sound medical judgment. What is a safe and effective amount of the active ingredient will vary with the specific active, the ability of the active to penetrate through the skin, the age, health condition, and skin condition of the user, and other like factors.
[0116] Anti-Acne Actives: Examples of useful anti-acne actives include the keratolytics such as salicylic acid (o-hydroxybenzoic acid), derivatives of salicylic acid such as 5-octanoyl salicylic acid, and resorcinol; retinoids such as retinoic acid and its derivatives (e.g., cis and trans); sulfur-containing D and L amino acids and their derivatives and salts, particularly their N-acetyl derivatives, a preferred example of which is N-acetyl-L-cysteine; lipoic acid; antibiotics and antimicrobials such as benzoyl peroxide, octopirox, tetracycline, 2,4,4′-trichloro-2′-hydroxy diphenyl ether, 3,4,4′-trichlorobanilide, azelaic acid and its derivatives, phenoxyethanol, phenoxypropanol, phenoxyisopropanol, ethyl acetate, clindamycin and meclocycline; sebostats such as flavonoids; and bile salts such as scymnol sulfate and its derivatives, deoxycholate, and cholate.
[0117] Anti-Wrinkle and Anti-Skin Atrophy Actives: Examples of antiwrinkle and anti-skin atrophy actives include retinoic acid and its derivatives (e.g., cis and trans); retinol; retinyl esters; niacinamide, salicylic acid and derivatives thereof; sulfur-containing D and L amino acids and their derivatives and salts, particularly the N-acetyl derivatives, a preferred example of which is N-acetyl-L-cysteine; thiols, e.g. ethane thiol; hydroxy acids, phytic acid, lipoic acid; lysophosphatidic acid, and skin peel agents (e.g., phenol and the like).
[0118] Non-Steroidal Anti-Inflammatory Actives (NSAIDS): Examples of NSAIDS include the following categories: propionic acid derivatives; acetic acid derivatives; fenamic acid derivatives; biphenylcarboxylic acid derivatives; and oxicams. All of these NSAIDS are fully described in U.S. Pat. No. 4 , 985 , 459 . Examples of useful NSAIDS include acetyl salicylic acid, ibuprofen, naproxen, benoxaprofen, flurbiprofen, fenoprofen, fenbufen, ketoprofen, indoprofen, pirprofen, carprofen, oxaprozin, pranoprofen, miroprofen, tioxaprofen, suprofen, alminoprofen, tiaprofenic acid, fluprofen and bucloxic acid. Also useful are the steroidal anti-inflammatory drugs including hydrocortisone and the like.
[0119] Topical Anesthetics: Examples of topical anesthetic drugs include benzocaine, lidocaine, bupivacaine, chlorprocaine, dibucaine, etidocaine, mepivacaine, tetracaine, dyclonine, hexylcaine, procaine, cocaine, ketamine, pramoxine, phenol, and pharmaceutically acceptable salts thereof.
[0120] Artificial Tanning Agents and Accelerators. Examples of artificial tanning agents and accelerators include dihydroxyacetaone, tyrosine, tyrosine esters such as ethyl tyrosinate, and phospho-DOPA.
[0121] Antimicrobial and Antifungal Actives: Examples of antimicrobial and antifungal actives include β-lactam drugs, quinolone drugs, ciprofloxacin, norfloxacin, tetracycline, erythromycin, amikacin, 2,4,4′-trichloro-2′-hydroxy diphenyl ether, 3,4,4′-trichlorobanilide, phenoxyethanol, phenoxy propanol, phenoxyisopropanol, doxycycline, capreomycin, chlorhexidine, chlortetracycline, oxytetracycline, clindamycin, ethambutol, hexamidine isethionate, metronidazole, pentamidine, gentamicin, kanamycin, lineomycin, methacycline, methenamine, minocycline, neomycin, netilmicin, paromomycin, streptomycin, tobramycin, miconazole, tetracycline hydrochloride, erythromycin, zinc erythromycin, erythromycin estolate, erythromycin stearate, amikacin sulfate, doxycycline hydrochloride, capreomycin sulfate, chlorhexidine gluconate, chlorhexidine hydrochloride, chlortetracycline hydrochloride, oxytetracycline hydrochloride, clindamycin hydrochloride, ethambutol hydrochloride, metronidazole hydrochloride, pentamidine hydrochloride, gentamicin sulfate, kanamycin sulfate, lineomycin hydrochloride, methacycline hydrochloride, methenamine hippurate, methenamine mandelate, minocycline hydrochloride, neomycin sulfate, netilmicin sulfate, paromomycin sulfate, streptomycin sulfate, tobramycin sulfate, miconazole hydrochloride, amanfadine hydrochloride, amanfadine sulfate, octopirox, parachlorometa xylenol, nystatin, tolnaftate, zinc pyrithione, clotrimazole and methyl- and ethylparaben.
[0122] Preferred examples of actives useful herein include those selected from the group consisting of salicylic acid, benzoyl peroxide, 3-hydroxy benzoic acid, glycolic acid, lactic acid, 4-hydroxy benzoic acid, acetyl salicylic acid, 2-hydroxybutanoic acid, 2-hydroxypentanoic acid, 2-hydroxyhexanoic acid, cis-retinoic acid, trans-retinoic acid, retinol, phytic acid, N-acetyl-L-cysteine, lipoic acid, azelaic acid, arachidonic acid, benzoylperoxide, tetracycline, ibuprofen, naproxen, hydrocortisone, acetominophen, resorcinol, phenoxyethanol, phenoxypropanol, phenoxyisopropanol, 2,4,4′-trichloro-2′-hydroxy diphenyl ether, 3,4,4′-trichlorocarbanilide, octopirox, lidocaine hydrochloride, clotrimazole, miconazole, neocycin sulfate, and mixtures thereof.
[0123] Cooling agents: examples include but are not limited to trimethyl isopropyl butanamide, ethyl methane carboxamide, menthol, and menthyl lactate.
[0124] Sunscreen Actives: Also useful herein are sunscreening actives. A wide variety of sunscreening agents are described in U.S. Pat. Nos. 5,087,445, 5,073,372, 5,073,371 and Segarin, et al., at Chapter VIII, pages 189 et seq., of Cosmetics Science and Technology . Nonlimiting examples of sunscreens which are useful in the compositions of the present invention are those selected from the group consisting of 2-ethylhexyl p-methoxycinnamate, 2-ethylhexyl N,N-dimethyl-p-aminobenzoate, p-aminobenzoic acid, 2-phenylbenzimidazole-5-sulfonic acid, octocrylene, oxybenzone, homomenthyl salicylate, octyl salicylate, 4,4′-methoxy-t-butyldibenzoylmethane, 4-isopropyl dibenzoylmethane, 3-benzylidene camphor, 3-(4-methylbenzylidene) camphor, titanium dioxide, zinc oxide, silica, iron oxide, and mixtures thereof. Still other useful sunscreens are those disclosed in U.S. Pat. Nos. 4,937,370 and 4,999,186. Especially preferred examples of these sunscreens include those selected from the group consisting of 4-N,N-(2-ethylhexyl)methylaminobenzoic acid ester of 2,4-dihydroxybenzophenone, 4-N,N-(2-ethylhexyl)methylaminobenzoic acid ester with 4-hydroxydibenzoylmethane, 4-N,N-(2-ethylhexyl)-methylaminobenzoic acid ester of 2-hydroxy-4-(2-hydroxyethoxy)benzophenone, 4-N,N-(2-ethylhexyl)-methylaminobenzoic acid ester of 4-(2-hydroxyethoxy)dibenzoylmethane, and mixtures thereof. Exact amounts of sunscreens which can be employed will vary depending upon the sunscreen chosen and the desired Sun Protection Factor (SPF) to be achieved. SPF is a commonly used measure of photoprotection of a sunscreen against erythema. See Federal Register , Vol. 43, No. 166, pp. 38206-38269, Aug. 25, 1978.
[0125] Nonlimiting examples of preferred actives useful herein include those selected from the group consisting of salicylic acid, benzoyl peroxide, niacinamide, cis-retinoic acid, trans-retinoic acid, retinol, retinyl palmitate, phytic acid, N-acetyl L-cysteine, azelaic acid, lipoic acid, resorcinol, lactic acid, glycolic acid, ibuprofen, naproxen, hydrocortisone, phenoxyethanol, phenoxypropanol, phenoxyisopropanol, 2,4,4,′-trichloro-2′-hydroxy diphenyl ether, 3,4,4′-trichlorocarbanilide, 2-ethylhexyl p-methoxycinnamic acid, oxybenzone, 2-phenylbenzimidozole-5-sulfonic acid, dihydroxyacetone, and mixtures thereof.
[0126] The compositions and personal care articles according to the present invention can also optionally comprise one or more anionic and/or cationic surfactants, provided these materials do not interfere with the entrapment or encapsulation materials.
[0127] The compositions and personal care articles of the present invention can comprise a wide range of other optional components. These additional components should be pharmaceutically acceptable. The CTFA Cosmetic Ingredient Handbook , Second Edition, 1992, describes a wide variety of nonlimiting cosmetic and pharmaceutical ingredients commonly used in the skin and hair care industry, which are suitable for use in the compositions of the present invention. Nonlimiting examples of functional classes of ingredients are described at page 537 of this reference. Examples of these and other functional classes include: abrasives, absorbents, anticaking agents, antioxidants, vitamins, binders, biological additives, buffering agents, bulking agents, chelating agents, chemical additives, colorants, cosmetic astringents, cosmetic biocides, denaturants, drug astringents, external analgesics, film formers, fragrance components, humectants, opacifying agents, pH adjusters, preservatives, propellants, reducing agents and skin bleaching agents.
[0128] Compositions according to the invention may be manufactured by mixing first fragrance with the entrapment material in a first step for a sufficient period of time to allow entrapment, typically about an hour, then adding the encapsulation material in a second step and mixing again for a sufficient period to allow encapsulation, typically about 15 minutes.
[0129] If water is present, it is preferably mixed with the entrapment material in a pre-mixing step, prior to addition of the first fragrance in the first step.
[0130] If a second fragrance is present, it is preferably mixed with the pre-encapsulated complex in a third step. By doing this, it does not have a chance to compete for association with the entrapment material, since it is added later, and may also be prevented from doing so by the encapsulation material.
[0131] If a volatile non-aqueous solvent is present, it is preferably added in a fourth step. This has the advantage that the solvent is less likely to interfere with the entrapment materials if they are already pre-complexed.
[0132] Personal care articles according to the invention may be manufactured by applying compositions according to the invention to a substrate in one of the ways defined above and in a ratio as defined above.
[0133] Compositions according to the invention may be applied directly to the skin or hair or may be applied via a personal care article according to the invention. On application, the fragrance-releasing complex will typically become freed from encapsulation by the encapsulation material, following which fragrance release may be triggered by contact with materials on the skin etc. as described above.
[0134] All documents cited are, in relevant part, incorporated herein by reference; the citation of any document is not to be construed as an admission that it is prior art with respect to the present invention.
EXAMPLES
[0135] The following examples further describe and demonstrate the preferred embodiments within the scope of the present invention. The examples are given solely for the purpose of illustration, and are not to be construed as limitations of the present invention since many variations thereof are possible without departing from its scope.
Example 1
[0136] [0136] Raw Materials % w/w Ethanol 10.00 Water 88.05 Methyl Beta Cyclodextrin 0.50 PEG 60, hydrogenated castor oil 0.40 Fragrance 2 0.07 Fragrance 1 0.13 Sodium Benzoate 0.2 Tetra Sodium EDTA 0.1 Hydrochloric Acid 1 M (used to adjust pH to approx 0.56 5.5)
[0137] Manufacturing Method
[0138] 1. To water add sodium benzoate, tetrasodium edta and hydrochloric acid. Stir until dissolved.
[0139] 2. Add methyl beta cyclodextrin and Fragrance 1 and stir continuously for 1 hour
[0140] 3. Add PEG-60 hydrogenated caster oil and continually stir for a further 10 minutes
[0141] 4. Add Fragrance 2 and stir for a further 5 minutes.
[0142] 5. Add ethanol and mix for a further 10 minutes.
[0143] 6. Transfer to appropriate container
[0144] Addition of Composition to Substrate to Make a Wet Wipe
[0145] A substrate comprising a 17 cm×24.5 cm piece of hydroentangled nonwoven (70% polyester; 30% rayon; basis weight of 64.0 gm −2 ; supplied by BBA Nonwovens of Bethune, S.C., USA under the name Snotox™) is sprayed with composition at a weight ratio of 3.1 (composition): 1 (wipe) weight level. It is then sealed in a water-tight container.
Example 2
[0146] [0146] Raw Materials % w/w Alcohol 10 Water 85.19 Fragrance 1 0.266 Fragrance 2 0.134 Gamma Cyclodextrin 1 PEG 40 hydrogenated Caster oil 0.4 Sodium Benzoate 0.2 Hydrochloric Acid (1 molar) 0.56 Benzyl Alcohol 0.25 Tetrasodium EDTA 0.1
[0147] The method of manufacture was as in Example 1.
Example 3
[0148] [0148] Raw Materials % w/w Alcohol 10 Water 81.14 Fragrance 1 0.665 Fragrance 2 0.335 Methylated Beta cyclodextrin 5 Polysorbate 20 2 Sodium Benzoate 0.2 Hydrochloric Acid (1 molar) 0.56 Tetrasodium EDTA 0.1
[0149] The method of manufacture was as in Example 1.
[0150] While particilar embodiments of the present invention have been illustrated and described, it would be obvious to those skilled in the art that variouis other changes and modifications can be made without departing from the spirit and scope of the invention. It is therefore intended to cover in the appended claims all such changes and modifications that are within the scope of this invention. | Compositions and personal care articles are described comprising a complexed perfume and a coating material which acts to retain the perfume in the complexed state and to keep out other competing materials. | 0 |
All publications and patent applications mentioned in this specification are incorporated herein, in their entirety, by reference to the same extent as if each individual publication or patent application was specifically and individually indicated to be incorporated by reference.
FIELD OF THE INVENTION
The present invention relates, generally, to management of Bowden-type cables in articulating instruments or snake-like robots. More particularly, the present invention relates to managing Bowden-type cables to reduce or eliminate catastrophic permanent lateral plastic deformation (also referred to herein as kinking or herniation) of these cables in articulating instruments or snake-like robots.
BACKGROUND OF THE INVENTION
The forms of robots vary widely, but all robots share the features of a mechanical, movable structure under some form of control. The mechanical structure or kinematic chain (analogous to the human skeleton) of a robot is formed from several links (analogous to human bones), actuators (analogous to human muscle) and joints permitting one or more degrees of freedom of motion of the links. A continuum or multi-segment robot is a continuously curving device, like an elephant trunk for example. An example of a continuum or multi-segment robot is a snake-like endoscopic device, like that under investigation by NeoGuide Systems, Inc., and described in U.S. Pat. Nos. 6,468,203; 6,610,007; 6,800,056; 6,974,411; 6,984,203; 6,837,846; and 6,858,005. Another example of a snake-like robotic device is shown and described in U.S. Patent Publication US2005/0059960 to Simaan, et al.
Snake-like robots often use Bowden cables to transfer forces from an actuator to particular sections or segments of the snake-like robot to effect articulation of that section or segment. Multiple, simultaneous articulations of the snake-like robot require the Bowden cables to go through multiple tortuous paths. One challenge faced by the practitioner is that Bowden cables can herniate under overloading conditions and axial loads placed upon them as a result of articulation. Various embodiments of the present invention address this issue.
SUMMARY OF THE INVENTION
An embodiment of the present invention is a system for managing the transmission of force to articulate an elongate device or snake-like robot. The system, of this embodiment, has an elongate body comprising a plurality of articulatable segments. The system includes a plurality of coil pipes, where each coil pipe is fixed at its proximal end relative to an actuator, at its distal end relative to a proximal portion of one of the plurality of articulatable segments, and where the coil pipes extend along each segment in a spiral pattern. A plurality of tensioning members is provided, where the tensioning members are housed in the plurality of coil pipes. The proximal end of each tensioning member is coupled to the actuator, and the distal end extends out the distal end of the coil pipe and is coupled to the articulatable segment to which the distal end of the coil pipe is fixed. The coil pipe/tensioning member combination works like a Bowden cable. The tensioning of one or more of the tensioning members causes articulation of the articulatable segment. In an alternative embodiment of the present invention, the articulatable segments are constructed from at least two links and preferably at least four links jointed together. Preferably, the links are control rings, such as and without limitation vertebrae, and the joints are hinges between the vertebrae. In an alternative embodiment the spiral pattern comprises an approximate integral number of approximately full turns along each of the plurality of articulatable segments, and preferably approximately one full turn.
In an alternative system for managing the transmission of force in an articulating device, the system comprises an elongate body have a plurality of articulatable segments. Bowden cables are coupled at a proximal end to an actuator and at a distal end to a proximal portion of one of the articulatable segments. Actuation of one or more of the Bowden cables causes the articulation of one or more of the segments to which the Bowden cables are coupled. The Bowden cables extend along each segment in a spiral pattern.
In another embodiment coil pipes are constructed from approximately round wire, D-shaped wire or are centerless ground. A D-shaped coil pipe that is less susceptible to herniation or axial overloading, in accordance with an embodiment of the present invention, can comprise D-shaped wire coiled, around a mandrel, for example, into a pipe shape. The wire used to make this embodiment of coil pipe has a cross-section having two approximately parallel approximately flat sides, a convex side and a concave side approximately parallel to said convex side. Preferably, the concave side of the wire of a first coil approximately nests with the convex side of the wire in a second adjacent coil, and the approximately parallel flat sides form an interior and an exterior of the coil pipe. The convex and concave sides can have an approximately curved shape, such as and without limitation a portion of a circle. Alternatively, the convex and concave sides can have an angular shape, such as and without limitation a V-shape. Alternatively, the wire can have a square or rectangular cross-section. A coil pipe can also comprise approximately circular cross-section wire coiled, around a mandrel for example, into a pipe shape. In a further embodiment of the present invention the pipe shape is ground or otherwise has material removed to form approximately parallel exterior flat sides, thereby forming a centerless ground coil pipe.
BRIEF DESCRIPTION OF THE DRAWINGS
The novel features of the invention are set forth with particularity in the claims that follow. A better understanding of the features and advantages of the present invention will be obtained by reference to the detailed description below that sets forth illustrative embodiments, in which the principles of the invention are utilized, and the accompanying drawings.
In the drawings:
FIG. 1 depicts an endoscope in accordance with an embodiment of the present invention;
FIG. 2 depicts an embodiment of a steerable distal portion or a controllable segment of an endoscope in accordance with the present invention;
FIG. 3 depicts a schematic diagram of either a steerable distal portion or a controllable segment of an endoscope in accordance with the present invention;
FIG. 4 depicts embodiments of vertebrae-type control rings in accordance with an embodiment of the present invention;
FIG. 5 depicts a schematic of how to arrange coil pipes and tendons relative to actuators and an articulatable segment or tip;
FIG. 6 provides a graphic for explaining static radial frictional forces between tendons and coil pipes in an embodiment of the present invention where the coil pipes are not spiraled;
FIG. 7 depicts a schematic of advancing an endoscope in a colon in accordance with an embodiment of the present invention;
FIG. 8 depicts a schematic of an undesirable bell-shape bend of a coil tube;
FIG. 9 depicts an embodiment of a coil pipe made with circular cross-section wire and a herniation of the coil pipe;
FIG. 10 depicts a centerless ground coil pipe in accordance with an embodiment of the present invention;
FIG. 11 depicts a coil pipe made with “D-shaped” wire in accordance with an embodiment of the present invention, and various embodiments of how to make “D-shaped” wire;
FIG. 12 depicts an illustration of coil pipe spiraled along a segment in accordance with an embodiment of the present invention;
FIG. 13 provides a graphic for explaining static radial frictional forces between tendons and coil pipes in an embodiment of the present invention where the coil pipes are spiraled;
FIG. 14 provides a schematic for describing one alternative for spiraling of coil pipes along a segment in accordance with an embodiment of the present invention; and
FIG. 15 depicts an alternative embodiment of a steerable distal portion or a controllable segment.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 depicts endoscope 10 , a colonoscope in particular, in accordance with an embodiment of the present invention. Endoscope 10 has elongate body 12 with steerable distal portion 14 , automatically controlled proximal portion 16 , and flexible and passively manipulated proximal portion 18 . The skilled artisan will appreciate that automatically controlled proximal portion 16 may also be flexible and passively manipulated, although it is preferred to provide automatically controlled proximal portion 16 . The skilled artisan will also appreciate that elongate body 12 can have only steerable distal portion 14 and automatically controlled portion 16 . Fiber optic imaging bundle 20 and illumination fiber(s) 22 may extend through elongate body 12 to steerable distal portion 14 , or video camera 24 (e.g., CCD or CMOS camera) may be positioned at the distal end of steerable distal portion 14 , as known by the skilled artisan. As the skilled artisan appreciates, a user views live or delayed video feed from video camera 24 via a video cable (e.g., wire or optical fiber, not shown) or through wireless transmission of the video signal. Typically, as will be appreciated by the skilled artisan, endoscope 10 will also include one or more access lumens, working channels, light channels, air and water channels, vacuum channels, and a host of other well known complements useful for both medical and industrial endoscopy. These channels and other amenities are shown generically as 26 , because such channels and amenities are well known and appreciated by the skilled artisan.
Preferably, automatically controlled proximal portion 16 comprises a plurality of segments 28 , which are controlled via computer and/or electronic controller 30 . Such an automatically controlled endoscope is described in further detail in commonly assigned U.S. patent application Ser. No. 10/229,577 (now U.S. Pat. No. 6,858,005) and Ser. No. 11/750,988, both previously incorporated herein by reference. Preferably, the distal end of a tendon (more thoroughly described below) is mechanically connected to a each segment 28 or steerable distal portion 14 , with the proximal end of the tendon mechanically connected to actuators to articulate segments 28 or steerable distal portion 14 , which is more fully described below and in U.S. patent application Ser. No. 10/229,577 (now U.S. Pat. No. 6,858,005) and Ser. No. 11/750,988, both previously incorporated herein by reference. The actuators driving the tendons may include a variety of different types of mechanisms capable of applying a force to a tendon, e.g., electromechanical motors, pneumatic and hydraulic cylinders, pneumatic and hydraulic motors, solenoids, shape memory alloy wires, electronic rotary actuators or other devices or methods as known in the art. If shape memory alloy wires are used, they are preferably configured into several wire bundles attached at a proximal end of each of the tendons within the controller. Segment articulation may be accomplished by applying energy, e.g., electrical current, electrical voltage, heat, etc., to each of the bundles to actuate a linear motion in the wire bundles which in turn actuate the tendon movement. The linear translation of the actuators within the controller may be configured to move over a relatively short distance to accomplish effective articulation depending upon the desired degree of segment movement and articulation. In addition, the skilled artisan will also appreciate that knobs attached to rack and pinion gearing can be used to actuate the tendons attached to steerable distal portion 14 . An axial motion transducer 32 (also called a depth referencing device or datum) may be provided for measuring the axial motion, i.e., the depth change, of elongate body 12 as it is advanced and withdrawn. As elongate body 12 of endoscope 10 slides through axial motion transducer 32 , it indicates the axial position of the elongate body 12 with respect to a fixed point of reference. Axial motion transducer 32 is more fully described in U.S. patent application Ser. No. 10/229,577, previously incorporated herein by reference.
In the embodiment depicted in FIG. 1 , handle 34 is connected to illumination source 36 by illumination cable 38 that is connected to or continuous with illumination fibers 22 . Handle 34 is connected to electronic controller 30 by way of controller cable 40 . Steering controller 42 (e.g., a joy stick) is connected to electronic controller 30 by way of second cable 44 or directly to handle 34 . Electronic controller 30 controls the movement of the segmented automatically controlled proximal portion 16 , which is described more thoroughly below and in U.S. patent application Ser. No. 11/750,988, previously incorporated herein by reference.
Referring to FIG. 2 , steerable distal portion 14 and segments 28 of automatically controlled proximal portion 16 are preferably constructed from a plurality of links 46 . Five links 46 are shown in this example for the sake of clarity, although the skilled artisan will recognize that any number of links may be used, the ultimate number being primarily defined by the purpose for which segments 28 or steerable distal portion 14 will be used. Each link 46 connects one joint (e.g., 47 ) to an adjacent joint (e.g., 47 ). Each link 46 , in this embodiment, can move with two degrees of freedom relative to an adjacent link.
Referring now to FIG. 3A-C a schematic diagram of either steerable distal portion 14 or segments 28 is provided for discussion purposes and to explain a preferred system and method for articulating steerable distal portion 14 or segments 28 . The skilled artisan will recognize that the system and method for articulation is the same for both steerable distal portion 14 and segments 28 of automatically controlled proximal portion 16 . Therefore, the system and method for articulation will be described referring only to segments 28 , with the recognition that the description also applies equally to steerable distal portion 14 . It is noted that details relating to links 46 , joints 47 and the interconnections of the links have been eliminated from this figure for the sake of clarity.
FIG. 3A shows a three-dimensional view of segment 28 in its substantially straight configuration. The most distal link 46 A and most proximal link 46 B are depicted as circles. Bowden cables extend down the length of elongate body 12 (not shown in FIGS. 3A-C ) and comprise coil pipes 48 and tendons 50 . The proximal end of the Bowden-type cable is coupled to an actuator (not shown) and the distal end is coupled to the segment for which it controls articulation. Coil pipes 48 house tendons 50 (i.e. a Bowden-type cable) along the length of elongate body 12 (not shown in FIGS. 3A-C ) and coil pipes 48 are fixed at the proximal end of segment 28 . Tendons 50 extend out of coil pipes 48 at the proximal end of segment 28 along the length of segment 28 , and are mechanically attached to the distal portion of segment 28 . It will be appreciated that the distal end of tendons 50 need only be attached to the segment being articulated by that tendon 50 at a location required to transfer the actuated force to that segment to effect articulation; the distal portion of the segment is provided by way of explanation and example, and not by way of limitation. In the variation depicted in FIG. 3A-C four tendons 50 are depicted to articulate segment 28 , but more or fewer may be used. The coil pipe/tendon combination, or Bowden cables, can be used to apply force to articulate segments 28 and can be actuated remotely to deliver forces as desired to articulate segments 28 . In this manner, actuation of one or more tendons 50 causes segment 28 to articulate. In the embodiment depicted, links 46 have joints 47 alternating by 90 degrees (see FIGS. 2 and 4 ). Thus, an assembly of multiple links 46 is able to move in many directions, limited only by the number of actuated joints. As will be appreciated by the skilled artisan, tendons 50 can be made from a variety of materials, which is primarily dictated by the purpose for which the endoscope will be used. Without limitation tendons 50 can be made from stainless steel, titanium, nitinol, ultra high molecular weight polyethylene, the latter of which is preferred, or any other suitable material known to the skilled artisan.
In the variation depicted in FIG. 3A-C , four tendons 50 are used to articulate segment 28 , although more or fewer tendons could be used, as will be appreciated by the skilled artisan. Four tendons can reliably articulate segment 28 in many directions. Tendons 50 are attached at the most distal link 46 A, for the purposes of this discussion but not by way of limitation, close to the edge spaced equally apart at 12, 3, 6, and 9 O'clock.
FIG. 3B-C show segment 28 articulated by independently pulling or slacking each of the four tendons 50 . For example, referring to FIG. 3B , pulling on tendon 50 at the 12 O'clock position and easing tension on tendon 50 at the 6 O'clock position causes steerable distal portion 28 to articulate in the positive y-direction with respect to the z-y-x reference frame 52 . It is noted that the most distal z-y-x coordinate frame 52 distal rotates with respect to the z-y-x reference frame 52 and that β is the degree of overall articulation of segment 28 . In this situation β is only along the positive y-axis, up, because only tendon 50 at the 12 O'clock position was pulled while easing tension or giving slack to tendon 50 at 6 O'clock. The tendons 50 at 3- and 9 O'clock were left substantially static in this example, and, thus, had approximately no or little affect on articulation of segment 28 . The reverse situation (not depicted), pulling on tendon 50 at the 6 O'clock position and slacking or easing the tension on tendon 50 at the 12 O'clock position results in articulation of segment 28 in the negative y-direction, or down. Referring to FIG. 3C the same logic applies to articulate segment 28 in the positive x-direction (right) or a negative x-direction (left, not shown). Segment 28 can be articulated in any direction by applying varying tensions to the tendons off axis, e.g., applying tension to the tendons at 12 O'clock and 3 O'clock results in an articulation up and to the left.
Referring now to FIG. 4 , links 46 may be control rings to provide the structure needed to construct steerable distal portion 14 and segments 28 . FIG. 4A shows a first variation of a vertebra-type control ring 54 that forms segments 28 or steerable distal portion 14 . FIG. 4B shows an end view of a single vertebra-type control ring 54 of this first variation. In this embodiment each vertebra-type control ring 54 define a central aperture 56 that collectively form an internal lumen of the device, which internal lumen is used to house the various access lumens, working channels, light channels, air and water channels, vacuum channels, and a host of other well known complements useful for both medical and industrial endoscopy. Vertebrae-type control rings 54 have two pairs of joints or hinges 58 A and 58 B; the first pair 58 A projecting perpendicularly from a first face of the vertebra and a second pair 58 B, located 90 degrees around the circumference from the first pair, projecting perpendicularly away from the face of the vertebra on a second face of the vertebra opposite to the first face. Hinges 58 A and 58 B are tab-shaped, however other shapes may also be used.
Referring briefly to FIG. 5 , tension applied to tendon 50 by actuator 60 is isolated to a particular segment 28 by use of coil pipe 48 housing tendon 50 , as previously described. Referring back again to FIG. 4A , vertebra-type control ring 54 is shown with four holes 60 through the edge of vertebra-type control ring 54 that may act as, e.g., attachment sites for tendon 50 , as a throughway for tendon 50 in other vertebrae-type control rings 54 (links) of that particular segment 28 and/or attachment sites for coil pipes 48 when vertebra-type control ring 54 is the most proximal link in segment 28 . The skilled artisan will appreciate that the number of tendons 50 used to articulate each segment 28 or tip 14 determines the number of holes 60 provided for passage of tendons 50 .
The outer edge of vertebra-type control ring 54 in the variation depicted in FIG. 4A-B may be scalloped to provide bypass spaces 62 for tendons 50 and coil pipes 48 that control more distal segments 28 or tip 14 , and that bypass vertebra-type control ring 54 and the present segment 28 . These coil pipe bypass spaces 62 , in this variation of the vertebrae-type control ring 54 , preferably conform to the outer diameter of coil pipes 48 . The number of coil pipe bypass spaces 62 vary depending on the number of tendons, and, therefore, the number of coil pipes needed to articulate all the segments 28 and steerable distal portion 14 . It will be appreciated that not all vertebrae-type control rings 54 of a particular segment 28 need to have coil pipe bypass spaces 62 . As described further below, intermediate vertebra-type control rings 54 ′ ( FIG. 4C ) between segments need not have coil pipe bypass spaces 62 , rather the coil pipes can simply pass through the lumen formed by central aperture 56 ′. In this alternative, the lumen formed by central aperture 56 ′ house the various access lumens, working channels, light channels, air and water channels, vacuum channels, as described above, as well as coil pipe/tendon combinations that do not control that particular segment.
FIG. 4D-E show another variation of vertebra-type control ring 64 in sectional and perspective views. In FIG. 4D-E , tendons 50 and coil pipes 48 that bypass a segment may be contained within body 66 ( FIG. 4D ) of vertebra-type control ring 64 in an alternative coil pipe bypassing space or quadrant 68 , rather than the scallops 62 along the outer edge of vertebra-type control ring 54 as previously described. Quadrants 68 are the preferred way to handle coil pipes 48 that must by-pass a segment. Vertebra-type control ring 64 of FIG. 4D-4E show four coil pipe bypassing spaces/quadrants 68 , but more or fewer may be used. It will be appreciated that cross bar 57 can pivot at hinge points 59 in one embodiment or may fixed relative to body 66 . Other aspects of this variation of vertebra-type control ring are similar to that described above and are, accordingly, called out with the same reference number. It is noted that tie-off rods 104 can be used to tie off the distal ends of tendons 50 in this embodiment.
The skilled artisan will appreciate that coil pipes 48 by-passing a vertebrae via quadrants 68 will define an approximately cylindrical coil pipe containment space roughly defined by the outer diameter of vertebrae-type control ring 64 . This space is loosely defined by the grouped coil pipes as they pass through and between the vertebrae. As described more thoroughly below, it is possible and preferred to have intermediate vertebra-type control rings without coil pipe bypassing spaces, as shown in vertebra-type control ring 54 ′ ( FIG. 4C ) or 65 ( FIG. 4F ). In either construction, central aperture 56 or 56 ′ of the control rings collectively forms a lumen (not shown) through which channels and cables necessary or desired for the endoscope function pass, as well as coil pipes and tendons by-passing that particular segment. Preferably, more proximal segments will have larger diameter vertebrae in order to provide larger quadrants 68 or central aperture 56 or 56 ′ to accommodate a larger number of coil pipes 48 that must reach the more distal segments 28 and tip 14 . The more distal segments 28 and steerable distal portion 14 can be constructed with vertebrae-type control rings 64 or 65 having a smaller diameter, thereby making the distal portions of elongate body 12 have a smaller diameter. While this is preferred, the skilled artisan will recognize that any diameter vertebrae may be used limited only by the need to accommodate the coil pipes and tendons necessary to articulate segments 28 and steerable distal portion 14 of the endoscope.
Referring again to FIG. 5 , coil pipes 48 are fixed at their distal and proximal ends between actuators 60 and the proximal end of segment 28 under control by those actuators. FIG. 5 shows only one segment 28 (which, as discussed, could also be steerable distal portion 14 ), and, for clarity, the other parts of a complete endoscope have been omitted from FIG. 5 . When tendons 50 are placed under tension, the force is transferred across the length of segment 28 ; coil pipes 48 provide the opposite force at the proximal end of the segment being articulated in order to cause the articulation. This force is, primarily, a compression force or axial loading transferred along the length of the coil pipe where it is fixed between the actuator and the proximal end of the segment being articulated. A preferred embodiment of the present invention utilizes one actuator per tendon, and utilizes four tendons per segment, as described above, although only one actuator 60 is depicted for clarity. Details relating to actuator 60 and connecting actuator 60 to tendons 50 are described in U.S. patent application Ser. No. 10/988,212, previously incorporated by reference.
The skilled artisan will appreciate that articulation of multiple segments 28 along the length of elongate body 12 will require that many coil pipes 50 extend down the length of elongate body 12 and through coil pipe by-passing spaces, with the number decreasing by four coil pipes (in this example) at the proximal end of each segment. Thus, a 17 segmented elongate body (16 segments 28 and 1 tip 14 ) requires 68 coil pipes going into the proximal end of elongate body 12 , which decreases by four coil pipes for each distally adjacent segment 28 (assuming one uses four tendon/coil pipes combinations per segment as in the present example). It also requires the actuation or tensioning of 68 tendons, with four tendons terminating at the distal end of each segment. This requires 68 actuators in this preferred embodiment, one actuator per tendon 50 .
The skilled artisan will also appreciate that there is not a one to one correspondence between the force applied by actuators 60 at the proximal end of tendons 50 and the force realized at the distal end of tendons 50 to articulate segment 28 . When elongate body 12 is in its substantially straight configuration, friction between tendons 50 and coil pipes 48 results in frictional losses along the length of the coil pipe while applying tension to articulate a segment or the tip. Articulation of segments 28 and steerable distal portion 14 results in further losses and inefficiencies for many reasons. For example, and without limitation, when elongate body 12 articulates (for example at the Sigmoid colon during a colonoscopy procedure), coil pipes 48 must move longitudinally along elongate body 12 to either “gain” or “lose” length depending whether coil pipes 48 are on the inner or outer portion of the bend created by the articulation. As described above, an embodiment of the present invention provides quadrants 68 or coil pipe by-passing spaces 62 that permit the passage of coil pipes 48 along elongate body 12 until they reach the proximal portion of the segment they control. The “gain” or “loss” of coil pipe length requires coil pipes 48 to slide up and down elongate body 12 and within quadrants 68 or coil pipe by-passing spaces 62 creating further frictional losses by virtue of friction between the coil pipes and/or between the coil pipes and the vertebra. There is also the additional friction created between a coil pipe and a tendon by virtue of the bend.
Frictional losses caused by the coil pipe/tendon bending (by virtue of a segment bending) reduce the working force available to articulate segments. The frictional loss is dependent on the material coefficient of friction and the accumulated bend (total tortuosity) of the coil pipe/tendon as elongate body 12 moves through a tortuous path. Total tortuosity is the amount of accumulated bend along the length of a coil pipe, which is closely approximated by the amount of accumulated bend along the length of that portion of elongate body 12 through which the coil pipe travels. For example an S-bend through the Sigmoid colon would contribute approximately 2×90° or 180° to the total tortuosity. As a segment bends coil pipes/tendons within that segment will also bend. The tendon tension applies a normal load towards the center of curvature of the coil pipe, as depicted in FIG. 6 that graphically depicts a coil pipe going through a 180 bend around a column.
Referring to FIG. 6 , the static friction for coil pipes extending down the length of elongate body 12 can be represented by the following balanced equations, where θ is the total tortuosity. Delta_F is constant with a given load L on either tendon. Note there are at least three sources of friction: (1) friction between the tendons and the coil pipe; (2) friction between the coil pipes and the ring structures; and (3) friction between the individual coil pipes.
∫
-
π
/
2
π
/
2
Delta_F
*
cos
(
θ
)
ⅆ
θ
=
2
*
L
;
(
units
of
Delta_F
are
in
force
/
angle
)
Delta_F
*
[
sin
(
π
/
2
)
-
(
sin
(
-
π
/
2
)
)
]
=
2
*
L
;
Delta_F
*
[
1
-
(
-
1
)
]
=
2
L
Delta_F
=
L
Having found Delta_F, the general normal cable loading is F N =Delta_F*θ=L*θ. The static radial friction is, therefore, F r (θ)=F N *μ=Delta_F*θ*μ=L*θ*μ (μ is coefficient of friction). Note that this equation has been solved for an ideal, hypothetical situation where the coil pipe is bent around a hypothetical column and static equal load is place at either end of the tendon going through the coil pipe. The same analysis applies for the static friction between a coil pipe and ring structures of a segment, where L is the given external load on the coil pipe. The solution is the same, but will have different loads (L) and different coefficients of friction (μ). This is a reasonable model to assess the static frictional loads for a coil pipe going through a segment comprised of vertebra-type ring structures having a total tortuosity of θ. Therefore, the static friction force for 180 degrees of accumulated tortuosity (two ninety degree bends or an S-bend, for example) is F r (π)=π*L*μ. The calculation for brake free forces and dynamic resistance loads is more complicated but can also be solved with an exponentially decaying resistance load.
Additionally, but related, elongate body 12 may enter more than one tortuous bend simultaneously. Referring to FIG. 7A-B , this occurs when, for example and without limitation, performing a colonoscopy with an embodiment of the present invention elongate body 12 must move through a highly tortuous path. Electronic controller 30 , in a preferred embodiment, controls the articulation of each segment 28 to take the shape of adjacent segments or tip as elongate body 12 is advanced through a tortuous path, such as the colon. Referring to FIG. 7A , a user articulates steerable distal portion 14 to select a desired path, through the Sigmoid colon S for example (an approximate S-bend or 180 degrees of total tortuosity), and then advances the endoscope through the anus A. Electronic controller 30 knows the shape of segments 28 and steerable distal portion 14 prior to the advancement of elongate body 12 into the colon, as described more thoroughly in U.S. patent application Ser. No. 11/019,963, previously incorporated herein by reference. Electronic controller 30 causes adjacent segments to adopt the shape of the segment or steerable distal portion immediately preceding it. Therefore, upon advancing elongate body 12 through the colon C, electronic motion controller 30 will maintain the approximate tortuous S-shape of the Sigmoid colon S in elongate body 12 by automatically controlling segments 28 to adopt the approximate shape of the immediately preceding segment. This follow-the-leader technique is further described in U.S. patent application Ser. No. 11/019,963, previously incorporated herein by reference. As described above, coil pipes 48 need to slide along elongate body 12 to accommodate the “gain” or “loss” of coil pipe length resulting from the articulation of elongate body 12 . Recall from the equation above that the frictional force is proportional to both total tortuosity and the material coefficient of friction. There are two coefficients of friction of interest, one for the tendon against the internal lumen of the coil pipe, and the other for the coil pipe against the vertebra-type ring structures.
Referring to FIG. 7B , when steerable distal portion 14 of elongate body 12 enters into a second tortuous bend, at the splenic flexure F 1 of the colon for example, coil pipes 48 need to accommodate the “gain” or “loss” of coil pipe length for both the new bend in the splenic flexure F 1 and for the first S-bend at the Sigmoid colon S. As the user advances elongate body 12 into the transverse colon T electronic controller 30 continues to maintain the bends at the splenic flexure F 1 and the Sigmoid colon S. However, coil pipes 48 need to slide the entire length of elongate body 12 (as described above), including through the first tortuous proximal bend in the Sigmoid colon S, and the second tortuous more distal bend in the splenic flexure F 1 to accommodate for the “loss” and “gain” of coil pipe length.
It was found that coil pipes 48 did not have the ability to slide along the length of elongate body 12 when in such a tortuous state. Without wishing to be bound by any particular theory, the inventors believe that the frictional forces between the coil pipes and the vertebra-type ring structures bind the coil pipes and they are unable to slide along the length of elongate body 12 . Referring to FIG. 8 , catastrophically the coil pipe exits the coil pipe containment boundary (discussed previously) in a severe bell-curve type shape 70 , or adopts severe bends (not shown) within the coil pipe containment boundary. This bell-curve bend 70 and/or other severe bends in coil pipes 48 dramatically increases friction between coil pipes 48 and tendons 50 , and also stiffens the segments requiring greater forces to achieve the desired articulation than would otherwise be required without the bell-curve or other severe bends in the coil pipes. As the segments having bell-shape curve 70 and/or other severe bends in coil pipe 48 straighten, the excess coil pipe length is no longer required to accommodate the bend in that particular segment of elongate body 12 . Therefore, coil pipe 48 moves back into the coil pipe containment area and/or the other severe bends begin to straighten as the bend in segment 28 begins to straighten, but in doing so coil pipe 48 frequently herniates. The skilled artisan will appreciate that herniation of the coil pipe can be caused by a variety of mechanisms. Moreover, the skilled artisan will appreciate that bell-curve shape 70 or other severe bends can occur anywhere along the length of elongate body 12 , and the location of such bends is not limited to the bending segments. A herniation, as will be described more fully below, is a permanent or plastic lateral deformation of the coil pipe. The primary cause of a herniation is believed by the inventors (without wishing to be bound by any particular theory) to be the result of the coil pipes binding (i.e. inability to slide or significantly reduced ability to slide) along the length of elongate body 12 .
Referring to FIG. 9 , coil pipes 48 are typically made of circular cross-section high tensile strength wire 72 wound in a tight coil to form a hollow pipe-like structure. The larger the tensile strength the more difficult it will be to make the material plastically deform. In a preferred embodiment high tensile 302 , 303 or 304 VT SST was specified with a tensile strength greater than about 40,000 PSI. In a herniated coil pipe 48 H ( FIG. 9B ) at least one of the coils 74 is permanently, laterally displaced, thereby significantly decreasing the effective diameter through which tendon 50 may pass. This results in a concomitant catastrophic increase in the frictional losses caused by friction between the coil pipe and the tendon passing therethrough. This lateral displacement also significantly reduces column strength of the coil pipe, thereby significantly reducing the ability to articulate a segment. In addition to significantly reducing the amount of force delivered by tendon 50 to articulate the segment or tip, the additional friction will prematurely wear out tendon 50 .
Without wishing to be bound by any particular theory, the inventors believe that the coil pipes rubbing on the vertebrae (or other ring structure) as the coil pipes re-enter the coil pipe containment area or otherwise straighten cause lateral forces on the coil pipes, which cause the coil pipes to resist axial movement or bind leading them to herniate. The inventors further hypothesize, again without wishing to be bound by any particular theory, that the ridges 76 ( FIG. 9A ) of the coiled wire 72 bump along the vertebrae or ring structure as the coil pipes re-enter the coil pipe containment area or otherwise straighten creating additional forces on the coil pipe structure. This is further exacerbated, again without being bound by any particular theory, by the bell-shaped curve or other severe bends separating the coils similar to the bending of a spring, thereby making the ridges more pronounced.
FIG. 10 depicts an embodiment of centerless ground coil pipe 78 in accordance with an embodiment of the present invention. As described above coil pipes 48 slide along the length of elongate body 12 as segments 28 articulate along a tortuous path. Adding lubricity between coil pipes 48 is, therefore, desired. However, using a lubricant, such as oil or other substance, is not highly desired because, at a minimum, the lubricant wears out making more frequent service of the endoscope necessary. Centerless ground coil pipe 78 is essentially the same as coil pipe 48 described above, but approximately half the diameter of coil wire 72 (shown in shadow) on either side of centerless ground coil pipe 78 is ground away or removed to create the centerless ground coil pipe 78 . The opposing flat sides 80 provide increased lubricity between coil pipes as they slide up and down elongate body 12 , and also provide increased lubricity as “excess” coil pipe length slides back into the coil pipe containment area or otherwise straightens. The skilled artisan will appreciate that any appropriate lubricant may also be used in combination with the centerless ground coil pipes, although this is not preferred. The inventors found that this solution did not sufficiently resolve the binding and ultimate herniation of the coil pipes. The inventors hypothesize that the design is sound, but the less preferred outcome of the solution resulted from the difficulty in reliably manufacturing centerless ground coil pipes with substantially opposing substantially flat sides.
In accordance with an alternative embodiment of the present invention FIG. 11A depicts D-shaped coil pipe 82 made from D-shaped wire 84 . In this embodiment convex portion 90 of D-shaped wire approximately nests in concave portion 92 of D-shaped wire ( FIG. 11A ). D-shaped wire 84 can be manufactured in a number of ways as will be appreciated by the skilled artisan. In one embodiment, referring to FIG. 11B , round wire 72 is rolled by first roller 91 or “Turkshead die” into an approximate oval shape 93 and the wire is rotated approximately 90 degrees and fed into second roller 94 or “Turkshead die.” Second roller 94 creates the concave shape 92 and convex shape 90 at opposite ends of the parallel substantially flat sides 86 created by first roller 91 . Alternatively, D-shaped wire can be formed by extrusion or by pulling a fully annealed or soft wire through one or more dies as shown in FIG. 11C . First, wire 72 is pulled through die 92 to obtain an approximately oval shaped wire 96 . Oval shaped wire 96 is then pulled through die 98 to provide the concave shape 92 and convex shape 90 at opposite ends of the parallel substantially flat sides 86 . The wire is then hardened to hold a set shape as in a coil pipe. The skilled artisan will appreciate that dies 95 and 98 can be a single die and that orientation of the die or rotation of the wire is a matter of manufacturing choice. This would also be true with the orientation of first and second rollers discussed above.
Manufacture of D-shaped coil pipe 82 with D-shaped wire is similar to the manufacture of coil pipe made with circular wire. Referring to FIG. 11D , the main difference is that D-shaped wire 84 needs to be oriented with one of the flat sides 86 against mandrel 88 . Preferably, the convex portion 90 of the “D” approximately nests into the concave portion 92 of the “D” as the D-shaped wire is wound onto the mandrel to form the coil pipe.
Nesting convex portion 90 into concave portion 92 provides for a higher surface area contact between wires of each coil than a coil pipe manufactured with circular cross section wire, particularly when the coil pipe is under compressive stresses. Additionally, the sides of convex portion 90 and concave portion 92 provide resistance against herniation upon application of lateral forces. Like the centerless ground coil pipe 78 , D-shaped coil pipe 82 also provides increased lubricity by virtue of substantially flat portions 86 of D-shaped coil pipe 82 . D-shaped coil pipe 82 worked better than centerless ground coil pipe 78 in preventing herniations, and is therefore more preferred over centerless ground coil pipe 78 . Additionally, the manufacturability of D-shaped coil pipe 82 is more consistent than that of the centerless ground coil pipe 78 , which adds to the preference of D-shaped coil pipe 82 . Furthermore, orienting coil pipe 48 to grind off or flatten the sides to achieve centerless ground coil pipe 78 can prove challenging, as discussed above. The skilled artisan will appreciate that shapes of wire other than D-shaped may be used in accordance with the present invention. For example the concave and convex portion of D-shaped coil pipe 82 may have any geometrical shape that can nest together. These may include, without limitation, V-shaped coil pipe 94 ( FIG. 11E ). Furthermore, an alternative embodiment, though not preferred, could be square or rectangular cross-section wire oriented to have flat sides against each other, as shown in FIG. 11F , which also will provide resistance against herniation upon application of lateral forces. Additionally, a benefit of using Bowden-type cables made from coil pipes is that they are flexible even when under compressive load. D-shaped coil pipes also remain very flexible under high compressive loads.
FIG. 12 depicts a preferred alternative embodiment for managing the coil pipes that reduces or eliminates the herniation problem by reducing or eliminating the need for the coil pipes to slide along the entire length of elongate body 12 . As described above, coil pipe 48 must slide up or down the entire length of elongate body 12 to accommodate a bend in a segment. Referring to FIG. 12 , spiraling coil pipes 48 along elongate body 12 and segments 28 significantly reduces and effectively eliminates the herniation problems identified above. Without wishing to be bound by any particular theory, the inventors hypothesize that the spiraled coil pipe localizes the movement or slacking of the coil pipes to an area at or close to the segment undergoing articulation. Therefore, again without wishing to be bound by any particular theory, when a segment articulates the spiraled coil pipe moves within or near a segment locally, thereby reducing or eliminating the need for the coil pipe to slide up or down the entire length of the elongate body. An analogy, again without wishing to be bound by any particular theory, would be a rope or cable made of spiraled strands bending over a pulley; the gain and loss of length of the individual strands in the rope takes place locally at the point of the bend around the pulley, because the strands alternate from the outside to the inside of the bend; the inside strand section gives what the outside strand needs.
The inventors observed that the spiraled coil pipes did not exit the coil pipe containment area in bell shaped curves or exhibit other extreme bends as described above, and they observed little to no herniation of the coil pipes. Spiraling the coil pipes will reduce or prevent herniation with D-Shaped, centerless ground or circular wire coil pipes as well. However, circular wire coil pipes are preferred for ease of manufacturing reasons.
The main benefit with using a spiraled structure identified by the inventors is reduced friction between a coil pipe and vertebra-type ring structures by virtue of the elimination or reduction of sliding of the coil pipes along the elongate body. There is a relatively smaller increase of frictional forces resulting from the increase of overall length of coil pipe through which a tendon must pass, and an increase of overall tortuosity as a result of spiraling the coil pipes along elongate body 12 .
The static friction from a spiral loading differs from that of radial loading described above. Tendon tension, as described for radial loading, applies a normal load toward the center of curvature and results in static radial friction of F r (n)=μ*L*μ for 180 degrees of total tortuosity. Static radial loading for a spiraled coil pipe can be solved and calculated in the same fashion. It is noted that because, as hypothesized by the inventors, spiraling localizes coil pipe movement to a segment undergoing a bend friction for coil pipes sliding against vertebra-type ring structures is reduced or eliminated. Referring to FIG. 13 , cable load L is assumed to be the same at both ends of the spiral. Balanced equations follow, where γ is the spiral angle and θ is, again, total tortuosity, which as noted is increased by virtue of the spiral:
∫
-
π
/
2
π
/
2
Delta_F
*
cos
(
θ
)
ⅆ
θ
=
2
*
L
*
sin
(
γ
)
;
units
of
Delta_F
are
in
force
/
angle
Delta_F
*
[
sin
(
π
/
2
)
-
(
sin
(
-
π
/
2
)
)
]
=
2
*
L
*
sin
(
γ
)
;
Delta_F
*
[
1
-
(
-
1
)
]
=
2
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L
*
sin
(
γ
)
Delta_F
=
L
*
sin
(
γ
)
Having found Delta_F the general normal cable loading is F N =Delta_F*θ*sin(γ)=L*θ*sin(γ). The static radial friction is, therefore, F r (θ)=F N *μ=Delta_F*θ*sin(γ)*μ=μ*L*θ*sin(γ). Note that this equation has been solved for an ideal, hypothetical situation where the coil pipe is spiraled around a hypothetical column 180° and static equal load is place at either end of the tendon going through the coil pipe. This is a reasonable model to assess the static frictional loads for a coil pipe spiraling through a segment comprised of vertebra-type ring structures. It must be recalled, however, that total tortuosity is now increased as a result of the spiraling.
Total tortuosity is the sum of all angles of bends in a coil pipe from its proximal end assuming the coil pipes are not spiraled along the elongate body. However, as will be appreciated, the spiral angle γ adds to the total tortuosity, but under larger (high degree of) bends of a segment the amount of tortuosity added by for small spiral angles (γ) is approximately the same as that of a non-spiraled embodiment undergoing the same multiple bends, so long as the spiraling is not excessive. Excessive spiraling with large spiral angle γ or wrapping the coil pipe too many times around a segment has a deleterious affect for several reasons. One reason is that the increased number of wraps dramatically increases the length of the coil pipe, thereby increasing the friction between the coil pipe and the tendon. More importantly, the overall tortuosity θ increases to an unacceptable level with the increased number of wraps (which proportionally increases the static friction) and spiral angle, i.e., friction added (F r ≈*L*θ*sin(γ)) increases directly with spiral angle. The inventors reasoned that too much spiraling would result in the detriment of increased friction by virtue of the increase of total tortuosity (θ) out weighing the benefit of reducing or eliminating binding. Numerically the inventors determined that a single 360 degree spiral, or approximately one wrap along each segment is the preferred amount of spiraling. It was determined empirically and numerically that approximately one 360 degree spiral wrap per segment of approximately 10 cm along the elongate body reduced or eliminated the need for the coil pipe to slide between segments to accommodate a bend, thereby reducing or eliminating herniation, and that this benefit far outweighed any increase of friction resulting from the amount of tortuosity added by the spiraled coil pipes. It was also determined numerically that an integral number of spiral wraps was preferred to ensure localization of coil pipe movement during the bending of a segment. The skilled artisan will appreciate the amount of spiraling or wraps used will depend on the system and the purpose for which the system will be used. It will also be appreciated that the spiral angle (γ) need not be constant along the length of a segment.
Referring back to FIG. 4D-F , in an embodiment of the present invention, quadrants 68 of vertebrae type control ring 64 are used to maintain coil pipes 48 spiraled along elongate body 12 . In this embodiment more than one vertebra-type control ring 64 in a segment has quadrants 68 , and the coil pipes are passed through the quadrants to established the preferred approximately one spiral wrap per segment. In another preferred embodiment, referring briefly to FIG. 15A , distal (not shown) and proximal vertebrae-type control rings 64 of each segment have quadrants 68 , and intermediate vertebrae-type control rings 65 do not have quadrants 68 . In this preferred embodiment the quadrants are approximately longitudinally aligned, and coil pipes are passed through the aligned quadrants after spiraling within the intermediate control rings 65 to achieve the preferred approximately one spiral wrap. It will be appreciated that the number of coil pipes passing through the quadrants will be equally divided between the quadrants, although other configurations can be used. The skilled artisan will appreciate that many different configurations and mechanisms may be used to maintain the spiral along the length of elongate body 12 .
Referring to FIG. 14 , coil pipes 48 are routed through quadrants 68 (not shown) in proximal vertebra-type control ring 64 in segment 28 , through vertebra-type control rings 65 without quadrants in that segment, through quadrants 68 (not shown) in distal vertebra-type control ring 64 in that segment. The working channel, fiber optics cable, suction channel, video cable and the like (not shown) are routed through central opening 56 of vertebra-type control rings 64 and through the lumen (along with the coil pipes) created by intermediate vertebra-type control rings 65 without quadrants. The vertebrae 64 with the quadrants are then rotated relative to each other to achieve the amount of desired spiraling of the coil pipes, the rotation being depicted graphically in FIG. 14B . Hinging of the vertebrae will maintain the spiral, as will be appreciated by the skilled artisan. As noted, approximately a full spiral wrap of 2π per segment 28 is preferred, but the skilled artisan will appreciate that the number of wraps will depend on the purpose for which the device will be used. As will also be appreciated, only four coil pipes are depicted with the other details of the segments and endoscope being omitted from FIG. 14 for purposes of clarity. It is noted that the skilled artisan will appreciate many different configurations of vertebra-type control rings with and without quadrants can be used to achieve the desired spiraling.
As noted, at least one vertebra control ring 64 with quadrants 68 is used per segment and preferably two to maintain the preferred spiral structure of the coil pipes by-passing that segment, and that the remaining vertebra-type control rings of that segment do not have quadrants. As discussed above, central opening 56 of vertebra-type control ring 64 provides a location for passing working channels, optical cables and the like through vertebra-type control ring 64 and quadrants 68 provide a separate by-pass space for coil pipes not controlling articulation of that particular segment, and for maintaining the spiral structure of the coil pipes. The remaining control rings 65 of a segment have no by-pass space. Rather, the coil pipes, the working channel, air line, water line, suction line, optical cables and the like all pass through the central lumen created by central opening 56 ′ ( FIG. 4F ) of vertebra-type control rings 65 by aligning vertebra-type control rings 65 , and are not separated by quadrants 68 as in vertebra-type control rings 64 .
Referring again to FIG. 15 , tendons 50 controlling a particular segment are kept separate from the spiraled coil pipes, the working channel, air line, water line etc. by intermediate ring structures 100 attached at the hinge between control rings 65 not having quadrants 68 . These intermediate ring structures 100 ( FIG. 15B ) are situated between vertebra control rings 65 . Four holes 102 are shown in ring structure 100 through which tendons 50 controlling articulation of that segment run. More holes may be used per tendon depending on how force is applied to the segment via the tendon(s), and the total number of holes depends on the number of tendons 50 used to control the segment, tour in this example. In the proximal vertebra-type control ring 64 having quadrants 68 , holes 60 are where coil pipes controlling that segment terminate and are fixed. As described above, tendon 50 extends out of the coil pipe and along the segment through holes 100 and then terminate at the distal end of the segment at tie off rods 104 of the distal vertebra-type control ring 64 . The skilled artisan will recognize that tendon 50 controlling a particular segment need only terminate somewhere within that segment such that force can be effectively transferred to and along that segment to effect articulation.
This preferred embodiment has the advantage of, at least, (1) spiraling the coil pipes along the length of the elongate body, as described above, and (2) providing relatively unconstrained space in vertebra-type control rings 65 without quadrants 68 intermediate to vertebra-type control rings 64 having quadrants 68 , such that coil pipes can move locally and relatively unconstrained to accommodate articulation of that particular segment. The inventors believe, again without wishing to be bound by any particular theory, that this permits the coil pipes to move locally and accommodate the bend in a segment without having to slide the entire length of the elongate body, thereby not binding the coil pipes and the concomitant reduction or elimination of herniations in the coil pipes.
The skilled artisan will appreciate there are many different ring structures and many different ways to achieve the desired spiral structure of coil pipes. For example, and without limitation, the coil pipes could be spirally arranged in scalloped by-pass spaces 62 in the outer edge of vertebra-type control ring 60 ( FIG. 4A-B ), although this is less desirable because it moves the coil pipes further away from the desired longitudinal centerline of elongate body 12 , and these spaces have more friction than when the coil pipes are passed through quadrants 68 or the center 65 of vertebrae. Additionally, the skilled artisan will appreciate that quadrants 68 can exist in more than one vertebra-type control ring 64 within a segment, and that more or fewer than four quadrants can be used. The skilled artisan will appreciate how to orient quadrants on one vertebra relative those on an other vertebra(e) having quadrants within a segment and along the elongate body to achieve the desired spiral arrangement of coil pipes.
The foregoing description, for purposes of explanation, used some specific nomenclature to provide a thorough understanding of the invention. Nevertheless, the foregoing descriptions of the preferred embodiments of the present invention are presented for purposes of illustration and description and are not intended to be exhaustive or to limit the invention to the precise forms disclosed; obvious modification and variation are possible in view of the above teachings. | The present invention relates, generally, to the reduction or elimination of permanent and catastrophic herniations in Bowden cables or coil pipes in articulating devices or snake-like robots. More particularly, the present invention relates managing the coil pipes in a spiral pattern along the articulating device or snake-like robot to reduce or eliminate the necessity of the Bowden cables or coil pipes to slide along the length of the articulating device or snake-like robot. Reduction or elimination of the necessity for the Bowden cables or coil pipes to slide reduces or eliminates catastrophic herniations in articulating devices or snake-like robots undergoing one or more articulations. | 5 |
RELATED APPLICATIONS
[0001] This application claims priority to a provisional patent application, Application No. 60/398,101, filed Jul. 25, 2002, entitled, “Method and System for Providing Filtered Advertisements Over the Internet,” still pending.
FIELD OF THE INVENTION
[0002] This invention relates to systems for and methods of filtering and masking advertising over a system of distribution partners over the Internet.
BACKGROUND OF THE INVENTION
[0003] Many content-based Internet sites enter exclusive advertising arrangements with a specific advertiser, so that the Internet site is precluded from also distributing or displaying advertisements for competitors of that specific advertiser. The specific advertiser usually pays a premium to the Internet site for such exclusivity rights. The content-based Internet site generally enters these relationships with long-term advertisers who are valuable customers of the Internet site. However, an Internet site generally generates revenue from advertising and usually would like to generate as much revenue as possible from placing other non-exclusive advertisements on its Internet site.
[0004] Over the Internet, one way for a website to generate advertising revenue without having to develop its own advertising infrastructure is to receive advertisement listings from a listings provider, such as one that maintains the infrastructure to place and rank advertisement listings. Such arrangements present problems for the content-based Internet site because the ads received from the listing provider could violate its exclusivity arrangement(s).
[0005] This problem may preclude the listings provider from being able to sell its services to some Internet sites and similarly may preclude an Internet site from being able to utilize the listings server to generate revenue for its site. These and other drawbacks exist with current systems and methods.
SUMMARY OF THE INVENTION
[0006] Various embodiments of the present invention relate to methods and systems that allow an Internet distribution partner of an advertisement listings provider to receive filtered and/or masked listings for display on the website of the Internet distribution partner. This system and method allows the Internet distribution partner to define characteristics of advertisement listings to be received by the Internet distribution partner in one or more filters. The characteristics may specify the features of the advertisement it desires, the features of advertisements to be excluded or various combinations thereof. Once the characteristics of advertisement listings are defined, the advertisement listings provider system applies those characteristic(s) to the listings in its database and identifies matches and/or excludes matches depending on the characteristic(s) specified. The advertisement listings provider may then send the Internet distribution partner advertisement listings based on the application of one or more filter(s) selected by the distribution partner. Thus, the advertisement listings provider and the Internet distribution partner are able to generate additional revenue without risking the Internet distribution partner's valuable relationships with its exclusive advertisers and without jeopardizing the Internet advertising distribution partner's relationships with its end users.
[0007] Also, each distribution partner may specify several filters and may, on its own, alter the filter to be applied by the advertising listings partner based on time of day, experimenting to determine effectiveness of different filters, the source page where the listings are to be provided and any other factor it chooses. Moreover, in current systems, distribution partners request the listings through HTTP “GET” command. Through one embodiment of the present invention, a filter identification code (e.g., an alphanumeric code) is supplied with the parameters of the GET command, resulting in a minimal addition to the size of its request and requiring little reprogramming of the distribution partner's website to request that the filter be applied.
[0008] Many advantages of such a system are achieved. Particularly, for an advertising listing provider that is open to all advertisers and whose advertisers may be constantly changing, it would be virtually impossible to have a human monitor outgoing advertisements to distribution partners to ensure that any exclusivity arrangements are not going to be violated. The system of the present invention allows the advertising listings provider to preclude such violations without regard to changes to the advertisements in its database.
[0009] Aside from violating exclusivity arrangements, many other reasons exist for why a distribution partner's website may wish to exclude certain advertisements or only include certain advertisements from a rapidly changing database of advertisement listings. Operators of one website may believe that its readers are predisposed to be offended by certain advertisements and may therefore create a filter to exclude offensive advertisement by “keyword” exclusion. Operators of another website may believe that only advertisements related to a specific topic may be of interest and may thus create a filter accordingly. Various combinations may be selected, such as excluding all advertisements containing keyword A and requiring that all advertisements include keyword B.
[0010] The filters created may be keyword-based, URL based, topic-based or any other metric known about an advertisement in the source database from which advertisements are generated from the advertisement listings provider system.
[0011] In addition to filters, the advertisement listings provider may define a plurality of masks that mask out advertisements in predetermined categories. An Internet advertising distribution partner may thus specify masks, filters, or combinations thereof to ensure that it receives the advertising content that best suits its purposes. According to one embodiment, a mask may be subject matter based and each advertisement listing recorded in the advertising database provided by the advertisement listings provider may be specified as to whether it falls within one of those predetermined categories. For example, five different masks may be defined—a vice ad mask, an adult/sexual ad mask, a gambling ad mask, a non-FDA drug ad mask and a psychic ad mask. By specifying one or more of those mask values, the advertising distribution partner may indicate that they do not wish to receive any advertisements that relate to any type of a vice (e.g., smoking, drinking, gambling, sex, etc.), adult or sexual advertisements, gambling, non-FDA drugs, or ads relating to psychics, respectively.
[0012] Other advantages of the various embodiments of the present invention will be appreciated from a review of the detailed description that follows.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] [0013]FIG. 1 is a schematic diagram of a system of providing filtered advertisement listings to at least one Internet advertising distribution partner in an embodiment of the present invention.
[0014] [0014]FIG. 2 is an example of a database containing multiple advertisement filters defined by Internet advertising distribution partners according to an embodiment of the present invention.
[0015] [0015]FIG. 3 is a flowchart showing a process for an Internet distribution partner to receive filtered advertisement listings from an advertisement listings provider according to an embodiment of the present invention.
[0016] [0016]FIG. 4A is an example of outputted advertisement listings that may be delivered to an Internet advertising distribution partner without any filters applied; FIG. 4B is an example of outputted advertisement listings that may be delivered to the same Internet advertising distribution partner with filter 1 applied.
[0017] [0017]FIG. 5 is an example of listings provided to an advertising distribution partner in response to a request from an advertising listings provider according to an embodiment of the present invention.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0018] Various embodiments of a filter-based advertisement distribution system are described below. An overview of the system 10 is depicted in FIG. 1.
[0019] [0019]FIG. 1 is a schematic diagram of a system that enables filtered advertisement listings 100 to be provided to at least one Internet advertising distribution partner 105 in an embodiment of the present invention. In the present embodiment, at least one advertisement provider 110 submits its advertisement listings to the advertisement listings provider 120 . In the present embodiment two (2) advertisement providers 110 are shown, although it is understood that any number of advertisement providers 110 may submit advertisement listings 115 to an advertisement listings provider 120 . Moreover, an individual advertisement provider 110 may submit more than one advertisement listing 115 to advertisement listings provider 120 . An advertisement listing 115 may include all or part of the following information fields, some of which are supplied by the advertising provider and some of which are stored by the advertising provider (e.g., the advertisement ID number): the name of the advertisement provider, a title of the advertisement, a description of the goods or services advertised, a URL to be displayed in the listing, where an end user will be directed upon clicking on the advertisement, contact information, an email address, billing information, pricing information, and an advertisement identification number.
[0020] In an embodiment of the present invention, the advertising listing provider 120 may rank the advertisement listings submitted (e.g., by keyword, subject or otherwise) and store the ranked listings in a database server 125 . The rank that an advertisement listing 115 is assigned may depend upon the bid the advertisement provider 100 offers the advertisement listings provider 120 for a “click-through.” For example, the price may be a flat rate for placement or a price per end Internet user 135 who selects the advertisement, often referred to as price-per-click through. Also, the ranking may be based on a revenue model as disclosed in co-pending application No. 60/406,064, filed Aug. 27, 2002, entitled “Method and System for Providing Advertising Listing Variance in Distribution Feeds over the Internet,” the entirety of which is hereby incorporated by reference. The advertisement listing 115 may contain a hyperlink so that when an end Internet user 135 may select the advertisement, and be redirected to a predetermined website defined in the advertisement listing 115 .
[0021] An Internet advertising distribution partner 105 may maintain a website. An end Internet user 135 may access that website via an http connection. The Internet advertising distribution partner 105 may have an agreement with an entity to place its predetermined advertisement listings on its website and not to place advertisement listings of other predetermined competitors. For example, an Internet advertising distribution partner 105 such as CNN (www.cnn.com) may have an agreement with Barnes and Noble to place a Barnes and Noble advertisement listing on its website. That agreement may also require that CNN not place any advertisements for Amazon.com on its website. Thus, CNN may wish to receive supplemental advertisement listings 110 to increase its revenue without receiving any advertisements for Amazon.com.
[0022] According to an embodiment of the present invention, CNN, an Internet advertising distribution partner 105 , may send the advertisement listings provider 120 a filtered listings request 130 . The filtered listings request 130 may direct that certain predefined filters stored in the database server 125 be applied such as by using a filter identifier. Also, it should be understood that the filters may be stored in another location, or the filters may not be stored at all, but defined each time a filter listings request 130 is generated. In the latter example, the filter may identify the characteristics the Internet advertising distribution partner 105 wishes to include or exclude from the advertisement listings 115 received.
[0023] Upon receiving a filtered listings request 130 , the advertisement listings provider 120 may send a listings request 140 to the database server 125 . In one embodiment of the present invention, the filtered listings request may be a single http GET command that requests listings and requests a filter to be applied. The database server 125 may return available listings 145 . These listings 145 may or may not be ranked. The advertisement listings provider 120 may then apply the requested filter and send filtered listings 100 to the Internet advertising distribution partner 105 . The Internet advertising distribution partner 105 may then dynamically include information from the filtered listings 100 in its website content delivered to end Internet user(s) 135 .
[0024] A distribution advertising partner 105 may generally transmit a filtered listing request 130 for each request of a webpage to contain the filtered listings 100 due to the dynamically changing content of listings, rankings, etc. It should be appreciated that advertising distribution partner 105 may cache the filtered listings to reduce the number of requests to advertisement listings provider 120 . The cache may be used for minutes, hours, etc., as desired.
[0025] Internet advertising distribution partner 105 may comprise a website and any structure, software and network connections to implement that functionality. End Internet users 135 may connect using an Internet-compatible device. Similarly, advertisement providers 110 may connect to advertisement listings provider 120 using any Internet-compatible device. Database server 125 may comprise any data storage system accessible and usable with an Internet-based server system such as advertisement listings provider 120 . Variations to the systems shown in FIG. 1 may be made as known those or ordinary skill in the art, such as by enabling some of the network connections to be made over a network other than the Internet or making connections secure or non-secure as deemed appropriate. As described above, the advertisement and filters may be stored in database server 125 .
[0026] End Internet user 135 may view the filtered listings 100 on the website of the Internet advertising distribution partner 105 . In this particular embodiment, there are two (2) Internet advertising distribution partners 105 shown. However, it should be understood that any number of Internet advertising distribution partners 105 may be incorporated into the present invention. Additionally, there are two (2) end Internet users 135 shown in this embodiment. However, it should be understood that any number of end Internet users 135 may receive filtered listing from each Internet advertising distribution partner 105 .
[0027] [0027]FIG. 2 is an example of multiple advertisement filters defined by Internet advertising distribution partners and stored in a database. An Internet advertising distribution partner 105 may desire to increase revenue by adding advertisement listings onto their website. The Internet advertising distribution partner 105 may receive monetary compensation for each click-through from their website to the advertiser's website in a preferred embodiment. However, the Internet advertising distribution partner may have an exclusive arrangement with a seller of books, Barnes and Noble for example, which precludes that Internet advertising distribution partner 105 from advertising for any other sellers of books on the website. Thus, in one embodiment of the present invention the Internet distribution partner 105 may wish to receive only listings which do not include “Amazon.com” in the URL.
[0028] One example filter database, as shown in FIG. 2, may include one or more of the following fields: filter number 200 , Internet advertising distribution partner 205 , filter type 210 , affirmative/negative 215 , filter characteristic 220 , filter creator 225 . The filter number 200 may be used as a storage and identity mechanism. Each filter may have a unique filter number 200 . The Internet advertising distribution partner 205 may represent the website or advertiser where the filtered listings may be delivered. The filter type 210 may identify what section of the advertisement listing to which the filter is to be applied to. Example filter applications include the text of the advertisement, the URL displayed, the URL to which the advertisement listing will direct the Internet end user, the title of the advertisement, or a content node of specific subject matter. The affirmative/negative 215 field may store whether the filter is to include or exclude the filter characteristic 220 , respectively. The filter characteristic 220 field may be used to store the particular text to be excluded. Moreover, the filter creator field 225 may identify the source of the filter. The filter creator 225 may or may not be the same entity as the Internet advertising distribution partner 205 . Other fields may be included in this database to store information relevant to placing an advertisement listing.
[0029] For example, filter number 1 may be applied to filter the advertisement listings provided to cnn.com. In this example, CNN may have a contract with Barnes and Noble which disallows it from placing advertisements for Amazon.com. Thus, filter 1 has a filter type 210 of URL and a affirmative/negative setting 215 of negative. This indicates that advertisement listings with a filter characteristic 220 of “Amazon.com” in the URL may be excluded from the filtered advertisement listings delivered to cnn.com. Filter number 1 has a filter creator 225 of Barnes and Noble. This indicates that Barnes and Noble is the source of the exclusion. Sometimes, the Internet advertising distribution partner itself may be the source of the filter. For example, filter number 2 may be applied to requests for advertisements from abc.com and may exclude advertisements with NBC in the URL, since NBC is a competitor of the Internet advertising distribution partner itself.
[0030] There may be other motivations for filtering the listings on an Internet site. For example, an Internet advertising distribution partner, such as www.disney.com may wish to be family friendly and may therefore wish to filter any listings with the word “sex” in any of the listing's text. Thus, as shown in filter number 6 , the Internet advertising distribution partner disney.com may submit a request for filtered listings to the advertisement listings provider with a negative filter type 210 of text, a filter characteristic of “sex” and filter creator 225 of the Internet advertising distribution partner, itself. In addition to filters, it may be desirable to also provide masks that generally exclude advertisements in certain predefined categories defined by the advertisement listing provider and/or advertising distribution partners. In such an embodiment, a series of masks may be identified by mask number. So, for example, a mask may be provided to exclude vice ads, adult/sexual ads, gambling ads, non-FDA drug ads, and psychic ads. In such an embodiment, the vice ad mask may be designated with a value of 1, the adult/sexual ad mask may be designated with a value of 2, gambling ad mask may be designated with a value of 3, the non-FDA drug ad mask may be designated with a value of 4, and the psychic ad mask may be designated with a value of 5. Also, it may be desirable to provide a certain number of bits to be able to enable the selection of an ad mask based on whether the bit value is 0 or 1. Accordingly, if there are five different masks, then a five bit code may be provided with each bit designating whether or not a particular mask is to be applied. So, in this embodiment, the vice ad may be assigned bit 1 , the sexual ad may be assigned bit 2 , the gambling ad assigned bit 3 , the non-FDA drug ad mask assigned bit 4 , and the psychic ad mask assigned bit 5 . So, for example, if an advertiser wished to mask out vice ads and psychic ads, it would provide a bit mask value of 10001.
[0031] An example of an affirmative filter is shown in FIG. 2 as filter number 3 . In this example, the Internet advertising distribution partner 205 , WebMD, may request advertisement listings which contain the word “health” in the text of the advertisement listing. This filter may be desirable so that the readers of the Internet advertising distribution partner 205 receive information relevant to their interests.
[0032] It should be understood that an Internet advertising distribution partner may store as many unique filters in the database as is desired. Moreover, an Internet advertising distribution partner may indicate which filters are to be applied in each filtered advertising request. Furthermore, the actual advertisement listings received by the Internet advertising distribution partner are determined by the particular filtered listing request submitted. Thus, a particular advertisement listing which is excluded by the application of a filter to one Internet advertising distribution partner may be delivered to other Internet advertising distribution partners.
[0033] It should also be appreciated that the advertisements in the database server 125 may be categorized based on keyword or subject with which the advertisement is associated. For example, advertisers may bid on keywords or subjects and therefore, the advertisement listings provider ranks advertisements based on bids for a given keyword or subject. Advertisements distribution partners then may request advertisements using the keyword or subjects by which the advertisements are categorized. The filter may then be applied to the ranked listing. In the CNN example above, CNN may request advertisement listings for its main “Sports” page from the advertisement listings stored in the advertisement listings provider associated with a keyword “sports.” CNN may then specify a filter to exclude advertisements made by ESPN by excluding all ranked listings which contain, in its text, the keyword “ESPN.”
[0034] Similarly, in the Sprinks System operated by the assignee of the present invention, advertisement providers may bid on subjects based on an hierarchical node-based system. A distribution partner may request ranked listings from a subject in such a system but request exclusion of any advertisement from a URL of a competitor. Other combinations of category-request and filter are all possible within the scope of the present invention.
[0035] While various methods may be employed within the scope of the present invention, one such method is depicted in FIG. 3 for a filter that excludes results. FIG. 3 is a flowchart showing a process for an Internet distribution partner to receive filtered advertisement listings from an advertisement listings provider according to one embodiment of the present invention. In step 300 of the process, an Internet advertising distribution partner may request listings from an advertisement listings provider. In step 305 of the process, the Internet advertising distribution partner may request one or more filters on the listings to be provided. In one embodiment of the present invention, the advertisement listings provider may then generate a ranked file of listings in its database in step 310 . In step 315 the advertisement listings provider may then compare the chosen filter fields to the fields in the database and identify matches in step 320 . The advertisement listings provider may delete the listings identified as matches from the rank file, but not from the database, and provide a filtered ranked file of listings to the advertising distribution partner in step 325 . The listings provider may notify the advertisement provider whose listing has been excluded, by the requested filter in step 330 . This step in the process is optional, because performing this step may discourage advertisement providers from paying greater amounts to increase their rankings. However, performing this step may inform the advertisement provider why their advertisement would not show up on certain web sites where the advertisement provider would expect to see their listing, instead of having the advertisement provider discover the omission on their own. In step 335 , an end Internet user may view the filtered listings while accessing the Internet web site of the Internet advertising distribution partner.
[0036] To better understand how the listings may be displayed by distribution partners, one example is depicted in FIGS. 4A and 4B. FIG. 4A displays a graphical user interface (GUI) with advertisement listings that may be delivered to an Internet advertising distribution partner without any filters applied. In this GUI, the Internet advertising distribution partner 405 , www.cnn.com, shows three advertisement listings 415 , 425 and 435 . In this example, the advertisement listings may be ranked in that order as a result of the price offered for listing the advertisements. For example, Barnes and Noble may be listed first as a result of an agreement from www.cnn.com not to place advertisements for Amazon.com. www.cnn.com desires to fill openings on its website for advertisement listings and thus may request advertisement listings from an advertisement listings provider to supplement its own advertising revenue. With the advertisement listings provider, Amazon.com may have offered 9 cents per click through for placement and The Weather Channel may have offered 3 cents per click through for placement. In the example shown in FIG. 4A no filters have been applied, thus all three advertisements appear in the following order: Barnes and Noble, Amazon.com, and The Weather Channel. If FIG. 4A were generated for end Internet users, www.cnn.com appears to have violated its contractual obligations to Barnes and Noble.
[0037] [0037]FIG. 4B is a GUI with advertisement listings that may be delivered to the same Internet advertising distribution partner with filter 1 from FIG. 2 applied. This filter would exclude any advertisement listings with “Amazon.com” in the URL. Thus, FIG. 4A shows that the advertisement for Barnes and Noble remains the first listed advertisement at 410 . The Amazon.com advertisement does not appear and in the second position, the Weather Channel advertisement listing has moved up to 420 . The third position is now occupied by and advertisement for TV Guide at 430 . Thus, with filter 1 applied, www.cnn.com is able to increase its potential for generating advertising revenue by supplementing its advertisement listings without breaching its contract with Barnes and Noble.
[0038] As discussed above, in one embodiment, the filter to be applied may be stored in association with the advertising listings provider 120 and identified by an identifier supplied by an Internet advertising distribution partner 105 . FIG. 5 is an example of the listings provided to an advertising distribution partner in response to an http GET command according to one embodiment of the present invention. In this example, the get request may be “http://get.about.com/xml_sprinks.txt?ref=shelley&type=g&term=dogs.” The “get.about.com” portion of the request identifies the advertisement listings provider's URL and directs where to send the request. In this example, “ref=shelley” identifies the Internet advertising distribution partner, so that the advertisement listings provider knows who is making the request and where to return the results. The “type=g” and “term=dogs” identify the category of listings desired within the database server. The GET command is instructing the advertisement listings provider to return listings based on bids for the “dogs.” In this case, the returned results may be limited to a listings associated with the “dogs” (term=dogs) content site (type=g) in the listing. If the Internet advertisement distribution partner wished to send a filtered listings request, the command may be http://get.about.com/xml_sprinks.txt?ref=shelley&type=g&term=dogs&f=0001.” “f=0001” indicates that the Internet advertisement distribution partner wishes to filter the rank file with the predefined filter number 1 , which may be stored in the advertisement listings provider database. The advertisement listings provider may access Internet advertising distribution partner shelley's filter number 1 from its database and apply the filter to the rank file. Any listings which are matches with the filter may be deleted from the rank file and the rank file may then be distributed to shelley via an http connection. If filter number 1 were predefined, for example to exclude any listings with a URL of “poochpillows.com,” then the rank file that would be delivered to shelley would exclude the first listing shown in FIG. 5. The listing which is listing number 2 in FIG. 5 would become listing number 1 in the rank file. If the advertising distributor partner also wished to specify a mask, the get request may be as follows: http.//get.about.com/xml_sprinks.txt?ref=shelley&type=g&term=dogs&f=0001&m=10001. This would specify that filter 1 was being applied as well as mask value 10001 as mentioned about which could mask out the vice ads and psychic ads from the content.
[0039] It should also be appreciated that multiple filters may be selected by an Internet advertising distribution partner and may be provided by specifying multiple filter values separated by the ampersand in the get http request.
[0040] While the foregoing description includes details and specificities, it should be understood that such details and specificities have been included for the purposes of explanation only, and are not to be interpreted as limitations of the present invention. Many modifications to the embodiments described above can be made without departing from the spirit and scope of the invention, as it is intended to be encompassed by the following claims and their legal equivalents. | Methods and systems that allow an Internet distribution partner of an advertisement listings provider to receive filtered and masked listings for display on the website of the Internet distribution partner. The Internet distribution partner defines filters to be applied to ranked advertising listings provided by an advertising listing provider. The advertisement listings provider system applies the filter to the listings in its database and identify matches and/or excludes matches depending on the characteristic specified. The advertisement listings provider may then send the Internet distribution partner advertisement listings based on the application of one or more filter selected by the distribution partner. Thus, the advertisement listings provider and the Internet distribution partner are able to generate additional revenue without risking the Internet distribution partner's valuable relationships with its exclusive advertisers and without jeopardizing the Internet advertising distribution partner's relationships with its end users. | 6 |
This is a continuation of application Ser. No. 07/937,303 filed on Aug. 31, 1992.
TECHNICAL FIELD OF THE INVENTION
This invention relates to a novel refrigerant mixture for use in refrigeration systems. The refrigerant is not harmful to the ozone layer, and is particularly applicable in systems such as automobile air-conditioning and home refrigeration.
BACKGROUND OF THE INVENTION
A continuing demand exists for a simple, inexpensive refrigerant which can be used to reduce the level of ozone damaging compounds which can escape and harm the earth's atmosphere. In particular, there exists a need for a simple, low cost refrigerant which can be used as a substitute for refrigerant R-12, also commonly known as dichlorodifluoromethane. At normal atmospheric pressure, R-12 boils a −21.7° F., thus, any substitute must have properties sufficiently comparable that equipment can be used without costly modification.
In addition to the undesirable ozone depletion consequences which have been widely reported, those familiar with refrigeration systems will also recognize that R-12 and other fluorchlorocarbon refrigerants can contribute to the formation of acids under as a result of decomposition in a refrigerant system. Formation of such acids is not uncommon, and when it occurs, severe damage to metal surfaces in a refrigerant system can result. Moisture in an R-12 based refrigeration system can contribute to such acid formation, as can use of contaminated lubricating oils.
For the most part, the R-12 substitutes which have been proposed have been various substituted hydrocarbons, utilizing addition of bromine or other atoms, primarily in an attempt to produce a non-flammable refrigerant. Such substitutes have their own problems, such as undesirable toxicological effects on exposed individuals.
SUMMARY OF THE INVENTION
I have now invented, and disclose herein, a novel, refrigerant mixture which does not have the above-discussed drawbacks common to the fluorchlorocarbon refrigerants heretofore used of which I am aware. Unlike the refrigerants heretofore available, my product is simple, relatively inexpensive, easy to manufacture, and otherwise superior to those heretofore used or proposed. In addition, it provides a significant, demonstrated improvement with regard to protection against release of ozone depleting compounds.
Another important feature is the fact that my novel refrigerant is not conducive to formation of undesirable acid compounds while in use in a refrigeration system. This provides a unique safety feature when compared to many previously known refrigerants.
My novel refrigerant mixture is essentially a 50-50 mixture of propane and butane. However, up to as much as 75% of propane, or alternately, butane, may be utilized.
My novel refrigerant differs from those prior art products mentioned above in one respect in that no substitution of hydrogen molecules by halogen or other species is required. In its simplest form, my invention is the discovery that a mixture of propane and butane will provide suitable properties for direct substitution in R-12 systems.
Thus, the dual advantages of protection of the ozone layer, and low cost of the commonly available gases propane and butane gases, become important and self-evident in direct refrigerant substitution applications.
OBJECTS, ADVANTAGES, AND FEATURES OF THE INVENTION
From the foregoing, it will be apparent to the reader that one important and primary object of the present invention resides in the provision of a novel, improved refrigerant which does not contribute to the destruction of the ozone layer.
Other important but more specific objects of the invention reside in the provision of a refrigerant which may be directly substituted in R-12 based refrigeration systems, and which:
can be manufactured in a simple, straightforward manner;
results in comparatively low cost refrigerant mixtures;
in conjunction with the preceding object, have the advantage that they can be widely used without cost penalty in selected refrigeration systems; and,
which provides a refrigerant gas mixture which is easy to use, install and remove.
Other important objects, features, and additional advantages of my invention will become apparent to the reader from the foregoing and the appended claims and as the ensuing detailed description and discussion proceeds in conjunction with the accompanying drawing.
BRIEF DESCRIPTION OF THE DRAWING
In the drawing:
FIG. 1 is a process flow diagram for an automobile refrigeration system, in which the present invention may be employed.
FIG. 2 is a process flow diagram for a refrigerator refrigerant circuit, showing the components of a typical residential refrigerator system.
DETAILED DESCRIPTION OF THE INVENTION
Widely utilized refrigerant systems which utilize R-12 include automotive and home refrigeration systems. Although the refrigerant mixture disclosed herein may be used with other types of refrigerant circuits, the invention will be disclosed with reference to several of the most commonly used types.
Turning now to FIG. 1, there is shown an automotive type refrigeration system 10 ; this type of system is commonly utilized to cool the passenger compartment of cars and trucks. Critical components of the refrigeration system 10 include the compressor 11 which is used to raise the pressure (and the temperature) of a circulating refrigerant 12 from the cold, low pressure suction side 14 to the high temperature, high pressure discharge side 16 . The refrigerant 12 pressure is raised so that it is capable of being condensed based at the internal temperature achievable in the condenser 18 . Actual operating temperatures and pressures will vary widely and may be reviewed in a variety of texts on refrigeration. However, for a convenient point of reference, when the outside air entering an automotive condenser is 100° F., the high pressure circuit may operate at about 220 to 270 psig, while the low pressure circuit may operate at about 20-30 psig. Thus, the low pressure circuit pressure corresponds to a temperature of the cold refrigerant of roughly 20 to 30° F. Refrigerant 12 vapors which are condensed in condenser 18 are passed through a receiver 20 , to accumulate the liquid refrigerant. The receiver may also include a desiccant (internal and not shown) for removal of water from the circulation refrigerant 12 , so as to minimize the tendency of the refrigerant to form harmful, normally acid decomposition products.
In order to allow the high pressure refrigerant 12 to enter the low operating pressure evaporator 22 , the refrigerant is metered through a thermal expansion valve 24 . The liquid refrigerant 12 is allowed to escape into the lower pressure evaporator 22 , and most of the refrigerant 12 will enter as a liquid to a pool 24 at the bottom of the evaporator 22 . As heat is introduced to the evaporator 22 (as via an airstream 26 passing through the air passageways 28 ), liquid refrigerant 12 boils and becomes low pressure vapor, and travels to the low pressure side suction side 14 of the compressor 11 , to repeat the process.
In most automotive type refrigeration systems, dichlorodifluoromethane (R-12) is used as the refrigerant. Unfortunately, this compound has been found to contribute to depletion of the upper atmospheric ozone layer. As a result, its use is being discontinued, as urged or as required by specific limitations in legislation in the United States and elsewhere.
I have found that a mixture comprised essentially of propane and butane can be directly substituted for R-12 in air-conditioning and refrigeration systems. Although the preferred composition is about 50% propane by liquid volume, with the remainder butane, the composition may be somewhat varied without encountering great difficulty. In fact, a mixture consisting essentially of up to about 75% propane, with the remainder butane, may be used. Preferably, as noted above, at least 50% propane may be used. In most cases, not less than 25% propane is desirable.
The aforementioned mixture is advantageous in that it does not contain halogen substituted molecules to cause problems such as acid formation and the resultant metal attack problems internal to the refrigeration circuit, as may be encountered with dichlorodifluoromethane. Also, both propane and butane are commonly available, at lower cost than most currently available refrigerants. Particularly in automotive applications, as set forth above, the flammable properties of propane and butane should not cause particular concern, in the quantities required for small refrigeration circuits, in view of the quantities of flammable fuel already successfully and safely transported on a regular basis.
My refrigerant mixture is also amenable for use in a home refrigerator system, such as is depicted in FIG. 2. A refrigerator 40 is shown having therein a compressor 42 , a condenser 44 , an expansion valve 46 , an evaporator 48 , and a low pressure vapor line 50 which returns to the compressor 42 . Operation of the system is similar to that set forth above for the automotive refrigeration system, and need not be repeated in detail as it will be quickly recognized by those skilled in the art and to whom this invention is addressed. For reference, it is common for R-12 based refrigerator systems to operate at about 120 psig on the high pressure side, and at about 0 psig on the low pressure side. As a 50-50 mixture of propane and butane will condense at about 75 psig, this mixture provides a change of state of the refrigerant within an ideal range.
I have now discovered that the refrigerant gas commonly used in home refrigerator systems, dichlorodifluoromethane (R-12) may be advantageously replaced by a propane-butane mixture, preferably containing about 50% butane and the rest essentially propane. Also, I have discovered that the refrigerant mixture of about 50% propane and about 50% butane is more energy efficient than utilization of an R-12 refrigerant in home refrigerators. The exact savings, however, will vary according to the mixture utilized and the size of the system, particularly the compressor.
Thus, it can be seen that I have developed and have set forth herein an exemplary refrigerant mixture, and a method for use of same in common refrigeration machinery. The material is of low cost, is easily prepared, and does not tend to produce harmful acid breakdown products in refrigeration systems. Further, the mixture is quite compatible with refrigeration oils, and can be safely used in refrigeration systems.
The invention may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. The present embodiments are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description; and all changes which come within the meaning and range of equivalences of the claims are therefore intended to be embraced therein. | A refrigerant mixture. The mixture of propane and butane may be advantageously used as a substitute for R-12, thus eliminating the use of ozone depleting R-12 refrigerant. Ideally, the mixture is comprised of approximately 50% propane and 50% butane by liquid volume. Alternately, the mixture may contain up to about 75% of either propane or butane. A refrigeration process utilizing the mixture is also disclosed. | 5 |
BACKGROUND OF THE INVENTION
The invention relates to improvements in powered roller conveyors and, in particular, to a novel drive sprocket arrangement for the rollers of such conveyors.
PRIOR ART
Power driven roller conveyors are used in process equipment for conveying materials such as wet slurrys, mats, and so forth, through dewatering and/or drying stations. By way of example, wet or water laden materials conveyed by such conveyors are processed into wall board, ceiling tile, and the like as is known in the art. Commonly, the rollers of the conveyor are each driven through a sprocket fixed to its shaft. The sprockets are typically driven by a common endless chain. The service conditions in which the sprockets operate are adverse, often with no practical way for sealing the materials being processed away from the sprockets and for lubricating the sprockets. The operating conditions typically result in a wear rate that requires replacement of the sprockets every year or so and, in any event, far more routinely than an entire conveyor is replaced.
Sprocket replacement is expensive in terms of both the cost of parts and labor. The sprockets typically occupy a crowded space and it is not easy to separate them from their respective shafts after they have been in service for any significant period. It is common for a mechanic to break the sprockets off, by striking blows with a hammer, rather than pulling them off, since it is difficult to grip them with a puller and it is not unusual for them to be tightly locked onto their shafts as a result of corrosion and the build-up of dirt and debris on the shafts.
SUMMARY OF THE INVENTION
The invention provides a novel sprocket arrangement for a powered roller conveyor useful in a hot air dryer or like processing equipment. The sprocket arrangement of the invention comprises mating hub and sprocket plate elements that allow ready replacement of the sprocket plate after its service life has been exhausted while allowing the hub to remain fixed on its associated roller shaft. The invention departs from the time honored practice of replacing worn out integrated sprocket and hub units. By only replacing that part of a sprocket and hub drive unit that experiences significant, and in practice, inevitable wear, the invention affords substantial savings in both material and labor.
Since only about half of the combined material of the sprocket and hub assembly is replaced, there can be significant savings in material costs. Moreover, the labor to replace a worn sprocket plate, in accordance with the invention, is considerably less than that involved in removing a prior art unitary sprocket and hub, typically frozen on to the roller shaft and difficult to reach because of obstructions posed by adjacent sprockets and other parts of the conveyor.
The disclosed sprocket plate and hub elements have unique mating configurations that allow the sprocket plate to apply torque to the hub through abutting surfaces that are generous in size and effective radius so as to transfer forces by low compressive stresses rather than at concentrated points by shear forces. In one embodiment, the torque coupling between the sprocket plate and hub is isolated from machine screws used to hold these components together. Consequently, these fastener elements or screws can be of moderate size, thereby saving costs and effort needed for their original assembly and eventual removal when a sprocket must be replaced. In another embodiment, the sprocket and hub are configured to be coupled together without separate fasteners.
The disclosed sprocket plate and hub arrangement solves a problem of removing a sprocket from an operational position where the hub has a maximum outside diameter larger than a minimum inside diameter of the sprocket plate.
Still further, in one disclosed preferred embodiment, the sprocket plate is configured as a ring with a large open center to permit it to be removed, when worn out, by slipping it over its associated roller thereby affording flexibility in the steps that can be taken for sprocket plate replacement. This flexibility in the manner in which the sprocket plate can be removed allows a mechanic to choose the easiest way, off either end of a roll assembly for its removal, while still avoiding the removal of the sprocket hub. The ring-like structure of a sprocket plate significantly reduces its material content over that compared with integrated sprocket and hub units thereby reducing the cost of manufacture of replacement parts.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a simplified fragmentary elevational view of a roller conveyor fitted with one embodiment of the sprocket arrangement of the invention;
FIG. 1A is an elevational end view of the relationship of a sprocket plate to its associated roller in the arrangement of FIG. 1 ;
FIG. 2 is a fragmentary plan view of the conveyor arrangement of FIG. 1 ;
FIG. 3 is a fragmentary exploded perspective view of the conveyor of FIG. 1 ;
FIG. 4 is a side elevational view of a sprocket plate in accordance with a second embodiment of the invention;
FIG. 5 is a cross-sectional view of a “half” sprocket plate taken in the plane 5 - 5 indicated in FIG. 4 ;
FIG. 6 is a cross-sectional view of a “full” sprocket plate taken in the plane 6 - 6 indicated in FIG. 4 ;
FIG. 7 is a side elevational view of a hub in accordance with the second embodiment of the invention;
FIG. 8 is an edge view of the hub of FIG. 7 ;
FIG. 9 is a side view of a sprocket and hub assembly in accordance with the second embodiment of the invention;
FIG. 10 is a fragmentary view, on an enlarged scale, of the sprocket and hub assembly where the sprocket plate is the “half” style of FIG. 5 ; and
FIG. 11 is a fragmentary view like FIG. 10 , showing the “full” style sprocket plate of FIG. 6 .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to the figures, there is shown a partial area of a roller conveyor 10 of the type used, for example, in dryers employed in the manufacture of drywall, particle, flake or chipboard, ceiling tile, and like products that are formed by drying a slurry or wet intermediate product. The conveyor 10 has cylindrical rollers 11 carried on respective concentric round shafts 12 mounted in bearings 13 as is conventional. Normally, a large number of rollers 11 are used in a conveyor but for simplicity only three are shown in the figures. It will be understood that a bearing 13 is provided at each end of each roller 11 . The rollers 11 are arranged parallel to one another in a common horizontal plane, typically, with a uniform center-to-center spacing. The rollers 11 can be mounted close to one another to adequately support the material being conveyed which is often in a weak state incapable of supporting itself across a significant span.
Ordinarily, in a typical dryer, there are several vertically spaced layers or decks of rollers 11 . The rollers 11 of each level or deck are all driven in the same direction of rotation by a common chain 14 , which may be of the conventional roller type. Customarily, the chain 14 contacts only one or a limited number of teeth 16 of a sprocket 17 associated with a respective roller 11 at any given time. Usually, the rollers 11 of a level or deck are driven by a single chain at one side of the conveyor 10 .
The sprockets 17 , in accordance with the invention, are assemblies of a sprocket plate 18 on which are formed the teeth 16 , and a hub 19 that is mounted on a roller shaft 12 . As will be described, the sprocket plate 18 and hub 19 are specially configured to interfit or mate with one another for a positive rotational drive between these elements and, alternatively, for passage of the sprocket plate axially completely over the hub. More particularly, the sprocket plate 18 has a spider-like internal bore 21 while the hub has a complementary external spider profile, characterized by radially extending legs or spokes 22 that can fit through the bore.
Each hub 19 is preferably a metal body with a plurality of three internally radially extending legs or spokes 22 . The hubs 19 can be formed of any suitable material such as a ferrous metal like cast iron, cast steel, or hot roll steel. A bore 26 of the hub 19 is sized to fit the shaft 12 of a respective roller 11 which shaft typically is 1-¼ inch in diameter.
The sprocket bore 26 includes an internal keyway 27 for receiving a key 28 . The key 28 is also received in an external keyway in the shaft 12 as is conventional. A set screw 29 threaded into a radial hole 31 in the hub 19 locks against the key 28 and releasably fixes the hub 19 onto the shaft 12 .
The sprocket assemblies 17 along the conveying direction alternate between two constructions or styles, one 36 lying outside, with reference to a zone occupied by the rollers 11 , of an imaginary vertical plane passing through the middle width of the chain 14 , and the other 37 lying to the inside of this imaginary plane. In other words, the inside and outside designations of these sprocket assembly styles 36 , 37 is made with the understanding that parts on the side of the imaginary vertical mid-plane of the chain adjacent the rollers 11 are “inside” and parts on the other side of this imaginary plane are “outside”. To the extent that the features of the sprocket plates and hubs are the same or similar in shape or function, the same reference numerals will apply. The sprocket plates of both styles 36 , 37 have essentially the same axial profile, including number of teeth and outside diameter.
The sprocket assemblies 17 , as mentioned, are all driven in the same rotational direction so that their respective rollers 11 also revolve in this same direction. Adjacent leading edges of the hub legs or spokes 22 , with reference to their direction of rotation, are radially extending lugs or stops 41 . The lugs 41 are formed with abutment surfaces 42 that facing rearwardly with reference to their rotational direction, preferably lie in radial planes that are parallel to and pass through the center of rotation or axis of the hub 19 . The abutment surfaces 42 extend radially outward from an imaginary cylinder concentric with the hub axis and coincident with cylindrical surface segments 43 at the base or radially inward ends of the legs 22 . The abutment surfaces 42 terminate radially outwardly at cylindrical outer surface segments 45 of the legs 22 on a common imaginary cylinder concentric with the bore 26 and forming the major outside hub diameter.
The sprocket plates 18 have asymmetric unidirectional teeth 16 that are shaped to provide a positive drive from limited tangential engagement of the chain 14 . Tips 56 of the teeth 16 represent the outside maximum diameter of the sprockets 17 . The sprocket plates 18 have central bores 57 . Arcuate surface areas 58 of the bore 57 , represent a major diameter area and three intervening arcuate surface areas 59 represent the minor diameter of the bore 57 . The internal sprocket legs 23 are equally angularly spaced and form the minor diameter areas 59 at their inner ends. As seen, the legs 23 span the arcuate space between the major diameter arcuate surfaces 58 . Leading abutment faces 61 , with reference to the direction of rotation of the sprocket assemblies 17 , extend between the inside diameter and outside diameter bore surfaces 58 , 59 and preferably lie in flat planes that are radial to, pass through, and are parallel to a central axis of the sprocket plate 18 .
In the illustrated embodiment, the hub legs 22 of either sprocket style 36 or 37 , are three in number and the sprocket plate legs 23 are of the same number. The arcuate extent of each hub leg 22 is slightly less than an arcuate gap 44 between the internal legs or spokes 23 of the internal sprocket plate bore 21 . This arcuate geometry of the hub and sprocket plate legs as well as the limited radial extent of these legs results in an outer hub profile that is complimentary to and slightly smaller than the interior bore 57 of the sprocket plate thereby enabling a sprocket plate to pass completely over a hub.
A face 47 of the hub 19 lies in a flat radial plane transverse to the hub axis and serves as a seat or abutment surface against which the sprocket plate 18 is secured by machine screws 62 , 63 . The sprocket plates 18 are removably assembled on corresponding hubs with the axes of these elements coincident and held in place by a set of the machine screws 62 or 63 . In the case of the outside style of sprocket assembly 36 , the sprocket plate 18 is held to the hub 19 with socket head machine screws 62 threaded into the sprocket plate and in the case of the inside style of sprocket 37 the sprocket plate 18 is held to the hub 19 by flat head machine screws 63 threaded into the hub. The screws 62 , 63 , hold the respective sprocket plates 18 in abutting contact with the radial hub face 47 . It is this surface 47 from which the hub lugs 41 axially project. When mounted on a hub 19 , radial sprocket surfaces 61 abut the radial lug or abutment surfaces 42 enabling the torque developing forces imposed by the chain 14 to be transmitted to the hub with low compressive stresses imposed on these surfaces as a result of being relatively large and being disposed radially outwardly significantly from their rotational axis. Non-threaded clearance holes 66 , 67 , that receive the machine screws 62 , 63 in the hubs of the respective outside sprocket styles 36 or in the sprocket plates of the inside sprocket style 37 , ensure that the torque transmitted from the sprocket plate 18 to the hub 19 is isolated from the screws, it being understood that this torque is developed by the abutment surfaces 61 , 42 .
As seen in FIG. 2 , and as discussed, the inside and outside styles 37 , 36 of the sprocket assembly 17 can alternate along the feed direction of the conveyor 10 to permit a relatively large sprocket diameter to be used in proportion to the center-to-center distance of the shafts 12 . By offsetting the sprocket assemblies 17 to either side of a center plane of the chain 14 , the sprocket plate 18 of one assembly does not interfere with the sprocket 18 or hub 19 of an adjacent sprocket assembly even where, as shown, the center-to-center distance of adjacent shafts 12 is less than the combined radius of a sprocket and a radius of essentially any part of the sprocket hub on the adjacent shaft. This geometry thereby allows relatively large sprockets to be used and, in turn, reduces the forces required of the chain on the sprocket teeth to develop a given level of torque.
At least the sprocket plates 18 on the outer sprocket assemblies 36 , and preferably the sprocket plates on the inner sprocket assemblies 37 , are able to be passed completely over their associated hubs 19 for purposes of removal and replacement.
The sprocket plates 18 can experience relatively high wear rates due to their operating environment and from time-to-time may need to be replaced. Both the inside and outside sprocket plates can be changed without removal of their associated hubs. Moreover, removal and replacement of these plates can be readily accomplished because the machine screws 62 , 63 securing these plates on their respective hubs can be conveniently reached from the outside, i.e. the space outward of the chain 14 , with the convention that the conveyor rollers 11 are to the inside.
With the invention, replacing each of the sprocket plates 18 is a simple matter of removing three screws 62 or 63 , and separating the plate from its hub. The need for breaking the hub loose from its fit on a shaft 12 is eliminated. Prior to assembly, the screws 62 , 63 , can be coated with a suitable protective sealant so that the risk of corrosion in the threaded holes in the sprocket plate 18 , or hub 19 is reduced. The torque between the sprocket plate and hub developed by the chain force is transmitted between the radial abutment faces 42 and 61 and is preferably isolated from the screws by appropriately dimensioning the parts and especially as mentioned, the clearance holes. Typically, where desired, the shaft 12 can be lifted slightly for access to any of the machine screws 63 on the inside sprocket plates. FIG. 4 shows that a sprocket plate 18 can be removed by sliding it axially over the respective roller 11 . This optional method of removal is permitted where, as shown, the minor inside diameter of the sprocket plate is slightly larger than the diameter of the roller. This geometry can be used on the inside sprocket assembly 37 enabling the inside sprocket to be removed, for example, while the adjacent outside sprockets remain in place or can be used on both inside and outside sprocket assemblies for greater flexibility in maintenance or replace operations.
In many instances, the rollers 11 can be spaced apart far enough to allow the sprockets of each roller to be in-line, i.e. in a common plane without interference. In this case, the width or thickness of a sprocket plate can be double that shown in the figures, while still using the illustrated chain and the axial sprocket plate profile can be the same as that of the described and shown sprocket plates. Such a wide or full width sprocket plate is conveniently used with the inside sprocket style hub illustrated in FIG. 2 .
FIGS. 4-11 illustrate a second embodiment of a sprocket assembly 70 that has structure and function analogous to that of the assembly 17 described in connection with FIGS. 1-3 . The sprocket assembly 70 comprises a sprocket plate 71 and a hub 72 each of which is made from a suitable material such as steel or other ferrous metal. The sprocket plate 71 and hub 72 can be cast, stamped, forged, machined or otherwise made into their respective shapes as desired. The sprocket plate 71 has peripheral unidirectional teeth 73 , distributed about its geometric center, to cooperate with the roller chain 14 like that shown in FIGS. 1 and 3 . The hub 72 has a keyed cylindrical bore 74 with an associated set screw 76 for locking a key 77 onto a shaft such as the shaft 12 shown in FIGS. 1 and 3 . When assembled on the hub 72 , the ring-like sprocket plate 71 has its teeth 73 concentrically disposed about the axis of the bore 74 .
The hub 72 has a central core 78 with a generally circular exterior surface 79 concentric with the bore 74 and with a plurality of three equally angularly spaced legs 81 extending radially outwardly from this core surface 79 . The legs 81 have radially outer surfaces 82 lying on a common imaginary cylinder concentric with the bore 74 . Between the legs 81 are arcuate spaces 83 . As shown in FIGS. 8 , 10 and 11 , the legs 81 each have a slot 84 at mid-length in the axial direction of the bore 74 . Each hub leg slot 84 is open at one arcuate side of the leg 81 and adjacent the cylindrical surface 82 . Each slot 84 has a bottom 86 concentric with the bore 74 on a radius equal or larger than the radius of the core 78 . In an angular direction with respect to the axis of the bore 74 the slot 84 ends to form a generally radially oriented abutment surface 87 that can be semi-cylindrical or otherwise somewhat rounded, when viewed in a plane transverse to the radial direction, for ease of manufacture.
The sprocket plate 71 is ring-like in form and has a plurality of three radially inwardly extending equally angularly spaced legs 89 . The legs have inner surfaces 91 on a common imaginary cylinder concentric with the geometric center of the body of the sprocket plate 71 . Arcuate spaces or gaps 92 between each sprocket plate leg are larger in profile than the profile of a hub leg 81 . The sprocket plate legs 89 have leading edges 93 in a rotational sense that are generally radial with respect to the center of the sprocket plate 71 . As indicated in FIG. 5 , showing a sprocket of “half” thickness, the legs 89 lie in a plane that is offset from the plane of the peripheral teeth 73 a distance that preferably is at least equal to the thickness of the sprocket in the base area of the teeth. The spaces 92 are radially bounded by surfaces 94 lying on a common imaginary cylindrical surface concentric with the center of the sprocket plate 71 . The surfaces 94 form the major inside diameter or bore of the sprocket plate while the surfaces 91 form the minor inside diameter of the sprocket.
As the case with the sprocket and hub shown in FIGS. 1-3 , the major and minor inside diameters of the sprocket plate 71 are at least as large as the major and minor outside diameters of the hub 72 . This relationship, in addition to the gaps between the sprocket legs 89 being larger than the arcuate widths of the hub legs 81 enables the sprocket plate 71 to pass completely over the hub 72 .
The sprocket plate 71 is assembled on the hub 72 by angularly aligning its legs 89 with the hub spaces 83 and slipping it onto the hub until the plane of the legs 89 is coincident with the plane of the hub grooves or slots 84 . The sprocket plate 71 is then rotated relative to the hub 72 in a manner similar to a bayonet connection such that the sprocket plate becomes rotationally coupled to the hub with the radial edge abutment faces 93 on the sprocket legs 89 abutting respective end walls or abutment surfaces 87 at the arcuate ends of the hub slots 84 . The sprocket plate 71 can be releasably locked in position on the hub 72 with a roll pin 95 received in holes drilled through the hub and sprocket plate parallel to their axis.
FIGS. 5 and 10 illustrate a “half” width sprocket that can be used as described earlier where the roller shaft centers are close and inside and outside half width sprockets are alternately mounted from shaft-to-shaft. The sprocket of FIG. 5 can be an outside sprocket and a complementary inside sprocket can be configured as a mirror image of it. A “full” sprocket useful when the conveyor roller spacing is large is illustrated in FIGS. 6 and 11 . It is desirable to proportion the hub 72 widthwise in the manner shown such that its axial length is three times the nominal thickness of a half sprocket at the base of the teeth or 1-½ times the width of a full sprocket at the base of its teeth and it is symmetrical about a mid-plane perpendicular to the axis of the bore 74 . This length permits the hub 72 to be used with both inside and outside style sprockets without interference with an adjacent sprocket as well as with full width sprockets.
It will be understood that sprocket plates of the style illustrated in FIG. 4 can be readily removed from a hub for replacement while the hub remains locked on a shaft. Removal of a sprocket plate 71 only requires the roll pin 95 to be knocked out and the sprocket plate to be rotated in a reverse direction relative to the hub until its legs 89 are aligned with the spaces 83 between the hub legs 81 and then moved axially off of the hub.
It should be evident that this disclosure is by way of example and that various changes may be made by adding, modifying or eliminating details without departing from the fair scope of the teaching contained in this disclosure. For example, in the embodiment of FIGS. 1-3 , the sprocket plate can be retained against the hub by elements other than machine bolts such as a wedge or a horseshoe clip. The invention is therefore not limited to particular details of this disclosure except to the extent that the following claims are necessarily so limited. | A sprocket assembly for a roller conveyor comprising a hub and a sprocket plate, the hub having a central cylindrical bore for fitting onto a round shaft of a roller, the hub having provisions for rotationally and axially locking it on a shaft in a manner adequate to transmit torque to the shaft and rotationally drive the roller, the sprocket plate having peripheral teeth adapted to be interengaged with a drive chain and a central bore capable of receiving the shaft, the sprocket plate and hub being constructed and arranged to be removably joined together with the centers of their respective bores coincident, said hub and sprocket plate having complementarily shaped radially extending abutting surfaces enabling the sprocket plate to develop torque on the hub by compressive forces developed by the radially extending sprocket plate surfaces against the radially extending hub surfaces. | 5 |
CROSS REFERENCE TO RELATED APPLICATIONS
This is a continuation-in-part of U.S. application Ser. No. 08/866,192, filed May 30, 1997, now abandoned.
BACKGROUND OF THE INVENTION
The invention relates to hydrogen storage alloys for use in rechargeable batteries.
A battery typically includes one or more galvanic cells (i.e., cells that produce a direct current of electricity) in a finished package. In each cell, two electrodes are separated by an electron insulator, but are joined by an ion-carrying path. The electron-carrying path of the battery is external; the path proceeds, via a conductor, through a device where work is done. The ion-carrying path of the battery is internal and proceeds via an electrolyte.
The electrodes are usually composed of dissimilar metals. For discharge of a cell, the electrode where the electrolyte is broken down upon the receipt of electrons is the positive electrode, also referred to as the cathode. The electrode where the metal goes into solution, releasing electrons, is called the negative electrode, or anode. The electrolyte generally is composed mainly of an ionizable salt dissolved in a solvent.
Batteries may be rechargeable; such batteries are called “storage” or “secondary” batteries. Storage batteries can be recharged by passing current through the cells in the opposite direction of current flow on discharge. The chemical conditions of the battery are restored, and the cells are ready to be discharged again. Primary batteries, on the other hand, are meant to be discharged to exhaustion once, and then discarded.
An example of a rechargeable battery is a metallic oxide-hydrogen storage battery. The positive electrode of this battery includes a metal oxide, such as nickel oxide; the negative electrode includes a hydrogen storage alloy; and the electrolyte includes an alkaline solution.
An example of an electrode reaction in a nickel oxide-hydrogen storage battery is as follows. Postive electrode:
Native electrode:
In the reaction equation (2), M represents a hydrogen storage alloy. Hydrogen storage alloys are capable of electrochemically absorbing and discharging large quantities of hydrogen. One type of hydrogen storage alloy is the AB 5 -type, which has a crystal structure of the CaCu 5 type. The A and B components of the AB 5 -type alloy are present in a mole ratio of about 1:5. The A component is generally composed of a mischmetal (a mixture of rare earth elements, generally cerium (Ce), lanthanum (La), neodymium (Nd), and praseodymium (Pr), as well as zirconium (Zr)), and the B component is generally composed of nickel (Ni), along with two or more elements selected from cobalt (co), manganese (Mn), aluminum (Al), copper (Cu), iron (Fe), or germanium (Ge). The subscripts, which indicate mole fraction, of the elements forming the A component generally have a sum of 1, while the subscripts of the elements forming the B component generally have a sum of 4.75 to 5.50.
It is desirable for metallic oxide-hydrogen storage batteries to have characteristics such as high energy density, relatively high charge retentions, relatively long cycle lives, and good discharge capacities over a range of temperatures. The hydrogen discharge reaction at the negative electrode, however, tends to slow down with decreasing temperature; discharge capacities may therefore deteriorate at low temperatures. The low temperature performance of batteries can be improved, but improved low temperature performance is often accompanied by the loss of other desirable properties such as high temperature performance, capacity (the ability to reversibly store hydrogen) or cycle life.
SUMMARY OF THE INVENTION
In general, the invention features a hydrogen storage alloy with a relatively high content of praseodymium (Pr). The preferred hydrogen storage alloy is of the AB 5 -type; the A component of this alloy includes at least 0.4 mole fraction Pr. The alloy also includes lanthanum (La) and/or neodymium (Nd). The alloy can be used to make batteries with good low temperature discharge capacities, good ambient temperature properties, good charge retention, good cycle life, and uniform discharge capacities over a range of discharge rates.
The invention also features an alkaline storage battery that includes a positive electrode, a negative electrode including a hydrogen storage alloy having a relatively high Pr content and including La and/or Nd, and an alkaline electrolyte.
Other features and advantages of the invention will be apparent from the description of the preferred embodiments thereof, and from the claims.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a sectional view of a cylindrical storage cell;
FIG. 2 a is a perspective view of a rectangular storage cell;
FIGS. 2 b and 2 c are sectional views of a rectangular storage cell;
FIG. 3 is a perspective view of the electrode assembly of a rectangular storage cell; and
FIG. 4 is a graph showing the capacity for various discharge rates for a hydrogen storage alloy.
FIGS. 5 a - 5 e are graphs showing cell capacities after conditioning for cells containing a hydrogen storage alloy at 20° C. (FIG. 5 a ), 45° C. (FIG. 5 b ), 0° C. (FIG. 5 c ), −10° C. (FIG. 5 d ), and −20° C. (FIG. 5 e ).
FIG. 6 is a graph showing cell cycle life for cells containing a hydrogen storage alloy at 20° C.
FIG. 7 is a graph showing cell cycle life for cells containing a hydrogen storage alloy at 45° C.
FIGS. 8 a - 8 e are graphs showing cell capacities after conditioning for a cell containing a hydrogen storage alloy at 20° C. (FIG. 8 a ), 45° C. (FIG. 8 b ), 0° C. (FIG. 8 c), −10° C. (FIG. 8 d ), and −20° C. (FIG. 8 e ).
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1, a cylindrical battery 10 includes a negative electrode 1 , a positive electrode 2 , and a separator 3 . The electrodes and the separator are contained within a case 4 . The top end of the case 4 is closed with a sealing plate 5 and an annular insulating gasket 6 that provide a gas-tight and fluid-tight seal. A positive lead 7 connects the positive electrode 2 to the sealing plate 5 . The sealing plate 5 is provided with a safety valve 8 disposed in the inner side of a positive terminal 9 . The valve 8 is configured to actuate when the pressure inside the battery exceeds a predetermined value.
The main component of negative electrode 1 is an AB 5 -type hydrogen absorbing alloy, which is formed by fusing the appropriate elements. The mixture of elements is melted in an induction furnace under vacuum, under an inert atmosphere such as argon, helium, or other non-reactive gas, under a protective atmosphere, such as an argon/hydrogen mixture, or combinations thereof. The melt is then allowed to cool. The resulting alloy is pulverized by hydrogen absorption and desorption, mechanical pulverization, jet-milling, or other methods known in the art to form a powder, which is sieved to remove particles larger than 75 microns. The alloy can be used in an as-cast and pulverized condition.
Alternatively, the alloy can be heat treated, and then pulverized. The heat treatment includes heating the alloy at 900° C. to 1100° C. for 1 to 12 hours, under vacuum, under an inert atmosphere, or under a protective atmosphere. The heat treatment helps to homogenize the elements.
Negative electrode 1 may contain other ingredients as well. For example, the electrode may include a high surface area carbon. The carbon catalyzes the conversion of O 2 , formed at the positive electrode, into H 2 0, thus promoting pressure reduction in the battery. The electrode may also include a binder such as polytetrafluoroethylene (PTFE), and thickeners, such as a polyvinyl alcohol/sodium polyacrylate copolymer, and carboxymethyl cellulose (CMC).
Negative electrode 1 may be prepared as follows. The alloy is combined with the carbon, the binder, the thickeners, and water to form a paste. The paste is applied to a conductive core substrate, such as perforated nickel-plated cold rolled steel foil, or expanded metal. The material then is dried, rolled, and die cut into pieces of the appropriate size.
Positive electrode 2 may include any of a number of materials known in the electrochemical arts. For example, the positive electrode may include spherical nickel hydroxide, which may contain zinc and cobalt; cobalt monoxide; a binder, such as PTFE; thickeners such as CMC and sodium polyacrylate (SPA); and a paste stabilizer such as sodium borate.
Positive electrode 2 may be prepared as follows. The ingredients are combined with water to produce a paste, which is then applied to a highly porous sintered, felt, or foam substrate. The filled substrate is compacted, then pieces of the appropriate size are cut from the substrate. A nickel tab, which serves as a current collector, is then applied by ultrasonic welding.
Separator 3 is a porous insulator film or thin sheet; the film or sheet can be composed of a polyamide (such as nylon), polypropylene, polyethylene, polysulfone, or polyvinyl chloride (PVC). A preferred material is polypropylene. The separator is cut into pieces of a similar size as the electrodes, and is placed between the negative and positive electrodes to separate them electrically.
Negative electrode 1 , positive electrode 2 , and separator 3 are wound into a Swiss roll and placed in a case 4 made of a metal such as nickel or nickel plated steel, or a plastic material such as PVC, polypropylene, polysulfone, ABS, or polyamide.
The case 4 is then filled with an electrolyte. The electrolyte may be any electrolyte known in the art. An ample of an electrolyte is potassium hydroxide (KOH) with a concentration of 20 to 40 weight %, plus lithium hydroxide (LIOH) with a concentration of 0 to 10 weight %.
The case 4 is then sealed with the sealing plate 5 and the annular insulating gasket 6 .
Examples of cylindrical batteries that may be prepared according to the present invention include A, AA, AAA, 4 / 5 A, 4 / 3 A, sub-C, and half-C batteries.
Alternatively, the battery may be rectangular in form; an example of a rectangular battery is the prismatic cell described in U.S. Pat. No. 4,977,043, which is incorporated by reference in its entirety herein.
Referring to FIGS. 2 a - 2 c , a rectangular battery 11 includes a case 12 , a lid body 13 , a positive electrode terminal 14 , a positive electrode 15 , a separator 16 which surrounds the positive electrode 15 , a U-shaped negative electrode 17 , a negative electrode lead 18 , a positive electrode lead 19 , and a frame body 20 .
FIG. 3 shows an expanded view of the electrode assembly. As shown there, the positive electrodes 15 are sandwiched between the U-shaped negative electrodes 17 . The bottom part of the U includes a negative electrode lead 18 .
The negative and positive electrodes may be prepared as described above, or as described in U.S. Pat. No. 4,977,043.
An example of a rectangular battery that may be prepared according to the present invention is a battery used to power electric vehicles.
Alternatively, a bobbin-type battery can be formed. To form this type of battery, the material forming the positive electrode is pressed into pellets. One or more of these pellets, surrounded by a separator, are placed into a case. The negative electrode material, in the form of a powder, and an electrolyte are added to the case. The case is then sealed.
Other types of batteries known in the art can be prepared as well.
EXAMPLES
Example 1
An alloy having the formula La 0.15 Ce 0.15 Pr 0.7 Ni 3.7 Co 0.7 Mn 0.1 Al 0.5 was made by fusing lanthanum, cerium, praseodymium, nickel, cobalt, manganese, and aluminum in the required proportions to achieve approximately 2 kg of the desired composition. The melt charge was loaded into a magnesia crucible installed in an induction furnace. The atmosphere inside the furnace chamber was evacuated to obtain a vacuum state of ≦0.02 torr. Immediately before melting, the furnace chamber was filled with argon to a pressure of 780 to 790 torr, which was maintained during the melting operation. The molten charge was maintained at 1400° C.-1415° C. for one minute, and then poured onto a copper block and allowed to cool to <50° C. The resulting alloy was pulverized by hydrogen absorption and desorption. The resulting powder was sieved to remove particles larger than 75 microns.
Test cells were prepared as follows. A pellet comprising 1 gram of Ni powder and 0.35 g of the alloy was compacted under a load of 3.5 tons in a die of 12.7 mm diameter. The compacted pellet was wrapped in 60 micron thick perforated nickel-plated cold rolled steel foil to which a tab of nickel was attached. The wrapped pellet and a positive, or counter, sintered Ni(OH) 2 electrode were immersed in 25 cc of de-aerated aqueous electrolyte of 5.5N KOH+2.0N NaOH+0.5N LiOH.
The cells were conditioned at room temperature with six charge/discharge cycles consisting of a 50 mA charge for 2.7 hours, followed by a discharge of 45 mA. The cells were discharged, after the sample temperature and electrolyte temperature stabilized, to −0.6V vs. a Hg/HgO reference electrode. The capacity was then determined at 25° C., 0° C., −10° C., and −20° C. at discharge rates of C/2 (45 mA), C/3 (30 mA), and C/5 (20 mA). The results are presented in Table 1.
TABLE 1
Discharge capacities in mA · hr/g to a cut-off
of −0.6 V vs. Hg/HgO
Temperature
C/2
C/3
C/5
22° C.
302
298
290
0° C.
289
288
—
−10° C.
261
282
286
−20° C.
162
248
275
As Table 1 illustrates, the cells showed high discharge capacities over a broad range of temperatures.
The test cells were then connected to cell cycling equipment and charged with 50 mA for 2.7 hours. The charging cycle was followed by a rest cycle of 10 minutes, with no current flowing. The cells were then discharged at the rates of C/2, C/3, and C/5. Instead of measuring the discharge potential against a reference electrode, the discharge was terminated when the cell voltage reached 1.0V.
The results are shown in FIG. 4, which illustrates that the cells exhibited relatively uniform discharge capacities over a range of discharge rates. The alloy described above showed a capacity decrease of 16 mA·hr/g at C/2 compared to C/5.
Example 2
An alloy having the formula La 0.3 Ce 0.15 Pr 0.55 Ni 3.7 Co 0.7 Mn 0.1 Al 0.5 was prepared. Test cells containing this alloy were prepared and tested as described above. A test cell including this alloy had a discharge capacity of 273 mA·hr/g at a temperature of −20° C. and a discharge rate of C/3.
Example 3
An alloy having the formula Lao 0.15 Ce 0.15 Pr 0.63 Nd 0.07 Zr 0.006 Ni 3.7 Co 0.7 Mn 0.1 Al 0.5 was prepared. Test cells containing this alloy were prepared and tested as described above. A test cell including this alloy had a discharge capacity of 262 mA·hr/g at a temperature of −20° C. and a discharge rate of C/3.
Example 4
An alloy having the formula La 0.15 Ce 0.3 Pr 0.55 Ni 3.7 Co 0.7 Mn 0.1 Al 0.5 was prepared. Test cells containing this alloy were prepared and tested as described above. A test cell including this alloy had a discharge capacity of 231 mA·hr/g at a temperature of −20° C. and a discharge rate of C/3.
Example 5
An alloy having the formula La 0.15 Pr 0.85 Ni 3.7 Co 0.7 Mn 0.1 Al 0.5 was prepared. Test cells containing this alloy were prepared and tested as described above. A test cell including this alloy had a discharge capacity of 245 mA·hr/g at a temperature of −20° C. and a discharge rate of C/3.
Example 6
An alloy having the formula La 0.3 Pr 0.7 Ni 3.7 Co0.7Mn 0.1 Al 0.5 was prepared. Test cells containing this alloy were prepared and tested as described above. A test cell including this alloy had a discharge capacity of 263 mA·hr/g at a temperature of −20° C. and a discharge rate of C/3.
Example 7
An alloy having the formula La 0.3 Ce 0.3 Pr 0.4 Ni 3.7 Co 0.7 Mn 0.1 Al 0.5 was prepared. Test cells containing this alloy were prepared and tested as described above. A test cell including this alloy had a discharge capacity of 232 mA·hr/g at a temperature of −20° C. and a discharge rate of C/3.
Example 8
An alloy having the formula La 0.1 Ce 0.01 Pr 0.8 Ni 3.7 Co 0.7 Mn 0.1 Al 0.5 was prepared. Test cells containing this alloy were prepared and tested as described above. A test cell including this alloy had a discharge capacity of 258 mA·hr/g at a temperature of −20° C. and a discharge rate of C/3.
Example 9
An alloy having the formula La 0.48 Ce 0.03 Pr 0.4 Nd 0.9 Zr 0.006 Ni 4.08 Co 0.4 Mn 0.44 Al 0.34 was prepared the procedure described above. A test cell, including this alloy had a discharge capacity of 254 mA·hr/g at a temperature of −20° C. and a discharge rate of C/3.
Example 10
A 4/5A battery of the type shown in FIG. 1 was prepared using the general procedure described above.
The main component of the negative electrode 1 was a hydrogen storage alloy having the formula La 0.5 Ce 0.15 Pr 0.7 Ni 3.7 Co 0.7 Mn 0.1 Al 0.5 . The alloy was pulverized by hydrogen absorption and desorption, and then sieved. The electrode also included (relative to the amount of hydrogen storage alloy, by weight): 0.7% high surface area carbon; 2.0% PTFE; 0.29% polyvinyl alcohol/sodium polyacrylate copolymer; and 0.12% CMC. The substrate used was perforated nickel plated cold rolled steel foil.
The main component of positive electrode 2 was nickel hydroxide, which included 5.0% zinc and 0.75% cobalt. The electrode also included (relative to the amount of nickel hydroxide, by weight): 0.5% PTFE; 0.13% CMC; 0.18% SPA; 5.0% cobalt oxide; and 0.1% sodium borate. The substrate used was a porous nickel material.
The electrolyte included 5.5N KOH+2.0N NaOH+0.5N LiOH, and the separator 3 was polypropylene.
Example 11
A 4/5A battery of the type shown in FIG. 1 was prepared using the general procedure described above.
The main component of the negative electrode 1 was a hydrogen storage alloy having the formula La 0.3 Ce 0.15 Pr 0.55 Ni 3.7 Co 0.7 Mn 0.1 Al 0.5 . The alloy was pulverized by hydrogen absorption and desorption, and then sieved. The electrode also included (relative to the amount of hydrogen storage alloy, by weight): 0.7% high surface area carbon; 2.0% PTFE; 0.29% polyvinyl alcohol/sodium polyacrylate copolymer; and 0.12% CMC. The substrate used was perforated nickel plated cold rolled steel foil.
The main component of positive electrode 2 was nickel hydroxide, which included 5.0% zinc and 0.75% cobalt. The electrode also included (relative to the amount of nickel hydroxide, by weight): 0.5% PTFE; 0.13% CMC; 0.18% SPA; 5.0% cobalt oxide; and 0.1% sodium borate. The substrate used was a porous nickel material.
The electrolyte included 5.5N KOH+2.0N NaOH+0.5N LiOH, and the separator 3 was polypropylene.
Example 12
A 4/5A battery of the type shown in FIG. 1 was prepared using the general procedure described above.
The main component of the negative electrode 1 was a hydrogen storage alloy having the formula La 0.48 Ce 0.03 Pr 0.4 Nd 0.09 Ni 4.08 Co 0.4 Mn 0.44 Al 0.34 . The alloy was pulverized by hydrogen absorption and desorption, and then sieved. The electrode also included (relative to the amount of hydrogen storage alloy, by weight): 0.7% high surface area carbon; 2.0% PTFE; 0.29% polyvinyl alcohol/sodium polyacrylate copolymer; and 0.12% CMC. The substrate used was perforated nickel plated cold rolled steel foil.
The main component of positive electrode 2 was nickel hydroxide, which included 5.0% zinc and 0.75% cobalt. The electrode also included (relative to the amount of nickel hydroxide, by weight): 0.5% PTFE; 0.13% CMC; 0.18% SPA; 5.0% cobalt oxide; and 0.1% sodium borate. The substrate used was a porous nickel material.
The electrolyte included 5.5N KOH+2.0N NaOH+0.5N LiOH, and the separator 3 was polypropylene.
Testing of Examples 10, 11, and 12
The nominal designed capacity of the cells of Examples 10, 11, and 12 was 1800 mA·hr. Cells were charged for four hours at 90 mA then for 18 hours at 180 mA. The cells were allowed to rest for 30 minutes with no current flowing. The cells were then discharged at a current of 360 mA until the cell voltage fell to 1.0V. After resting for 30 minutes, the cells were given five conditioning cycles according to the following schedule: charge at C/5 (a charge current of 360 mA) with a charge termination of 10 mV −ΔV; rest for 30 minutes with no current flowing; discharge at C/5 (360 mA) to 1.0V; and rest 30 minutes rest with no current flow.
After conditioning, five cells of each of Examples 30 10, 11, and 12 were tested for dependency on discharge rate (0.2C to 2.8C) and discharge temperature (−20° C. to 45° C.). The cells were given a three-hour rest at 20° C. prior to being charged at 600 mA for 3.75 hours at 20° C. The cells were then allowed to rest for three hours at the test temperature prior to discharge at a rate between 0.2C (or 0.36 Amp) and 2.8C (5.0 Amp). In FIGS. 5 a - 5 e , each datum is the average of 5 measurements. The results shown in FIGS. 5 a - 5 e indicate that cells from Examples 10, 11, and 12 have high discharge capacity over a wide range of temperatures and discharge rates. For example, the discharge capacity can be greater than 260 mA·hr/g, preferably greater than 280 mA·hr/g, at room temperature or greater than 230 mA·hr/g, preferably greater than 250 mA·hr/g, at −20° C. and a discharge rate of C/3. The data in FIG. 5 a were collected at 20° C. The data in FIG. 5 b were collected at 45° C. The data in FIG. 5 c were collected at 0° C. The data in FIG. 5 d were collected at −10° C. The data in FIG. 5 e were collected at −20° C.
After conditioning, four cells from each of Examples 10 and 11 were also tested for cycle life at 20° C. The cells were cycled according to the following procedure: charge at 20° C. at 1.8 A with a charge termination of 10 mV −ΔV, rest for 30 minutes at 20° C. with no current flow, discharge at 20° C. at 1.8 A to 1.0V, and rest for 30 minutes with no current flow. Both groups of cells show good cycle life. Cycle life of a battery is the number of charging cycles that the battery can withstand during which the capacity of the battery remains above a threshold level (e.g., 80% of the original capacity). Good cycle life can be greater than 200 cycles, preferably greater than 300 cycles, at room temperature or greater than 150 cycles, preferably greater than 200 cycles at 45° C. Results of the cycling experiments are shown in FIG. 6 . The curves in FIG. 6 are for the average capacities for each of the four cells from Example 10 and 11.
Another set of cells from Examples 10 and 11 were tested for cycle life at 45° C. The cells were cycled according to the following procedure: charge at 45° C. at 1.8 A with a charge termination of 10 mV −ΔV, rest for 30 minutes at 45° C. with no current flow, discharge at 45° C. at 1.8 A to 1.0V, and rest for 30 minutes with no current flow. Both groups of cells show good cycle life. Results are shown in FIG. 7 .
Example 13
The alloy used in Example 13 was that shown in Example 3. The nominal designed capacity of the cells was 1800 mA·hr. Cells were charged for four hours at 90 mA then for 18 hours at 180 mA. The cells were then allowed to rest for 30 minutes with no current flowing; the cells were then discharged at a current of 360 mA until the cell voltage fell to 1.0V. After a rest of 30 minutes, the cells were given five conditioning cycles according to the following regime: charge at C/5 (a charge of 360 mA) with a charge termination of 10 mV −ΔV, rest for 30 minutes with no current flow, discharge at C/5 (360 mA) to 1.0V, and rest for 30 minutes with no current.
After conditioning, three cells were tested for dependency on discharge rate (0.2C to 2.8C) and discharge temperature (−20° C. to 45° C.). The cells were given a three-hour rest at 20° C. prior to being charged at 600 mA for 3.75 hours at 20° C. The cells were then allowed to rest for three hours at the test temperature prior to discharge at the rate and temperature indicated. The results shown in FIGS. 8 a to 8 e indicate that both groups of cell have high discharge capacity over a wide range of temperatures and discharge rates. In FIGS. 8 a to 8 e each datum is the average of 5 values. FIG. 8 a shows the discharge capacities at 20° C. at rates from 0.2C (or 0.36A) to 2.8C (5.0A). FIG. 8 b shows the discharge capacities at 45° C. FIG. 8 c shows the discharge capacities at 0° C. FIG. 8 d shows the discharge capacities at −10° C. FIG. 8 e shows the discharge capacities at −20° C. Other embodiments are within the claims. | A hydrogen storage alloy of the AB 5 -type, where the A component includes La and/or Nd and at least 0.4 mole fraction Pr, as well as batteries including the alloy, are disclosed. | 8 |
This application claims benefit of U.S. Ser. No. 60/554,636, filed Mar. 19, 2004, and U.S. Ser. No. 60/602,893, filed Aug. 19, 2004, the entire contents of which are incorporated by reference into this application.
Throughout this application, various publications are referenced and the full citations for these publications may be found in the text where they are referenced. The disclosures of these publications in their entireties are hereby incorporated by reference into this application to more fully describe the state of the art to which this invention pertains.
BACKGROUND OF THE INVENTION
Flossing and the typical manipulation of the dental floss with the hands and fingers can be uncomfortable activities that result in manual as well as oral discomfort. Because the hands and fingers are intimately involved and the activity is an invasive one involving the mouth, flossing can be a messy activity that people may feel uncomfortable in undertaking outside of a private bathroom setting, such as at home.
As a result, a variety of dental floss applicators have been developed over the years to overcome the need for insertion of the fingers in the mouth when flossing. However, it can be difficult to mimic the dexterity of the human hand with a stiff, probe-like flossing apparatus. Consequently, it may be quite difficult to properly floss the teeth situated further back in the mouth without discomfort and/or injury resulting from the pointed end to the floss applicator. There have been a number of attempts to deal with the abovementioned issues as shown in the following U.S. Patents:
U.S. Pat. No. 6,915,81 may be the first patent on a dental floss applicator design that provides a C-shaped device for a user to install dental floss. This C-shaped device is adjustable such that the dental floss can be parallel or perpendicular to the handle. The disadvantage with U.S. Pat. No. 6,915,81 is that it lacks a flexible elbow for maneuverability and a tapered end for interdental cleaning and gum stimulation.
U.S. Pat. No. 8,933,45 is an adjustable C-shaped device for a user to install dental floss. This device is designed to be attached to a toothbrush. The disadvantage with U.S. Pat. No. 8,933,45 is that it lacks a handle, a flexible elbow for maneuverability, and a tapered end for interdental cleaning and gum stimulation.
U.S. Pat. No. 1,306,998 is similar to U.S. Pat. No. 6,915,81. The disclosed C-shaped device is adjustable such that the dental floss can be parallel or perpendicular to the handle. Additionally, this design includes a built-in storage for dental floss. The disadvantage with U.S. Pat. No. 1,306,998 is that it lacks a flexible elbow for maneuverability and a tapered end for interdental cleaning and gum stimulation.
U.S. Pat. No. 1,512,633 describes a fixed dental floss applicator with one C-shaped device on each end of the applicator. One C-shaped device is parallel to the handle, while the other C-shaped device is perpendicular to it. The disadvantage with U.S. Pat. No. 1,512,633 is that it lacks a flexible elbow for maneuverability and a tapered end for interdental cleaning and gum stimulation.
U.S. Pat. No. 2,172,591 describes a dental floss applicator that is similar to the one described in U.S. Pat. No. 8,933,45. It is an adjustable C-shaped device that allows a user to install a dental floss. This device is designed to attach to a toothbrush and also includes built-in storage for dental floss. The disadvantage with U.S. Pat. No. 2,172,591 is that it lacks a flexible elbow for maneuverability and a tapered end for interdental cleaning and gum stimulation.
U.S. Pat. No. 3,368,553 describes a design similar to the one described in U.S. Pat. No. 6,915,81. It is designed to be an adjustable toothpick applicator. The disadvantage with U.S. Pat. No. 3,368,553 is that it lacks floss, a floss-applicator, a flexible elbow for maneuverability, and a tapered end for interdental cleaning and gum stimulation.
U.S. Pat. No. 4,002,183 describes a design similar to that of U.S. Pat. No. 1,512,633. It is a fixed dental floss applicator with one C-shaped device on each end of the applicator. One C-shaped device is parallel to the handle, while the other C-shaped device is perpendicular to it. It is designed to be easily-manufactured and inexpensive. The disadvantage with U.S. Pat. No. 4,002,183 is that it lacks a flexible elbow for maneuverability and a tapered end for interdental cleaning and gum stimulation.
U.S. Pat. No. 4,005,721 describes a dental floss applicator where a user installs dental floss onto the device. This device is adjustable such that the dental floss can be parallel or perpendicular to the handle. This device is interchangeable and can be replaced with a device with a different shape. The disadvantage with U.S. Pat. No. 4,005,721 is that it lacks a flexible elbow for maneuverability and a tapered end for interdental cleaning and gum stimulation.
U.S. Pat. No. 4,051,857 describes a dental floss applicator where a user installs dental floss onto the device. This device is adjustable such that the dental floss can be parallel or perpendicular to the handle. This applicator provides an improved control mechanism to control the angle of the dental floss. The disadvantage with U.S. Pat. No. 4,051,857 is that it lacks a flexible elbow for maneuverability and a tapered end for interdental cleaning and gum stimulation.
U.S. Pat. No. 4,671,307 describes an adjustable dental floss applicator with one C-shaped device on each end of the applicator. One C-shaped device is parallel to the handle, while the other C-shaped device is perpendicular to it. It is a permanent applicator that requires users to install dental floss before each use. The disadvantage with U.S. Pat. No. 4,671,307 is that it lacks a flexible elbow for maneuverability and a tapered end for interdental cleaning and gum stimulation.
U.S. Pat. No. 4,706,694 is similar to U.S. Pat. No. 6,915,81. A C-shaped device is adjustable such that the dental floss can be parallel or perpendicular to the handle and is also designed to maintain sufficient tension in the dental floss. The disadvantage with U.S. Pat. No. 4,706,694 is that it lacks a flexible elbow for maneuverability and a tapered end for interdental cleaning and gum stimulation.
U.S. Pat. No. 5,125,424 is similar to U.S. Pat. No. 6,915,81. A C-shaped device is adjustable such that the dental floss can be parallel or perpendicular to the handle. This design also allows users to install a length of dental floss as well as other devices, such as an interdental brush. The disadvantage with U.S. Pat. No. 5,125,424 is that it lacks a flexible elbow for maneuverability and a tapered end for interdental cleaning and gum stimulation.
U.S. Pat. No. 5,279,315 is similar to U.S. Pat. No. 6,915,81. A C-shaped device is adjustable such that the dental floss can be parallel or perpendicular to the handle. The design allows users to change the angle of the dental floss with more ease than the other prior art. Nevertheless, the disadvantage with U.S. Pat. No. 5,279,315 is that it lacks a flexible elbow for greater maneuverability and a tapered end for interdental cleaning and gum stimulation.
Another general disadvantage of the above-discussed designs is that the devices are permanent in nature. The permanent nature of these applicators discourages their widespread adoption since dental floss is typically disposed of after use in removing food and bacteria from the mouth. Accordingly, repeated use of a permanent dental floss applicator is not acceptable many consumers. Furthermore, the permanent nature of the applicators, factors such as size, weight, and upkeep, do not translate into convenient use for users during excursions away from the private bathroom setting.
References Cited:
United States Patents
691,581
Baumeister, Auguste
Jan. 21, 1902
893,345
Monson, Otto J.
Jul. 14, 1918
1,306,998
Dimitroff, Vladimir T.
Jun. 17, 1919
1,512,633
Peckham, John A.
Nov. 15, 1924
2,172,591
Peterson, Arthur L.
Jun. 20, 1939
3,368,553
Kirby, James B.
Jan. 29, 1965
4,002,183
Restall, Raymond B.
Sep. 8, 1977
4,005,721
Yasumoto, Michio
Feb. 1, 1977
4,051,857
Zambito, James B.
Oct. 4, 1977
4,671,307
Curbow et al.
Jul. 15, 1985
4,706,694
Lambert, Joseph
Mar. 24, 1986
5,125,424
Eisen, Ewald
Mar. 26, 1991
5,279,315
Huang, Ming-Liang
Jan. 25, 1993
SUMMARY OF THE INVENTION
It is an object of this invention to provide an apparatus for interdental hygiene that manipulates and applies one or more lengths of dental floss for cleaning the interstices of the teeth. In particular, it is an object of this invention to provide a dental floss applicator that is strong, but pliable, with a flexible elbow that enables sufficient maneuverability to properly floss the teeth, including the teeth in the rear of the mouth.
It is another object of this invention to provide an apparatus with a pliable tapered end, preferably pick-like, for cleaning the teeth and massaging and stimulating the gums.
It is still another object of this invention to provide an economical and disposable dental floss applicator that is convenient to carry during excursions where a user will not have ready access to a private bathroom setting. Such applicators are also suitable for dispensing by restaurants to their patrons, in the same manner as mints are freely dispensed.
It is yet another object of this invention to provide a guard on the dental floss applicator to help users identify whether a particular applicator has been used. This is important where the applicators are freely dispensed in a public setting, such as in a restaurant.
These and other objects and advantages of this invention will become apparent to those skilled in the art after considering the following detailed specification together with the accompanying drawings.
DETAILED DESCRIPTION OF THE FIGURES
FIG. 1A : Detailed design of Flexible Dental Floss Applicator and Interdental Gum Stimulator. Presented is a side view of the apparatus illustrating the detailing of the applicator and its utilitarian sections: the tapered end 1 ; the middle handle 2 for grip; the flexible elbow 3 ; and the “c” shaped applicator arms 4 through which a segment of floss 5 is to be threaded and secured.
FIG. 1B : Presented is a bottom view of the apparatus illustrating the detailing of the applicator and its utilitarian sections: the tapered end; the middle handle with ridges for grip; the flexible elbow; and the “c” shaped applicator arms through which a segment of floss is to be threaded and secured.
FIG. 1C : Presented is a rear view of the apparatus looking at the tapered end 1 illustrating the detailing of the applicator and its utilitarian sections: tapered end 1 ; the middle handle for grip 2 . The tapered end 1 shown is chisel-like, but it may also be pointed.
FIG. 1D : Presented is a side view of the apparatus embodying a second length of floss 6 .
FIG. 2A : Presented is a top view of the apparatus illustrating the 0 to about 90 degree flexible sweep of the floss applicator arms in either direction permitted by the flexible elbow.
FIG. 2B : Presented is a side view of the apparatus illustrating the flexible sweep of the floss applicator arms away from the page permitted by flexible elbow.
FIG. 2C : Presented is a top view of the apparatus illustrating the 0 to 90 degree flexible sweep of the tapered end in either direction.
FIG. 3 : Presented is a side and top view of the flexible elbow. The flexible elbow 3 may be constructed of polypropylene.
FIG. 4A : Presented is a side view of the dental floss applicator that is designed to accept a dental floss guard. There is a hole 17 on the “C” shape applicator arms to receive a locking device 20 .
FIG. 4B : Presented is a bottom view of the dental floss applicator that is designed to accept a dental floss guard. There is a hole 17 on the “C” shape applicator arms.
FIG. 4C : Presented is a front view of the dental floss guard 19 that is designed to protect the dental floss in the applicator in FIGS. 4A and 4B . There is a locking device 20 on the dental floss guard that secures dental floss guard onto the dental floss applicator.
FIG. 4D : Presented is a side view of the dental floss guard 19 that is designed to protect the dental floss. There is a locking device 20 on the dental floss guard that secures dental floss guard onto the dental floss applicator.
FIG. 5 : Presented is a side view of the dental floss applicator with dental floss guard 19 installed. The dental floss guard 19 protects the dental floss 5 which is hidden behind the dental floss guard 5 . There is a locking device 20 on the dental floss guard that secures dental floss guard onto the dental floss applicator.
FIG. 6A : Presented is a side view of the dental floss applicator that is designed to accept a dental floss guard. There is a hole 26 on the “C” shape applicator arms to accept a locking device 28 .
FIG. 6B : Presented is a bottom view of the dental floss applicator that is designed to accept a dental floss guard. There is a hole 26 on the “C” shape applicator arms to accept a locking device 28 .
FIG. 6C : Presented is a front view of a dental floss guard 29 that is designed to protect the dental floss in the applicator in FIGS. 6A and 6B . There is a locking device 28 on the dental floss guard that secures dental floss guard onto the dental floss applicator.
FIG. 6D : Presented is a top view of a dental floss guard 29 that is designed to protect the dental floss in the applicator in FIGS. 6A and 6B . There is a locking device 28 on the dental floss guard that secures dental floss guard 29 onto the dental floss applicator.
FIG. 6E : Presented is a side view of a dental floss guard that is designed to protect the dental floss in the applicator in FIGS. 6A and 6B . There is a locking device 28 on the dental floss guard that secures dental floss guard onto the dental floss applicator.
FIG. 7A : Presented is a side view of the dental floss applicator with dental floss guard 29 installed. The dental floss guard 29 protects the dental floss 5 which is hidden behind the dental floss guard 29 . There is a locking device 28 on the dental floss guard that secures dental floss guard onto the dental floss applicator.
FIG. 7B : Presented is a bottom view of the dental floss applicator with dental floss guard 29 installed. The dental floss guard 29 protects the dental floss 5 which is hidden behind the dental floss guard 29 . There is a locking device 28 on the dental floss guard that secures dental floss guard onto the dental floss applicator.
FIG. 8A : Presented is a side view of the dental floss applicator that is designed to accept the dental floss guard. There are two holes 37 on the “C” shape applicator arms to accept a locking device 39 .
FIG. 8B : Presented is a bottom view of the dental floss applicator that is designed to accept the dental floss guard. There are two holes 37 on the “C” shape applicator arms to accept a locking device 39 .
FIG. 8C : Presented is a front view of a dental floss guard 38 that is designed to protect the dental floss in the applicator in FIGS. 8A and 8B . There are two locking devices 39 on the dental floss guard that secures dental floss guard onto the dental floss applicator.
FIG. 8D : Presented is a top view of a dental floss guard 38 that is designed to protect the dental floss in the applicator in FIGS. 8A and 8B .
FIG. 8E : Presented is a side view of a dental floss guard that is designed to protect the dental floss in the applicator in FIGS. 8A and 8B . There are two locking devices 39 on the dental floss guard that secures dental floss guard onto the dental floss applicator.
FIG. 9A : Presented is a side view of the dental floss applicator with dental floss guard 38 installed. The dental floss guard 38 protects the dental floss 5 which is hidden behind the dental floss guard 38 . There are two locking devices 39 on the dental floss guard that secures dental floss guard onto the dental floss applicator.
FIG. 9B : Presented is a bottom view of the dental floss applicator with dental floss guard 38 installed. The dental floss guard 38 protects the dental floss 5 which is hidden behind the dental floss guard 38 . There are two locking devices 39 on the dental floss guard that secures dental floss guard onto the dental floss applicator.
FIG. 10 : Presented is a side view of a dental floss applicator with dental floss guard 47 installed. A dental floss guard 47 protects the dental floss 5 which is hidden behind a dental floss guard 47 . There are no locking devices here. Instead, the dental floss guard is made of a soft material that is wrapped around and secured onto the dental floss applicator.
FIG. 11A : Presented is a top view of how one would floss the back teeth in the left side of the mouth with the dental floss applicator.
FIG. 11B : Presented is a top view of how one would floss the back teeth in the right side of the mouth with the dental floss applicator.
DETAILED DESCRIPTION OF THE INVENTION
The invention provides a dental hygiene apparatus with teeth-cleaning means and a flexible handling means whereby the teeth-cleaning means and the flexible handling means are united and pliable at their points of joinder. The teeth-cleaning means and handling means are “united” in the sense that they are brought together to form a single apparatus by joining, securing, connecting, linking, or the like. The apparatus can be of one construction or an aggregate of parts composed of the same or different material, consistent with the teachings of this disclosure.
“Pliable” means that the apparatus is flexible and receptive to change such that it is capable of being flex adjusted (bent) numerous times without breaking and will readily adhere to a new configuration after flex adjustment. The meaning will become more apparent upon reading the full disclosure and the examples contained herein.
The teeth-cleaning means comprises arms for securing one or more lengths of floss. However, the strands of material need not be limited to floss. The floss can be substituted for strands of other interdental materials, such as those related to cosmetics (e.g., whitening) or medicine for the gums. The teeth-cleaning means further comprises a tapered portion at one end of the apparatus, chisel-shaped or pointed, for use as an interdental cleaner and/or stimulator.
The invention further provides a flexible elbow and tapered end for increased maneuverability and effectiveness when cleaning the teeth. Between the flexible elbow and tapered end is the handling means which comprises a handle with ridges, grooves, or a combination thereof for the desired grip.
In one embodiment, the dental hygiene apparatus is made of one solid construction of polypropylene. It comprises a narrow, chisel-shaped feature at one end which gradually transitions and widens into a handle and before tapering to a flexible elbow adjoining the two applicator arms which secure a length of floss. The flexible elbow and chisel-shaped feature are pliable and designed to permit maximum maneuverability for the user when flossing. Many other embodiments are possible and will become apparent upon reading the entire disclosure and the examples contained herein.
Flexible Feature:
Approximately where the handle transitions into the applicator arms, there is a ridged flexible elbow that is capable of being flex adjusted into the desired position when flossing. The user need merely bend the apparatus at the flexible elbow to the desired angle. The invention is designed such that is pliable but yet remains sufficiently strong for use, despite numerous flex adjustments.
For instance, the user may flex adjust the flexible elbow anywhere from 0 to about 15 degrees when flossing the teeth in the front of the mouth. When flossing the teeth on the side, the user may desire to flex adjust the flexible elbow anywhere from about 15 to 30 or to about 45 degrees. When flossing the teeth in the rear of the mouth, the user may then desire to flex adjust the flexible elbow anywhere from about 45 to 60 or to about 90 degrees. The invention is such that the apparatus will remain at the desired angle after it is flex adjusted. When flossing the other side of the mouth, the user need merely flex adjust apparatus as described above. The apparatus can be flex adjusted multiple times and still remain strong.
The dental floss applicator is designed for single-use and thus be disposable. In most circumstances, one single dental floss applicator will last for an entire flossing session, depending on the number of flex adjustments. During a complete flossing session, users will be bending the flexible elbows to the left and the right, and to different angles. The flexible elbow is designed to withstand multiple bendings. Some users may just want to floss one or two gaps between their teeth, so they would bend the flexible elbow maybe just 2 times. Other users may bend the flexible elbow 5 times before discarding the dental floss applicator. During a typical flossing session, users may bend the flexible elbow about 10 times. During a long flossing session, users may bend it about 20 times. If the users intend to reuse the dental floss applicator, the flexible elbow should be able to last until about 40 bendings before breaking. Experiments were conducted on the prototypes of the dental floss applicators to see how many times a flexible elbow can be flex adjusted (bent) before it breaks. A group of 50 applicators were tested. The following is a summary of the results:
Number of Times the Dental
Percent of Dental Floss
Floss Applicator were Bent
Applicator That Break
2
0%
5
0%
10
0%
20
0%
40
2%
It is important that the dental floss applicator be capable of withstanding multiple flex adjustments. Typically, a material loses much of its strength when bent multiple times. However, the present dental floss applicator is designed such that the flexible elbow remains relatively strong, stable, and rigid even after it has been bent multiple times. Experiments were conducted on the prototypes of the dental floss applicators to see how rigid the flexible elbow is after it is bent multiple times (and remains bent at 45 degrees). A group of 50 applicators were tested. The following is a summary of the results:
Average Force Needed to Bend Number of Times the Dental Dental Floss Applicator Away Floss Applicator were Bent from the Teeth by 30 Degrees 2 12 lbs 5 12 lbs 10 12 lbs 20 12 lbs 40 10 lbs
Flexible Pick:
On one end of the dental floss applicator is a tapered portion, chisel-shaped or pointed, that can be a used as a pick to clean the teeth and to stimulate the gums. The tapered portion is designed to be pliable such that a user can bend it to effectively reach the gums and interstices of the back teeth.
Typically, when people use toothpicks, the teeth in the front of the mouth do not present a challenge. However, there is difficulty in trying to reach the interstices of the back teeth because the toothpick is straight and cannot reach the rear interstices since they are essentially perpendicular to the toothpick. As a result, people will try to bend the toothpicks, but the results are limited. The toothpicks are not very flexible and can only be bent so much before they begin to splinter.
On the other hand, the flexible tapered end (pick) of the present invention (like the flexible elbow discussed previously) can be bent anywhere from 0 to about 15, 30, 45, 60, or about 90 degrees depending on which teeth and gums the user wishes to clean and stimulate.
Like the flexible elbow, the tapered end of the apparatus is designed so as to “remember” and remain in the adjusted position while it is being used. In other words, the flexible tapered end will not bounce back to its original position after one stops applying force to it.
Like the flexible elbow, the flexible tapered end is designed to withstand multiple bending. A flexible pick can be bent a number of times during a session. Some users just want to pick one or two gaps between their teeth, so they may bend the flexible pick maybe 2 times. During a longer session, users may bend it 10, 20, or more times. The flexible pick should be able to withstand 20 flex adjustments without breaking. Experiments were conducted on the prototypes of the dental floss applicators to see how many times the flexible pick can be bent before breaking. A group of 50 apparatus were tested. The following is a summary of the results:
Number of Times the Dental Percent of Dental Picks Picks were Bent That Break 2 0% 5 0% 10 0% 20 0%
Preferred Material:
The flexible feature of the dental floss applicator is accomplished by using a class of polypropylene materials, possessing the desired properties of being able to “remember” a new position when flex adjusted and having the requisite strength necessary for manipulation of the applicator/stimulator while still being yielding enough to allow for the safe and gentle cleaning of the interdental spaces and proximate gum tissues. Suitable thermoplastic resins and polymers may be used to wholly or partly construct the apparatus so as to provide it with the desired characteristics described. For the present invention, polypropylene has performed particularly well. Colors can also be added to increase the appeal to users of all ages and groups. From the colors of the rainbow, pastels, or fluorescents, the applicators can be manufactured in an array of colors according to the target audience. For example, bright, “fun” colors may be used to attract a younger user by making the floss applicator appear appealing as opposed to clinical and unpleasant. For the present invention, the preferred class of polypropylene has the following physical properties:
ASTM Physical Properties Methods Units Value Melt flow rate D1238L gram/10 15 minutes Density D792 Gram/cm 3 0.904 Tensile Strength, yield D638 Kg/cm 2 365 Elongation, yield D638 % 9 Flexural modulus D790IA Kg/cm 2 17000 Hardness, Rockwell D785A R scale 100 Heat deflection temperature at D648 ° C. 100 4.6 kg/cm 2 Izod impact strength, Notched D256A Kg-cm/cm 2.3 Mold shrinkage D995 % 1.51
Dental Floss Guard:
A device is provided near the dental floss so as to cover it. This device is designed as a “guard” of the dental floss such that one has to remove this “guard” before one can use the dental floor applicator. This device is also designed such that it cannot be installed back onto the dental floss applicator once it is removed. The intent is to allow users to easily identify unused and/or untampered applicators. Because the applicator will be used in a semi-internal fashion (the mouth), cleanliness is a key concern.
Several designs of these guards have proved useful. In general, one or more small holes are added onto the dental floss applicator such that the dental floss guard can be installed. The dental floss guards are manufactured separately from the dental floss applicator. There are one or more locking devices designed to fit securely into the holes on the dental floss applicators. The part connecting the locking devices and the main body of the guards are designed to be thin and weak and therefore easily broken. When a user takes away the dental floss guard, the locking devices will break off but remain in the holes on the dental floss applicators. With the holes on the applicators blocked, no guard can be installed back to the dental floss applicators once it has been used or otherwise tampered with.
Another design of the dental floss guard is to make such guard with thin plastic film that will be tightly wrapped around the area around the dental floss. When a user takes away the dental floss guard, the dental floss guard would be destroyed and cannot be reused.
With this “guard,” users of the dental floss applicators can be guaranteed that the dental floss applicators are new, unused, and safe.
The invention is significant because of the following reasons:
To floss in between all the teeth properly, the dental floss should be positioned ouch that it is parallel to the gap between teeth. However, the gaps between teeth in the front of mouth are perpendicular to the gaps between teeth in the back of mouth. Most existing disposable dental floss applicators have their handle parallel to the dental floss. While it is quite easy to floss in between the teeth in the front, it is all but impossible to floss the teeth in the back properly. The solution is the invention of a disposable dental floss applicator that allows the users to easily manipulate the angle of the dental floss.
This invention is significant because if the dental floss applicator is flexible, users can now adjust the applicator such that the sharp dental simulator will never point toward the vulnerable portions of the mouth, thus promoting safe use.
This invention is significant because if the dental floss applicator is flexible, it is feasible for the manufacturer to make a longer dental floss applicator. A longer dental floss applicator achieves at least two goals. 1.) It is now impossible to point the sharp dental simulator toward the mouth flesh or gums when in use because it is too long. The chance of getting hurt during flossing is reduced. 2.) Users can control the applicators without putting their fingers in their mouths. Thereby, users do not need to open their mouths extra wide during flossing, allowing them to floss more discreetly if they intend to do so in public.
Users have different preferences and needs regarding how they use dental floss. A dental floss applicator allows users to be creative in how to achieve the task of comfortably placing the dental floss between the teeth or maneuvering the interdental stimulator/pick within the mouth in a safe and comfortable manner.
The invention is pocket size, can be made disposable, and thus can be carried in public and used in a discreet and unembarrassing manner.
This invention is also significant because of the dental floss “guard” device. With this device, one can be sure that the dental floss applicators are new, unused, and safe. This further encourages users to use the dental floss applicators they are given in public establishments, such as hotels or eateries. This invention also helps users to use dental floss applicators more discreetly and to distinguish new from used applicators.
In the preferred form of the invention, the handle and applicator arm are formed from polypropylene and/or the like to define a short “c” shaped handle with applicator arms reaching off from the flexible elbow. The applicator arms do not protrude from the applicator handle like straight tines, but rather curve out in a manner visually resembling a “C” with a short handle rather than the “Y” shape employed by some existing designs.
The handle itself comprises an interdental stimulator (pick) and then widens into a thicker middle (designed for a secure grip) and then narrows down before softly angling up and transitioning into the applicator arms. At the point of transition a strong, flexible section capable of repeated bending is imbedded [or externally applied] providing for a 90 degree adjustable sweep of the applicator arms in either direction. The apparatus is such that it will respond to pressure without losing the desired angle and shape, thus allowing for easy and gentle usage. The pick is also designed to be flexible such that it can reach the back teeth and gums.
Other features and advantages of the invention will become apparent from the following description and figures which further illustrate the principles of the invention.
Production Process:
After the designs of the dental floss applicator and/or the dental floss guard are finalized, industrial grade moldings are custom made according to the final designs. Depending on the size of the moldings, a number of copies of the dental floss applicator and/or dental floss guard can be made simultaneously.
To produce the dental floss applicators, multiple lines of dental floss are placed on one side of the moldings first, then heated polymer material in liquid form is injected into the moldings to form the dental floss applicators. The dental floss applicators are then ejected from the moldings. Based on the design of the moldings, some dental floss applicators ejected from some moldings are connected by dental floss, some are not connected by dental floss. To separate the dental floss applicators connected by dental floss, one can cut the dental floss either by a sharp object or by heat.
To produce the dental floss guard, heated polymer material in liquid form is injected into the moldings to form the dental floss guards. The dental floss guards are then ejected from the moldings. | The invention is dental floss applicator and interdental stimulator that is flexible and also includes a guard to ensure that the dental floss has not been used or otherwise tampered with. Users can adjust the angle of the dental floss applicator and stimulator into a configuration that best suits their particular needs. When flex adjusted, the applicator is able to hold its new configuration while maintaining sufficient strength to allow the user to comfortably maneuver the apparatus to properly floss the teeth or stimulate the gums. Furthermore, the invention is disposable, rendering it convenient to use after a meal when the user is away from a private bathroom setting, such as at a home or other lodging. | 0 |
BACKGROUND OF THE INVENTION
The present invention relates to design and construction of lightweight elevated suspended guideways whereon high-speed vehicles will experience virtually no guideway-induced oscillations. More specifically it relates to a method of arranging suspension cables to suspend guideways along multiple towers so that deflections under vehicle load are virtually constant along the way, and temperature fluctuations do not affect alignments. Furthermore, the method of arranging suspension cables is designed to facilitate installation of pre-assembled suspension towers and pre-assembled guideway spans by helicopter.
Present multiple-span suspension bridges require anchors in alternate spans to prevent wavy rocking motion of decks and towers, thus precluding constant resilient suspension, which is necessary for oscillation-free high-speed travel.
SUMMARY OF THE INVENTION
The present invention provides structural components for an elevated suspended guideway comprising:
(a) A-frame-shaped suspension towers at regular intervals;
(b) continuous structural truss supported guideway with expansion joints at towers;
(c) above each guideway span between towers, a first tier of 32 identical inwardly sloping and upwardly extending suspension cables attached evenly spaced with their lower ends, 16 each along left and right edges, to the structural truss supporting the guideway, attaching points beginning and ending one-half space from adjacent towers, and having their upper ends attached in pairs to each other;
(d) above each guideway span between towers, a second tier of 16 identical inwardly sloping and upwardly extending suspension cables attached one each with their lower ends to the upper joints of the paired first tier suspension cables, and centrally above the guideway having their upper ends attached in pairs to each other and to their counter-parts from the opposite edge of the guideway truss;
(e) above each guideway span between towers, a third tier of four identical in vertical plane upwardly extending suspension cables having their lower ends one each attached to the upper joints of the paired second tier suspension cables, and having their upper ends attached in pairs to each other;
(f) above each guideway span between towers, a fourth tier of two identical in vertical plane upwardly extending suspension cables having their lower ends one each attached to the upper joints of the paired third tier suspension cables, and having their upper ends flexibly attached to the top of their next adjacent towers;
(g) above each guideway span between towers, cables parallel to guideway connecting the top joints of paired first, second and third tier suspension cables located nearest mid-span on one side of mid-span to their counterparts on the other side of mid-span;
(h) above each guideway span between towers, cables parallel to guideway flexibly connecting the top joints of paired first and second tier suspension cables located nearest towers to their respective next adjacent towers;
(i) above each guideway span between towers, cables parallel to guideway connecting the top joints of paired first tier suspension cables located on either side of one-quarter and three-quarter of the distance between towers to each other;
(j) motion dampers flexibly connecting guideway truss to tower legs.
The present invention is specifically directed at providing that guideway sagging under moving load is constant and fully resilient. This physical sameness is achieved by having suspension cables arranged whereby the load, irrespective of where it is located along the guideway, is substantially carried by the same type, number, size, length and position angle of suspension cables. Furthermore, this design also provides that temperature expansion and contraction does not cause guideway bending or misalignment, yet allows incorporation of horizontal and vertical curves, curve transitions, banking in curves, ascends and descends.
When used for high-speed conveyor-type automated people movers or fast freight pipelines, for example Articulated Train Systems (U.S. Pat. No. 3,320,903, Re. 26,673) or Bulk Material Conveyors (U.S. Pat. No. 4,024,947), a lightweight design would allow whole spans with suspension cables attached to be assembled at remote locations, transported to the site by helicopter and inserted between towers using quick snap-on connectors.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 is a side view of a section the suspended elevated guideway including two towers and one span.
FIG. 2 shows a cross-section of the guideway with a front view of an A-frame suspension tower.
FIG. 3 shows a cross-section as in FIG. 2, except it depicts the guideway banked in a horizontal turn.
FIG. 4 is a graphic presentation of how temperature expansion and contraction lowers and raises the guideway while maintaining its longitudinal alignment.
FIG. 5 shows a typical guideway expansion joint located at each tower.
FIG. 6 shows construction of towers and guideway by helicopter.
FIG. 7 is a plan view of a typical span containing a horizontal curve.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 is a side view of a section of the suspended elevated guideway. Shown are two A-frame suspension towers 1 , a structural truss supported guideway 2 , first tier suspension cables 3 , second tier suspension cables 4 , third tier suspension cables 5 , fourth tier flexibly connected suspension cables 6 , longitudinal cables 7 , 8 and 9 , and flexibly connected longitudinal cables 10 and 11 . Not visible are expansion joints in guideway 2 behind viewed side legs of towers 1 . The height of each tier is shown here to approximate ¼ of tower height above guideway.
FIG. 2 is a cross-sectional view of guideway 2 . Shown are motion dampers 12 holding guideway 2 centrally between legs of tower 1 , a silhouette of vehicle 13 on guideway 2 , attaching locations 14 for cables 11 on a cross bar of tower 1 , attaching location 15 for cables 10 on a cross bar of tower 1 , and attaching location 16 for fourth tier cables 6 at the top of tower 1 . All connection locations in FIG. 2 are shown for towers 1 along a straight guideway 2 . At locations along the way where guideway 2 is horizontally curved, attaching locations 15 and 16 are moved laterally along tower 1 cross bars in the direction away from the center of the curve in amounts depending on span length and radius of curve.
FIG. 3 is a cross-sectional view of guideway 2 similar to FIG. 2, showing tower 1 located in a banked horizontal turn. Cantilevered arms 17 are attached to guideway 2 for use by first tier suspension cables 3 to prevent them from making contact with vehicle 13 leaning into the banked turn. Fourth tier suspension cables 6 are attached to the top cross bar of tower 1 at attaching location 18 , which lies on the center line of the arc of guideway 2 between towers 1 . Depending on weight of vehicles travelling on guideway 2 , tiebacks 19 may be added to towers 1 in tight curves.
FIG. 4 is an exaggerated graphic presentation of how temperature change affects cables connected to tower 1 . Shown are cold temperature position in solid lines, and warm temperature position in dashed lines. With temperature change, fourth tier suspension cable 6 and longitudinal cable 7 combine to raise and lower guideway 2 . All other cables expand and contract with the guideway in unison. Thus, do not disturb the guideway's relative alignment.
As an example, assuming all components are made of steel with similar temperature expansion factors, spans are 160 feet (50 m) long and towers 80 feet (25 m) high. If the design temperature range is from −50 F. to +120 F. (−47 C. to +49 C.), then the coldest connection location 20 between fourth tier suspension cable 6 and lateral cable 7 would move to the hottest connection location 21 , which is a movement to the left by 0.67″ (1.70 cm) and a lowering by 3.67″ (9.3 cm). Guideway 2 would drop uniformly by the same amount, and lateral cables 10 and 11 would rotate around their tower attaching points, similarly to that of fourth tier suspension cable 6 . All other components of the span would expand directly proportional away from he center of the span, which remains in fixed location.
FIG 5 shows a typical expansion joint between adjacent truss supports of guideway 2 . Structural members 22 are held together by gussets 23 with lateral flanges to which machined bolt 24 is attached to one truss section and in sliding engagement with a bushing 25 attached to a counter-part of its adjacent truss section. Machined bolts 24 have sufficiently length to permit guideway 2 thermal expansions and contractions, which, with the assumption detailed for FIG. 4 above would come to 2.7″ (6.8 cm). Bolt heads 26 would prevent accidental disconnection of expansion joints. For cross-section of guideway 2 , as shown in FIGS. 2 & 3, there would be 5 expansion joints as shown in FIG. 5 at each tower 1 . Dampers may be added to limit motion in expansion joins to those caused by temperature change.
FIG. 6 depicts the general method of erecting the suspended elevated guideway using helicopters. After surveying and clearing the route, concrete tower footings 27 are poured and allowed to cure. A-frame towers 28 are secured to footings 27 by ground crews brought in by small helicopter 29 . Large helicopters 30 carry pre-assembled towers 1 and guideway 2 spans from assembly location to erection site. Suspended from helicopter 30 is a load spreader 31 with four hooked carrying straps 32 attached to the upper joints of second tier suspension cables 4 . Hooked hanging straps 33 are merely holding the loose cables 6 , 10 and 11 in readiness for hookup to their respective towers 1 . At the erection site, guideway 2 is lowered into place until spreader 31 , which is longer than the span between towers 1 , comes to rest with its front and rear end on top of towers 1 , at which time helicopter 30 disconnects and returns for its next load. The ground crew connects suspension cables 6 and lateral cables 10 and 11 to towers 1 , and guideway 2 to the previously installed guideway 34 using vertical adjusting means incorporated in carrying straps 32 to achieve proper alignment. To prevent newly connected towers 1 from bending under uneven load, spreaders 31 remain and support the weight of guideways 2 until the next following span is added.
High tension electric power line construction experience has shown that heavy lifting helicopters 30 can make about 60 trips per day when the assembly location is not more than 5 miles (8 Km) away. On that scale, the here-described methodology could achieve a construction rate of one-mile (1.6 Km) per day. Lifting capacity of these helicopters 30 is in excess of 10 tons. A 160 feet (50 m) long, 5 by 5 feet (1.5×1.5 m) cross-section aluminum spreader 31 would weigh about 3 tons, and an equally lightly constructed guideway 2 may weigh 4 tons, for a total of 7 tons.
FIG. 7 is a plan view of a guideway 2 span containing a horizontal curve. Fourth tier suspension cables 6 and longitudinal cable 7 are shown in heavy outline. They are located on the centerline of the arc of the span of guideway 2 . For curved spans with equal radii, attaching points 18 of fourth tier suspension cables 6 are located opposite each other on the top cross-bar of towers 1 , and their horizontal components of cable tension cancel each other out. However, in guideway 2 horizontal curvature transitions from straight-line to curved, between curves of different radii or S-curves, attaching points 18 of fourth tier suspension cables 6 are not located opposite each other on the top cross-bar of towers 1 . For high-speed guideways 2 , such transitions would take place over several spans and the opposite attaching point 18 discrepancy in each span would be minimal. A simple solution would be to have fourth tier suspension cables 6 split in two near the top of towers 1 and attached to the top cross bar at spaced apart locations.
The sameness of suspension achieved by this design can be demonstrated with a graphical force analysis at each junction point of the suspension cables. However in principle, since a horizontal cable cannot transmit a vertical force, an incremental increase in cable tensions due to a vehicle with weight W on guideway 2 must necessarily travel only upwards, from guideway 2 through first, second, third and fourth tier suspension cables to the top of towers 1 . Thus, incremental tension increase F x in each tier suspension cable due to weight W amounts to:
F x =W/ cos α x ,
where α is the angle between cable direction and vertical, and x the tier number.
Assuming FIG. 1 is drawn to scale, then approximate angles between cable directions and vertical are, first tier α 1 =38°, second tier α 2 =42°, third tier α 3 =63° and fourth tier α 4 =67°. If weight W is acting at the lower end of any first tier cable 3 , incremental tension increases in cables directly above due to weight W are, in first tier 1.27 W, in second tier 1.35 W, in third tier 2.20 W and in fourth tier 2.56 W. Force diagrams also show that incremental tension increases F horiz occur in horizontal cables 7 and 8 due to weight W. The magnitudes of F horiz depend on location of weight W as follows:
(a) In horizontal cable 7 when weight W is in span portion:
First and fourth quarter F horiz =W(tan α 3 +tan α 4 ),
Second and third quarter: F horiz =W(tan α 4 −tan α 3 )
(b) In horizontal cable 8 when weight W is in span portion:
First and fourth quarter: F horiz =0,
Third and sixth eighth: F horiz =W(tan α 2 +tan α 3 ),
Fourth and fifth eighth: F horiz =W(tanα 3 −tan α 2 ).
Using above measured angles, incremental tension increase in horizontal cable 7 ranges from 0.39 W to 4.32 W, and in horizontal cable 8 from zero to 2.86 W. Incremental tension increases F horiz due to vehicle weight W in one half of the span travel via horizontal cables 7 , 8 and 9 across mid-span to the other half of the span, redistributing themselves there in reverse order and causing lifting forces to act on guideway 2 . To prevent these lifting forces from inducing seesaw-rocking motions of guideway 2 spans in the wake of intermittently passing vehicles 13 , guideway 2 must be tied down at each tower 1 by cables attached with their lower ends to the legs of towers 1 . With a tension spring in parallel with a damper inserted in each tie-down cable at towers 1 , there would also be automatic length adjustment when guideway 2 spans rise and fall with temperature change. | Suspension cables for an elevated lightweight guideway are arranged so that high-speed traffic along the guideway is not subjected to guideway-induced oscillation. Furthermore, suspension cables are interconnected so that pre-assembled towers and guideway spans can be transported and rapidly installed by helicopter. | 4 |
CROSS-REFERENCE TO RELATED APPLICATIONS
The present Application is based on International Application No. PCT/EP2006/062972 filed on Jun. 7, 2006, which in turn corresponds to French Application No. 05 06178 filed on Jun. 17, 2005, and priority is hereby claimed under 35 USC §119 based on these applications. Each of these applications are hereby incorporated by reference in their entirety into the present application.
FIELD OF THE INVENTION
The present invention relates to a method for antimissile protection of vehicles and a device for using this method.
BACKGROUND OF THE INVENTION
The invention relates to the protection of vehicles such as aircraft (airplanes, helicopters) or ground vehicles (trucks, tanks) from the threat of missiles using infrared, TV or electromagnetic guidance, and more generally, missiles fitted with a target-seeking device, or associated with such a device.
Portable missiles, fired by a single individual, are a significant threat, both from a military point of view and with respect to possible terrorist use. The well-known example of the firing of an IR missile at a jumbo jet during takeoff by a lone activist located in the vicinity of an airport illustrates this type of threat.
In order to combat this type of threat, current solutions are based on the principle of detection of the threat and dealing with it using appropriate countermeasures. The detection is carried out by stationary (ground-based) systems or systems carried on moving vehicles and consists of either radar detection or optical detection. This detection uses tracking methods to trigger such countermeasures as evasive actions, active or passive radar decoys, passive or active infrared decoys and lasers, antimissile weapons, etc.
The current solutions have the following disadvantages. The use of a method of detection then a countermeasure to the threat requires a very short response time compared with the minimum flight time of a missile, since missile flight times are short. This constraint results in a potentially high rate of false alarms. If the system is mounted on an aircraft or a vehicle, the cost and the weight of the system are major factors in the selection of the solution. Moreover, the integration of optronic countermeasure systems into fleets which are already operational can be achieved by the addition of a detachable “pod” which may alter the aerodynamic characteristics of the carrier, which affects the consumption.
The use of decoys, such as infrared jamming canisters, is not possible near civil airports, because of the fire risks inherent in such devices. The use of laser jammers requires a missile/target tracking system ensuring the beam is aimed into the field of view of the missile.
SUMMARY OF THE INVENTION
An aspect of the present invention is a method for antimissile protection of vehicles which has a very short response time with practically no false alarms and not requiring the use of means such as decoys of the type previously mentioned or conventional laser jammers, while providing the best possible protection.
Another aspect of the present invention is also a device for antimissile protection of vehicles which is as simple and light and economical as possible.
In one aspect of the invention, a method for antimissile protection of vehicles includes creating one curtain of plasma filaments between these vehicles and the probable launch point of these missiles, this curtain being intended to blind the target-seeking device of the missiles.
According to one advantageous feature of the invention, the plasma filaments are close together so as to produce an almost continuous ionized layer.
According to another advantageous feature of the invention, the plasma curtain is created by a laser beam sweeping a corresponding portion of space in a plane generally perpendicular to the probable trajectory of missiles on the approach to threatened vehicles.
The antimissile protection device according to the invention is characterized in that it comprises a pulsed laser, a device for controlling the spectral phase of the laser and a spatial sweep device for orienting the laser beam in various directions in space.
Still other objects and advantages of the present invention will become readily apparent to those skilled in the art from the following detailed description, wherein the preferred embodiments of the invention are shown and described, simply by way of illustration of the best mode contemplated of carrying out the invention. As will be realized, the invention is capable of other and different embodiments, and its several details are capable of modifications in various obvious respects, all without departing from the invention. Accordingly, the drawings and description thereof are to be regarded as illustrative in nature, and not as restrictive.
BRIEF DESCRIPTION OF THE DRAWINGS
Other characteristics and advantages of the invention will become apparent with the aid of the description which follows in conjunction with the appended drawings which represent:
FIG. 1 is a simplified diagram of an example of a device for using the method of the invention for protection of an airport, its upper portion being a top view, and its lower portion a side view;
FIG. 2 is a simplified diagram of another example of a device for using the method of the invention for protection of an airport, its upper portion being a top view, and its lower portion a side view;
FIG. 3 is a simplified example of a device for using the method of the invention for protection of an airplane in flight; and
FIG. 4 is a simplified example of a device for using the method of the invention for protection of a ground vehicle, its lower portion being a top view, and its upper portion a front view.
DETAILED DESCRIPTION OF THE INVENTION
In brief, the invention includes making a plasma curtain by using a laser placed in a particular area. The purpose of the protective screen formed by this curtain is to prevent the homing devices of missiles from locking on to the target. The invention uses the properties of ultrashort laser pulses (preferably with a duration of less than 10 ps) to create filaments of plasma by ionizing the air. In fact, a laser pulse which spreads through the atmosphere can be focused on a given point in space to create a plasma at this point. Along the extension of this point a filament is then produced in the propagation axis of the beam. This filament spreads over long distances (up to several kilometers) and has emissivity properties like those of a black body brought to high temperature (>1000 K up to 3000° K.). This filament typically has a diameter of a few hundred microns.
The laser used by the invention is a pulsed laser, having a pulse repetition frequency for example between 10 Hz and 10 kHz. The duration of the pulses of this laser is as brief as possible, for example less than 10 ps. In fact, the longer the duration of these pulses, the more energy the laser must supply. This energy is advantageously between 1 mJ and several joules, its value depending in particular on the duration of the pulses and the characteristics of the filaments that need to be produced. The laser wavelength value is not critical. Advantageously, commercially available lasers are used, for example solid-state media of the titanium-sapphire type which have a wide fluorescence spectrum in the vicinity of the 800 nm wavelength, which makes it possible to produce sub-picosecond (“femtosecond”) pulses using CPA (“Chirp Pulse Amplifier”) technology.
The protective screen is created as follows. The output beam of the pulsed laser is made to sweep in a plane, to create a curtain of filaments that need to be placed between the vehicle to be protected and the homing device or aiming system of a missile. Since the filaments emit in the spectral bands of the sensors with which the homing devices (or target-seeking devices) of missiles are usually provided, a blinding effect and masking of the line of fire occurs. The screen formed by this curtain of filaments can be used either to prevent launches by neutralizing the target acquisition, or to jam the missile in flight by masking the target with an effect similar to that of decoys.
The inventive device, hereinafter simply called a “jammer”, essentially comprises the laser such as described above, a device for controlling the spectral phase of this laser and a spatial sweep device for the beam of this laser.
The construction of a laser for creating a filament of ionized air, and the control of the spectral phase of its beam with a view to controlling the length of this filament being already known, will not be described in more detail. A device for controlling the spectral phase of a laser beam is known for example according to the French patent 2 751 095. It will however be noted that since the device for deflection of a laser beam is also already known, the present description relates more particularly to the combination of these various means to produce a screen of filaments and its use for the protection of vehicles.
Schematically illustrated in FIG. 1 is a first embodiment of the invention for the protection of an airport, in which the inventive device is used to create a screen below the planes of descent or ascent of aircraft. The effect of this is to block the line of fire of the homing device of any missile ready to be fired from the side or into the rear section of the aircraft. The device is placed at the end of the runway and aims upward at an angle slightly less than that of the trajectories followed by the aircraft. An azimuthal sweep creates the curtain of filaments. In this FIG. 1 , the upper portion is a top view of an example of a configuration of a device of the invention for protecting an airport, while the lower portion of this figure is a side view of this same configuration.
It is assumed, as would usually be the case, that a possible threat of terrorist attack is likely to occur near the takeoff and/or landing runway 1 of an airport, from the ground and generally in an area where the aircraft are at low or very low altitude. To protect these aircraft, there is placed on the axis of the runway 1 , along the extension of its end, near this end, a jammer 2 of which the laser beam, when the laser is operating, in the rest position 3 (not sweeping), is directed along the axis of this runway, away from the runway, and of which the angle of elevation is slightly less than the angle of the landing (or takeoff) trajectory 4 of aircraft 5 . When the protective device is operating, the laser beam is made to sweep in a plane, generally symmetrically in relation to the rest position 3 . The plane in which this sweep takes place is such that its intersection with the ground is perpendicular to the axis of the runway 1 . The angle of deflection of the laser beam to provide this sweep depends, in particular, on the distance between the jammer and the edge 6 of the curtain 7 of plasma filaments (edge formed by the points of creation of the filaments) and the lateral extension of the zone 8 where the protection needs to be provided. It will be noted that this protection zone is slightly more extensive longitudinally and laterally than the curtain of filaments because the blinding by a plasma filament of a missile target-seeking device is caused in a space which is wider than the diameter of this filament. The frequency of this sweep depends on the lifetime of the filaments (a few hundred microseconds to a few tens of microseconds, even a few hundred microseconds, depending on the ionization of the medium in which these filaments are created). It is for example a few kHz. Thus, the plasma screen 6 protects the aircraft when they are near the runway 1 (within missile range) against missiles fired from a launch point 9 located near the runway 1 , the line of fire coming from this launch point (and passing through a point marked by a cross 10 on the drawing) being able to be directed toward any point in the protected zone 8 .
Of course, to provide better airport protection, it is advantageous to use crisscross multiple jammers placed at the ends of takeoff runways and/or at various distances from these ends. A simplified example of an airport protection is illustrated in FIG. 2 . Schematically illustrated in this FIG. 2 are two runways 11 , 12 which intersect and which have different orientations. Jammers 13 to 16 are placed near the ends of the runways 11 and 12 respectively, according to an arrangement similar to that of the jammer 2 in FIG. 1 . These jammers 13 to 16 create protected zones 17 to 20 respectively, similar to the zone 8 in FIG. 1 . In the case of a heliport, the same method is used to protect the low altitude approach or departure corridors of helicopters.
It is also possible to use a method for moving the curtain of filaments which follows the trajectory of the vehicle to be protected. This tracking can be generated at the laser by controlling the focusing distance and/or by controlling the spectral phase of the pulses in order to pre-compensate for the effect of dispersion of the propagation medium, i.e. the atmosphere. Schematically illustrated in FIG. 3 is an example of using such a method at an airport similar to the one in FIG. 2 , and comprising the runways 11 and 12 . Illustrated is only one mobile protection zone for one jammer 14 A (similar to the jammer 14 , but able to produce a mobile protection zone). It is clearly understood that all the other jammers 13 A, 15 A and 16 A (similar to the jammers 13 , 15 and 16 respectively) can have the same characteristics as the jammer 14 A. Illustrated are various successive positions 21 to 24 of the protection zone created by the jammer 14 A, the movement of this protection zone being synchronized with the movements of the aircraft to be protected, advantageously so that the aircraft is generally near the center of the protection zone at all times.
Of course, as illustrated in FIG. 4 , the jammer of the invention can be used in the case of the protection of a convoy 25 of moving vehicles on the ground (cargo trucks, for example) against a ground-ground threat (a tank 26 , for example). In that case, the geometry of the plasma curtain 27 generated on board at least one of the vehicles (for example by the jammer 28 placed in the tail vehicle 29 ) is in the form of a vertical plane placed between the whole of the convoy 25 and the threat 26 .
According to another embodiment of the invention, the plasma of the filaments of the curtain of filaments is initiated by using a femtosecond pulsed laser of the type described above, and as soon as the initiation has taken place, instead of maintaining the ionization of these filaments by using the same femtosecond laser, it is maintained by using a power laser of the pulsed type (of a few watts to a few kilowatts, depending on the duration of its pulses), producing relatively long laser pulses (with a duration of several nanoseconds to several microseconds), of which the wavelength is not very critical (it can be located in the infrared, the visible or the ultraviolet).
An advantageous application of the method of the invention consists in generating remotely a virtual object moving in space, this object being either a plasma curtain or a plasma filament. This virtual object can have the dimensions and the form of normal ground or air vehicles, and its movements can, due to its intense brightness, either simulate the trajectory of a vehicle in space, or act as decoys capable of attracting optronic homing sensors. Thus, the protection of real vehicles described above can be replaced or supplemented, by attracting the missiles toward these virtual objects.
The main advantages of the method of the invention and the device for using it are that it does not use a missile detector, and is therefore not limited by a rapid response loop, it helps to mislead optronic homing device missiles and it does not produce any chemical, mechanical or more generally material residues.
It will be readily seen by one of ordinary skill in the art that the present invention fulfills all of the objects set forth above. After reading the foregoing specification, one of ordinary skill will be able to affect various changes, substitutions of equivalents and various other aspects of the invention as broadly disclosed herein. It is therefore intended that the protection granted hereon be limited only by the definition contained in the appended claims and equivalents thereof. | The present invention relates to a method for antimissile protection of vehicles having a very short response time with practically no false alarms and not requiring the use of means such as decoys or conventional laser jammers, while providing the best possible protection. It is characterized in that at least one curtain of plasma filaments is created between these vehicles and the probable launch point of these missiles, this curtain being intended to blind the target-seeking device of the missiles. | 5 |
BACKGROUND OF THE INVENTION
The present invention relates generally to method and apparatus for adjusting vehicle wheel alignment and, more particularly, to method and apparatus for adjusting caster and camber in a vehicle steerable wheel suspension assembly.
Many utility vehicles such as trucks and four-wheel-drive vehicles have a front wheel suspension assembly which includes a fixed axle housing which pivotally supports a wheel knuckle through a pair of ball joints. The wheel knuckle supports a wheel spindle which, in turn, rotatably supports a vehicle wheel assembly.
A number of devices have been provided for adjusting the camber and/or caster of wheels supported by such suspension assemblies. Such adjustment devices are generally of two types: (1) wheel shim-type adjustment devices, or (2) bushing-type adjustment devices.
Plate-type adjustment devices generally comprise a tapered shim member which is interposed between the steering knuckle and spindle. The amount of shim taper and the orientation of the shim determine the amount of camber adjustment provided. Grove, U.S. Pat. No. 4,037,680, issued July 26, 1977, which is hereby specifically incorporated by reference for all that is disclosed therein, describes such a camber adjusting shim.
Bushing-type camber and/or caster adjustment devices are described in Ingalls et al., U.S. Pat. No. 4,252,338, issued Feb. 24, 1981; Ingalls, U.S. Pat. No. 4,400,007, issued Aug. 23, 1983; Ingalls et al., U.S. Pat. No. 4,420,272, issued Dec. 13, 1983; and Drotar et al., U.S. Pat. No. 4,509,772, issued Apr. 9, 1985, all of which are hereby specifically incorporated by reference for all that is disclosed therein. In bushing-type camber adjustment devices, a camber and/or caster adjustment bushing is mounted in a bore portion of an axle housing. The bushing member has a generally cylindrical shape and has a bore extending therethrough which is adapted to accept the shaft portion of the ball joint therein. The bore which extends through the bushing is positioned in noncoaxial relationship with the central longitudinal axis of the bushing. Camber and/or caster adjustment are provided by relative rotation of the bushing within the associated bore in the axle housing. Due to the noncoaxial alignment of the bushing bore with the bushing central longitudinal axis, rotation of the bushing causes relative shifting displacement in the lower end of the ball joint which is mounted in the associated wheel knuckle. Relative forward and rear shifting movement of the ball joint lower end portion produces a change in the "caster" of an associated wheel. Relative lateral shifting movement of the ball joint lower end portion produces camber adjustment.
In certain vehicles manufactured by the Ford Motor Company, locating lugs are positioned adjacent to a bushing mounting bore in an axle housing. Camber adjustment bushings are provided which have peripheral cutouts in head portions thereof. These bushings are adapted to be installed in an associated axle housing bore with the cutout portions thereof engaged with the locating lugs. Such bushings are adapted to be positioned in a first orientation for providing a positive camber setting and a second, 180° rotated position for providing a negative camber setting. No incremental camber adjustments between these two positions may be provided. No caster adjustments are provided by such bushings. Generally, a plurality of such bushings are provided. A different camber adjustment is provided by each bushing, e.g. plus or minus 1/4 degree, plus or minus 1/2 degree, plus or minus 3/4 degree, etc. In order to adjust camber using such bushings, it is necessary to first install the bushing in either a positive or a negative camber adjustment position. Next, the associated ball joint shaft is mounted in the bushing and the camber of the wheel is measured. If the camber is incorrect, it is necessary to remove the ball joint, remove the bushing, and select another bushing. The next bushing is then installed and the process is thus repeated until a bushing having the correct amount of camber adjustment has been selected.
A bushing assembly described in Ingalls, U.S. Pat. No. 4,400,007, includes a bushing member, annular lock ring, and snap ring which enable multiple camber and caster adjustments to be provided in a Ford-type suspension system as described above, without removal of the bushing member from the axle housing bore. However, a problem with this bushing assembly is that the surface portions of the bushing and lock ring members have relatively complex configurations which add significantly to production costs. Another problem with the bushing assembly of U.S. Pat. No. 4,400,007 is that only a limited number of alignment settings are provided.
SUMMARY OF THE INVENTION
The present invention is directed to a method and apparatus for adjusting at least one wheel alignment parameter in a steerable wheel suspension system.
The invention may comprise: a steerable wheel suspension assembly comprising: fixed axle housing means for pivotally supporting a wheel knuckle means therein; wheel knuckle means for supporting a wheel spindle thereon; first ball joint means for pivotally connecting said axle housing means with said wheel knuckle means; said ball joint means comprising a shaft portion mounted in said axle housing means and a ball housing portion mounted in said wheel knuckle means; bushing means having a central bushing axis and having a bushing bore extending therethrough having a central bore axis positioned in noncoaxial relationship with said central bushing axis; said bushing means being received in a bore in said axle housing means and being rotatable therein about said central bushing axis; said ball joint shaft portion being received in said bushing bore; bushing head means fixedly attached to said bushing means and projecting radially outwardly therefrom; annular plate means located between said bushing head means and said axle housing means and rotatably received about said bushing means for facilitating angular adjustment between said bushing means and said axle housing means; plate locking means for locking said plate means in angularly fixed relationship with said axle housing means; adjustable bushing locking means for locking said bushing means in a selected angular orientation with respect to said annular plate means.
The invention may also comprise a bushing assembly for adjusting at least one wheel alignment parameter for use in a vehicle wheel suspension system of the type having a suspension member with a bore therein having a central longitudinal axis and adapted for mounting a ball-joint-shaft-receiving bushing and with at least one positioning surface located adjacent to the bore in the suspension member, comprising: (a) a bushing member comprising: a generally cylindrical body portion adapted to be inserted into the suspension member bore; a head portion fixedly attached to one end of said body portion and extending radially outwardly therefrom and having axially extending post receiving head opening means therein for receiving a post means; a ball-joint-shaft-receiving bore extending through said body portion and said head portion and having a central bore axis positioned in noncoaxial relationship with said cylindrical body central longitudinal axis; (b) an annular locking member comprising: a first end surface adapted to be positioned adjacent to said bushing member head portion and a second end surface adapted to be positioned adjacent to the suspension member; a central bore extending therethrough adapted to receive said bushing member body portion therein; post receiving locking member opening means selectively axially alignable with said post receiving head opening means for receiving said post means; a positioning surface engaging means for engaging the positioning surface on the suspension member for preventing relative rotation of said annular locking member with respect to the suspension member bore; (c) post means insertable into said post receiving head opening means and said post receiving locking member opening means for preventing relative rotation between said bushing member and said locking member.
The invention may also comprise: a bushing assembly for adjusting at least one wheel alignment parameter for use in a vehicle wheel suspension system of the type having a suspension member with a bore therein adapted for mounting a ball-joint-shaft-receiving bushing, comprising: (a) a bushing member comprising: a generally cylindrical body portion adapted to be inserted into the suspension member bore; a head portion fixedly attached to one end of said body portion and extending radially outwardly therefrom and having first axially extending opening means therein for receiving a post means; a ball-joint-shaft-receiving bore extending through said body portion and said head portion and having a central bore axis positioned in noncoaxial relationship with said cylindrical body central longitudinal axis; (b) second axially extending opening means stationarily associated with said suspension member means and selectively axially alignable with said first opening means for receiving said post means; (c) post means axially insertable into said first and second opening means for preventing relative rotation between said bushing member and said suspension member.
The invention may also comprise a method of correcting a wheel alignment parameter in a vehicle wheel suspension system of the type having a first suspension member connected to a second suspension member by a ball joint and having a bore in the first suspension member adapted to receive a ball joint bushing assembly and having a positioning lug located adjacent to the bore comprising the steps of: (a) mounting an annular locking member on the first suspension member with a recessed axial end surface thereof in locking engagement with the positioning lug; (b) inserting a bushing member through a central opening in the locking member; (c) inserting the bushing member into the bore in the first suspension member; (d) inserting the shaft portion of a ball joint assembly through a bore in the bushing member; (e) rotating the bushing member within the bore in the first suspension member until an associated wheel assembly is located in a desired wheel alignment position; (f) axially inserting at least one pin through aligned bores in the locking member and bushing member so as to prevent relative rotation therebetween.
BRIEF DESCRIPTION OF THE DRAWINGS
An illustrative and presently preferred embodiment of the invention is shown in the accompanying drawings in which:
FIG. 1 is perspective view of a portion of a prior art front wheel suspension assembly.
FIG. 2 is a detail perspective view of an installed bushing and ball joint of the suspension assembly of FIG. 1.
FIG. 3 is an exploded perspective view of an adjustable bushing assembly and a portion of a suspension member.
FIG. 4 is a bottom plan view of a bushing member of the bushing assembly of FIG. 3.
FIG. 5 is a bottom plan view of an annular plate member of the bushing assembly of FIG. 3.
FIG. 6 is a front elevation view of the bushing assembly of FIG. 3 installed in a suspension member.
FIG. 7 is a top plan view of the installed bushing assembly of FIG. 6.
DETAILED DESCRIPTION OF THE INVENTION
Prior Art Suspension Assembly
FIG. 1 illustrates a portion of a prior art steerable front wheel suspension assembly. This suspension assembly includes a fixed axle housing 10 which is adapted to have a wheel knuckle 12 pivotally mounted thereon by means of a pair of ball joints 14, 16.
The fixed axle housing 10 comprises an upper yoke portion 22 having a cylindrical bore 24 therethrough. The bore 24 may comprise a generally vertically oriented central bore axis AA. The axle housing comprises a lower yoke portion 26 which has a cylindrical bore 28 extending therethrough which may have a central longitudinal axis BB extending parallel to upper bore axis AA.
The wheel knuckle 12 may comprise an upper portion 30 having a cylindrical bore 32 therein and a lower portion 34 having a cylindrical bore 36 therein. The bores 32, 36 may have parallel central longitudinal bore axes.
The ball joints 14, 16 may be identical in construction, each comprising a ball joint shaft 40 having a first, threaded end portion 42 which is adapted to receive a nut 43 thereon and having a second end portion 44 which terminates in a ball configuration The ball portion 44 is received in a ball joint housing 46 which is adapted to be fixedly mounted as by a press fit in an associated bore 32 or 34 of the wheel knuckle 12.
A bushing 50 is provided having an outer cylindrical surface 52 and having a radially projecting head portion 54. A bore 56 extends through the bushing and comprises a central longitudinal bore axis CC which may be positioned in either skewed or eccentric relationship with the central longitudinal axis DD of the cylindrical bushing. The bushing 50 is adapted to be positioned in close-fitting relationship with bore 24 of the axle housing. The bushing comprises peripheral cutouts 58, 60 in the head portion 54 thereof which are adapted to closely receive locating lugs 62, 64 provided on the upper surface of the axle housing adjacent to bore 24. The lugs may project upwardly approximately 1/2 inch and may have a width of approximately 3/8 inch. The bushing 50 provides a fixed amount of positive camber adjustment or a fixed amount of negative camber adjustment depending upon the relative rotated position of the peripheral cutouts 58, 60, with respect to the locating lugs 62, 64.
Adjustable Bushing Assembly
FIG. 3 illustrates an adjustable bushing assembly 68 which is adapted to be used in a steerable front wheel suspension assembly of the type illustrated in FIGS. 1 and 2. The adjustable bushing assembly 68 replaces the prior art bushing 50 and provides a plurality of positive and negative camber adjustment settings as well as a plurality of positive and negative caster adjustment settings The bushing assembly comprises a bushing member 70, an annular locking member 72, and a post member 74.
The bushing member has a cylindrical body portion 80 having a central longitudinal axis MM and a cylindrical outer surface 82. A ball joint receiving bore 84, which in one embodiment comprises a truncated cone, extends through the cylindrical body portion 80. The central longitudinal axis NN of the bore 84 is positioned in noncoaxial relationship with axis MM of the cylindrical body portion. In the illustrated embodiment, bore axis NN is positioned in skewed relationship with cylindrical axis MM, FIG. 6.
The bushing member has a radially projecting head portion 86 having a planar top surface 88 which project perpendicularly to the bore axis NN. The head portion 86 comprises a planar bottom surface 90 which extends perpendicular to the cylindrical axis MM. The bore 84 extends continuously through the bushing head portion 86 as well as the cylindrical body portion 80. A pair of small-diameter, e.g. 0.125 inch, bores 92, 94 are provided in peripheral, diametrically opposed positions on the head portion and extend parallel to the cylindrical axis MM.
The bushing member cylindrical body portion may have an outside diameter of 1.40 inches and may have an axial length of 1.08 inches. The head member may have a generally square configuration as viewed axially of the cylindrical body portion. The square head configuration may be, e.g., 2.0 inches on a side. The minimum thickness of the head portion may be 0.230 inches, and the maximum thickness may be 0.520 inches. An axially and radially extending cut 96 having a width of 1/16 inch may be provided in the bushing member 70 to facilitate press insertion of the bushing member into an associated axle housing bore 24.
The annular locking member 72 comprises a planar top surface 102 and a planar bottom surface 104. The locking member 72 has a central cylindrical bore 106 extending therethrough having a bore axis PP which is adapted to be positioned in coaxial alignment with the bushing member central longitudinal axis MM. Lug engaging channels 108, 110 which may have a width of, e.g., 0.4 inches and a depth of, e.g., 0.125 inches are provided on the bottom portion of radially and circumferentially extending surface 112 and a pair of radially and axially extending surfaces 114, 116. A plurality of evenly circumferentially spaced, axially extending holes 120, 122, 124, which may each have a diameter of, e.g., 0.125 inches and which may be circumferentially spaced 10° apart, are provided near the periphery of the annular member 72. The radial distance of each of the circumferentially spaced bores 120, 122, etc., from the central longitudinal axis PP of the annular member is the same as the radial spacing of the bores 92, 94 from the central longitudinal axis MM of the bushing member. This distance, in one preferred embodiment, is 1.125 inches. In one preferred embodiment, the diameter of the annular member 72 is 2.50 inches, and the total axial dimension of the annular member is 0.250 inches The diameter of the annular locking member central bore 106 may be 0.70 inches.
The post member 74 may comprise a conventional cotter pin.
In order to adjust camber or caster with the bushing assembly 68, the associated vehicle is suspended on a lift and a conventional wheel alignment electronic measuring device is attached to the front wheel which is to be aligned.
Next, the nut 43 of the upper ball joint 14 is removed and the existing bushing 50 is removed from the axle housing upper bore 24. Next, the annular locking member 72 is installed with the cutout portions 108, 110 thereof in engagement with the alignment lugs 62, 64. The cutouts 108, 110 are adapted to closely receive the lugs 62, 64, thus the annular member 72 is locked against rotation about central longitudinal axis PP thereof.
Next, the body portion 80 of the bushing member is inserted though the central bore 106 in the locking member 72 and is pressed into bore 24 until the lower surface of the head portion 86 engages the upper surface of the annular ring member 72. The ball joint shaft is received through the bore 84 in the bushing member as it is installed, and thus the threaded end portion of the ball joint member projects from the bushing member, as illustrated in FIGS. 6 and 7, after the bushing member is pressed into position.
Next, the bushing member is rotated, as through the use of a conventional wrench engaged with the bushing head portion, until a desired camber and/or caster position in indicated by the wheel alignment measuring device.
Next, a cotter pin 74 is inserted through at least one of the bores 92, 94 in the bushing head portion and an aligned bore in the annular locking member 72 and is fixed into position therewith. In a preferred embodiment of the invention, there is sufficient clearance, e.g. 0.25 inches, between the bottom surface of the annular locking member 72 and the upper surface 25 of the axle housing to enable conventional bending of the tip of a cotter pin received thorough member 72, as best illustrated in FIG. 6. In another embodiment (not shown) in which no such clearance is provided, the post member 74 rather than a cotter pin may comprise a tight-fitting shaft member which may be pressed through bores 94, 120, etc., or a member 74 having threads thereon which may be threadingly inserted through bores 94, 120, etc.
A plurality of bushing members 70, each having a bore which is positioned at a different inclination or offset from the central longitudinal axis of the bushing, may be provided to enable different ranges of camber and/or caster adjustment.
In another embodiment of the invention as shown in phantom in FIG. 3, the bushing member head portion is provided with a plurality of circumferentially spaced, axially extending bores 210, 212, etc., which are adapted to be selectively aligned with a small-diameter, axially extending bore 220 in the housing portion itself. The bushing may be locked into position with respect to the housing portion by a suitable post member such as 74 received through selected bushing head bore and through the housing bore.
While an illustrative and presently preferred embodiment of the invention has been described in detail herein, it is to be understood that the inventive concepts may be otherwise variously embodied and employed and that the appended claims are intended to be construed to include such variations except insofar as limited by the prior art. | A bushing assembly for adjusting at least one wheel alignment parameter for use in a vehicle wheel suspension system of the type having a suspension member with a bore therein adapted for mounting a ball-joint-shaft-receiving bushing and with at least one positioning surface located adjacent to the bore in the suspension member, including a bushing member with a generally cylindrical body portion and a radially extending head portion having a ball joint shaft receiving bore therethrough; an annular locking member having at least one recess in a bottom portion thereof for engaging the suspension member locating surface; and a post member insertable through axially extending peripheral bores in the locking member and the bushing head portion for adjustably locking the bushing member against rotation with respect to the locking member, the locking member being positioned between the bushing head portion and the suspension member. | 1 |
BACKGROUND OF THE INVENTION
Removal of contaminants or debris from a flowing liquid stream by the employment of a filter media comprised of particulated filter material is old in the art, as evidenced by the patents listed herebelow. These prior U. S. patents teach the advantages of using various different sizes of various different particulated filter material. Many of the described filter systems require that the filter media be removed from the filter vessel each time it becomes necessary to scrub the contaminant from the media, thereby enabling the media to be used many times. These prior art systems require a considerable amount of additional space, and complicated plumbing must be connected between the various pumps, valves, and other mechanical members in order to interconnect the scrubbing vessel and filtering vessel so that various different predetermined flow patterns are attained. A substantial amount of equipment is required in order to return the filter media to the filter vessel. In addition to the added cost and the required additional space considerations, all of the external plumbing presents a continued maintenance problem; and, the numerous additional mechanical connections involved therein greatly increase the likelihood of leakage occurring from the different components of the filter system.
Furthermore, when transferring the filter media from the filter vessel into the scrubber vessel, one is never absolutely certain that all of the filter media has been properly translocated from one to the other vessel. Hence, in the absence of visual or other exacting determinations, one is never sure exactly what has been scrubbed in the scrubber vessel. Moreover, after the filter media has been scrubbed in the scrubbing vessel, it is never certain that all of the filter media has been returned to the filter vessel, in the absence of exact determination thereof. Accordingly, it would be desirable to have made available a filter system wherein the filter media remains within the filter vessel for the entire life of the media, and wherein the filter media is scrubbed or rejuvenated without removing the filter media to a second vessel. A filter system which achieves these and other desirable and novel attributes is the subject of the present invention.
______________________________________THE PRIOR ART______________________________________Hirs 25,761 Martin 2,136,660Hirs 3,557,955 Stuart, Sr. 3,557,961Hirs 3,737,039 Toth 3,757,954Hirs 3,780,861 Maroney 3,812,969______________________________________
SUMMARY OF THE INVENTION
The invention encompassed by this disclosure broadly comprehends filtering a liquid through a filter media, and thereafter scrubbing the media insitu, and thereafter filtering a liquid through the scrubbed media. More specifically the invention includes a vessel within which there is enclosed a filter media comprised of particles of particulated filter material. A screen means is positioned at the lower end of the vessel and below most of the filter media, while the upper end of the vessel provides a liquid and scrubbing space, with there being a contaminated water inlet, and a clean water outlet attached to the vessel in a manner whereby flow of dirty or contaminated water is conducted into the upper end of the vessel, proceeds down through the filter media, where the filter media removes the contaminants from the flowing liquid, whereupon the clean water flows through the screen, through the outlet, and away from the vessel, leaving the contaminants and media within the vessel.
From time to time, as the removed contaminants progressively accumulate within the vessel, the filter media is scrubbed clean, thereby re-establishing the original filter efficiency. The scrubbing of the media is carried out within the vessel by flowing the liquid along a unique flow path within the vessel, to cause great agitation of the media, to thereby translocate the removed contaminants from the media into the scrubbing liquid. The highly contaminated scrubbing liquid is then discharged from the vessel in an unusual manner, while relatively clean make-up water is added thereto.
Next, the filter media is reset or repositioned into the lower end of the vessel by shutting down all systems which causes the media to gravitate to the bottom. Thereafter, the various flow lines are cleaned by flowing filtered liquid from the vessel, along a closed circuit, and back into the vessel, thereby separating any residual contaminants from the liquid. The filter system is placed back on stream and used until the contaminant load on the media again increases to a magnitude which justifies undertaking another cleaning cycle.
The scrubbing cycle preferably is achieved by disposing the inlet and outlet of a pump means within the upper end of the vessel, and directing the outlet of the pump towards a circulation guide means. The guide means is supported at a central location respective to the interior of the vessel, with the guide means preferably being located slightly above the prescribed media level. The outlet of the pump is connected to a discharge nozzle which is arranged slightly above and in axial alignment with the guide means. This unusual arrangement of the scrubbing apparatus enables the pump suction to take liquid from the upper end of the vessel and to force the liquid through the guide means, whereupon the guide means directs the liquid down towards the bottom of the vessel. This action sets up a desirable flow pattern wherein the filter media becomes intimately admixed with the liquid contained within the vessel and great agitation of the individual particles of the media achieves an unusually efficient cleaning and scrubbing action. The flow at this time follows a geometrical flow path which is in the form of a toroid having a central vortex which coincides with the axial centerline of the vessel, with the outer upward flowing part of the vortex being confined by the inner peripheral wall surface of the vessel.
In one embodiment of the invention, the circulation guide means is in the form of an annular area, with an annulus being formed between an outer barrel and an inner screen means. The inner screen means is preferably cylindrical and arranged to provide the before mentioned outlet through which the heavy contaminated scrubbing water is exhausted from the system during a blow-down cycle which occurs towards the end of the scrubbing cycle. Hence, the inner screen precludes significant loss of filter media from the vessel during the scrubbing cycle. Another screen means is mounted below the filter media near the bottom of the vessel and precludes significant loss of media during the main filtering cycle.
Accordingly, a primary object of the present invention is the provision of method and apparatus for sequentially filtering with and then cleaning a filtering media which is used to filter a stream of liquid.
Another object of the invention is to provide method and apparatus by which a contaminated stream of liquid is filtered for one interval of time to provide separation of the contaminants and the liquid, and the filter media is then scrubbed clean in a new and unobvious manner during another interval of time, with the filtering step and cleaning step both occurring within the same enclosure.
A further object of this invention is to disclose and provide a method of filtering a stream of contaminated liquid by flowing the contaminated liquid into a vessel having a liquid space and a filter media space; whereupon, the contaminated liquid proceeds through the filter media, thereby leaving the contaminant within the media, so that clean, filtered liquid exits from the vessel; and, thereafter, the filter media is scrubbed without removing the media from the vessel.
A still further object of this invention is to provide an unusual and unobvious filter system having particles of filter media contained therein which filters contaminants from a flowing liquid, and wherein the filter media is occasionally scrubbed clean of contaminants, and the contaminants removed from the system, with both the scrubbing and filtering action occurring within the same vessel.
Another and still further object of the present invention is the provision of method and apparatus by which contaminated liquid flows into a liquid containing part of a vessel, through a filter media containing part of the vessel, thereby filtering the contaminant from the liquid and providing clean liquid as the liquid stream exits the vessel. The filter media is scrubbed within the vessel by flowing liquid through a circulation guide means which agitates the mixture of liquid and filter media in a manner to cause the contaminants to be translocated from the media into the liquid. The contaminated liquid is replaced with relatively clean liquid, and thereafter the filter media is repositioned within the media containing part of the vessel. A closed circuit flow path cleans contaminated liquid from the lines, and the filter then resumes efficient operation until the load of contaminant on the media necessitates another scrubbing cycle.
An additional object of the present invention is the provision of apparatus by which a contaminated stream of liquid is cleaned by flowing the contaminated liquid through a vessel containing particulated filter material which separates the contaminants from the liquid as the liquid flows therethrough. The media is scrubbed within the vessel by the employment of a pump means which flows liquid within the vessel along a toroidal flow path achieved with a circulation guide means. The circulation guide means causes the contaminants to be translocated from the filter media into the liquid contained within the vessel so that the contaminated liquid can be disposed, while relatively clean liquid flows thereinto.
These and other objects and advantages of the invention will become readily apparent to those skilled in the art upon reading the following detailed description and claims and by referring to the accompanying drawings.
The above objects are attained in accordance with the present invention by the provision of a method for use with apparatus fabricated in a manner substantially as described in the above abstract and summary.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a part diagrammatical, part schematical, side elevational view of a filter system made in accordance with the present invention;
FIG. 2 is a diagrammatical representation of part of the system seen in FIG. 1, and showing the flow characteristics during one part of the cycle of operation of the system;
FIG. 3 is a part diagrammatical, part schematical representation showing the filter system of FIGS. 1 and 2, shown in another operative configuration;
FIG. 4 is an enlarged, more detailed, longitudinal, cross-sectional representation of a filter apparatus made in accordance with the present invention;
FIGS. 5, 6, 7, and 8, respectively, are cross-sectional views taken along lines 5--5, 6--6, 7--7, and 8--8, respectively, of FIG. 4;
FIG. 9 is a cross-sectional view taken along line 9--9 of FIG. 5;
FIG. 10 is an enlarged, detailed, cross-sectional view of part of the apparatus disclosed in some of the foregoing figures; and,
FIG. 11 is a fragmentary, detailed, part cross-sectional representation of a modification of part of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In FIG. 1, there is disclosed a filter system 10 made in accordance with the present invention. The system 10 includes a vessel 12 having an inlet 14 located at the upper extremity 16 thereof. A filter media level 18 is defined by the uppermost surface of the particulated filter material 20 which is enclosed within the lower end of the vessel 12. A screen means 22, which can take on several different forms, is supported within the lowermost end of the vessel, and preferably is comprised of an array of screens, the details of which will be more thoroughly discussed later on in this disclosure. The screen means 22 is connected to outlet 24.
The arrows at numeral 26 broadly indicate scrubbing apparatus, made in accordance with the invention, by which the filter media 20 can be scrubbed while remaining within the interior of the vessel 12. The scrubbing apparatus includes a pump means 28 having a suction 30 located to receive flow from the upper end 16 of the vessel, and further includes the illustrated outlet shown connected to an outlet nozzle 32. A circulation guide means 34 is provided with a guide inlet 36, annulus 38, guide outlet 40, and interior scrubbing screen means 42. A back-wash discharge 44 is connected to receive flow from annulus 38, with the back-wash flow being directed through screen 42, so that liquid exits through the back-wash discharge 44.
As best seen illustrated in FIG. 3, during a scrubbing cycle a toroidal flow path 46 is established within the vessel 12, with the entire contents of the vessel being forced to assume the toroidal flow path and flow from the lower end 48 to the upper end 16 of the vessel, as illustrated. Numeral 50 indicates an outer barrel which forms part of the circulation guide means 34.
In FIGS. 4-10, together with other figures of the drawings, there is disclosed additional details of the present invention. As seen in FIG. 4, for example, the free upper terminal end 52 of the scrubbing inner screen means 42 is positioned in close proximity of the circulation guide inlet 36. The scrubbing screen means 42 is supported by a vertical support conduit 54. Conduit 54 is connected to the back-wash discharge 44. Valve 56 controls the flow of liquid through the back-wash discharge.
The before mentioned outlet header 24 is connected to a three-way valve 58 which controls flow of liquid from the vessel to a clean water outlet 60, and to conduit 62, which is a feed pump suction for clean tube purge cycle. Numeral 64 generally indicates a plurality of lower screens, each of which are connected to the before mentioned outlet header 24. The lower screens are located near the bottom of the vessel 12, and the details thereof will be more fully discussed later on in this disclosure.
Three-way valve 66 is connected to control the flow of contaminated water to pump 67 and into the inlet 14, and to receive flow from conduit 62. Numeral 68 indicates the free terminal end of the piping which forms the inlet 14.
In FIGS. 4 and 10, a pump discharge line 70 is connected to the outlet of pump 28. The pump 28 preferably has the suction 30 thereof located within the upper end 16 of the vessel, below the liquid level thereof, so that inexpensive seals such as associated with an open impeller can be advantageously employed in the system. Numeral 72 indicates the interior of the inner scrubbing screen means. In FIG. 4, numeral 74 indicates the bottom of vessel 12 while numeral 75 indicates the top thereof. In FIG. 9, the lower screen 64 and inner screen 42 are seen to be provided with a plurality of slots 76 which are discontinuous, thereby leaving lands 78 by which the slotted screen elements are attached to one another. Numeral 80 indicates the interior of the lower screens.
In FIGS. 1 and 2, it will be noted that valve 58 is connected to provide flow along two different flow paths, one of which is a closed path defined by 24, 58, 62, 66, 67, 14, 16, 18, 20, and 22. The valve 58 is also connected to provide flow from 24, 58, 82, and into the wellhead W and down through the string of well tubing 84.
As seen in FIG. 2, during the filtering mode of the invention, flow occurs from inlet 14, proceeds down through the upper end 16 of the vessel 12 as noted by numeral 86, where the flow continues in a downward direction at 88 through the top 18 of the filter media 20 as indicated by the arrow at numeral 90, where the flow enters the lower screens 22 and continues through the header at outlet 24, thereby providing clean water free of contaminants.
In FIG. 10, numeral 92 indicates a build-up or layer of filter material on the inner screen, while numeral 93 indicates the absence of any appreciable amount of filter media attached to the inner screen. Numeral 94 and 96 indicate the dynamic flow of particles of filter material admixed with contaminants through the annulus 38. As indicated, the discharge nozzle 32 provides a flow at velocity V1 which is reduced to velocity V2 as the flow is induced through annulus 38. Velocity V3 indicates entrained liquid from proximity of the inlet end 36 of the circulation guide. Velocity V4 indicates the velocity of material exiting the circulation guide outlet. The arrows at numeral 98 indicate highly contaminated liquid flowing into the interior 72 of the scrubbing inner screen means 42.
The scrubbing cycle is diagrammatically disclosed in FIG. 3, wherein a toroidal flow path 46 is established down through the annulus 38 and up along the outer annular area of the vessel 12. Pump suction 30 is connected to pump 28 which provides flow through nozzle 32 of piping 70. During the first part of the scrubbing cycle, it is preferred that only the internal toroidal flow path 46 be employed. During the latter part of the scrubbing cycle, contaminants are evacuated from the liquid phase of the vessel as a back-wash discharge at 44, while make-up water at 67 replaces the discharged material.
In FIG. 11, a screen means in the form of a flat plate 164 has been substituted for the wedge tubes. The flat plate member 164 has closely spaced slots 132 formed therein, thereby forming a lower screen 164 for supporting the filter media 20. Outlet 124 is connected to chamber 125 formed by the lower screen means 164.
In FIG. 1, a pressure sensor is connected at 108 to pipe 24, and at 110 to pipe 14, thereby enabling the computer 112 to monitor the pressure drop across the media. Scrubbing pump 28 is controlled at 114, while the operation of valves 56, 58, and 66 are computer controlled by circuitry 116, 118, and 120. Feed pump 67 is computer controlled by circuitry 122.
The computer is programmed to switch the variables of the system to achieve various modes of operation in accordance with the desired program thereof.
OPERATION
The method of the present invention is set forth in FIGS. 1-3, wherein, in FIG. 1, there is disclosed a source of contaminated liquid S, as for example salt water containing the following contaminants: sludge, scale, dirt, fiber, and other debris of relatively small particle size which is inherently suspended within the liquid pumped at P1 and through the valve 66. The valve 66 is a three-way valve which enables liquid to flow from S into the inlet 14, or alternatively from valve 58 and then through the inlet 14.
In the first mode of operation, contaminated liquid enters the upper end 16 of the vessel 12 and flows down through the filter bed 20 in the indicated manner of FIG. 2, whereupon the contaminants are removed from the liquid, and clean liquid exits at header outlet 24. The clean liquid at 24 flows along conduit 24, through three-way valve 58, into the wellhead W of the illustrated borehole, down through the tubing string 84 and into a geological strata located downhole in the borehole.
It should be understood that the employment of clean filtered water at 24 for purposes of the illustrated water flooding at W is illustrative of one of a multitude of uses for the apparatus and method of the present invention. Similarly, the use of contaminated salt water at source S is illustrative of one of a manifold of different liquid streams requiring filtration which can be used according to method and apparatus of the present invention.
The filtering process continues in accordance with FIGS. 1 and 2 until the magnitude of the removed contaminants unduly increase the load on the filter media, causing the pressure drop across the media 20 to attain the threshold of uneconomical or inefficient operation. At this stage of the operation, valves 58 and 66 are moved to the alternate closed positioned while simultaneously pump 28 is energized and pump means 67 is rendered isolated, thereby setting up the illustrated toroidal flow path seen indicated in FIG. 3, which represents the second mode of operation and the first phase of the scrubbing cycle of the system. At this time, as illustrated in FIG. 10, the velocity V1, V2, V3, and V4 of the flowing material is of a sufficient magnitude to intimately disperse particles 94 of the entire media 20 and contaminants 96 throughout the liquid contained within the vessel 12, so that the individual particles 94 of the filter media 20 continually abrade against one another, and great sheer forces are setup between the agitated liquid, media, and contaminants. During this mode of operation, flow occurs from the upper end 16 of vessel 12, into suction 30 of pump 28, through discharge nozzle 32 of the scrubbing apparatus, down through the annular area 38, where the flow is directed down towards the bottom 74 of the vessel 12, with the flow pattern describing the illustrated toroidal configuration 46 set forth in FIG. 3. The scrubbing cycle is continued for the required length of time for translocating sufficient contaminants from the media into the scrubbing liquid required to subsequently restore the media to efficient filtering condition.
During the third mode of operation, which is also the second phase of the scrubbing action, valves 56 and 66 are moved to the open position, whereupon scrubbing liquid flows from the vessel while make-up liquid flows through pump 67 and into the inlet 14. Clean make-up liquid at 102 (FIG. 1) can be ingested into the system at 104 if considered necessary; however, it is preferred to use second order dirty water at S, depending upon the concentration of contaminants contained within liquid S during this blow-down or third mode of operation. The rate of flow of make-up liquid at 14 equals the rate of discharge of the highly contaminated liquid being discharged at 44.
When the discharge at D indicates that the residual liquid flowing at 46 has been substantially replaced by relatively clean liquid, the system is changed to the fourth mode of operation, wherein valve 56 is closed and pump 28 is de-energized. The system then lies dormant while the filter media gravitates back into a bed 20. This fourth mode of operation is an important step in the operational cycle for it causes the media particle size to be stratafied or layered with the media size being graduated towards the larger size in a downward direction. This novel action has the unexpected advantage of placing the larger particles of filter material adjacent to the lower screens which minimize plugging the screen openings. Next the system is caused to assume the fifth mode of operation, wherein the pump 67 is energized, and the apparatus is arranged into the scavaging configuration as follows: valve 56 remains closed while valves 58 and 66 are shifted, whereupon liquid flows along a closed circuit comprised of outlet 24, valve 58, conduit 62, valve 66, pump 67, inlet 14, where liquid flows into the upper end 16 of the vessel 12, down through the filter media 20, into the header 24, until the liquid contained within the closed circuit is cleaned of all contaminants, and the media bed is set into place in response to the pressure differential effected thereacross. Thereafter, valves 58 and 66 are moved to another alternate position, thereby returning the apparatus back to the first mode of operation or to the filtering configuration seen illustrated in FIG. 2. This last shift in operation provides an unexpectedly smooth transition in modes and eases the system back on line with a minimum of disturbances due to the unique uninterrupted closed to opened flow paths involved.
Example. A vessel 12, which measures 10 feet in diameter and 12 feet in height, is provided with a 75 horsepower pump means 28 having the suction and discharge thereof arranged in the manner of FIGS. 1 and 4, and capable of delivering 3000 gpm. The scrubbing apparatus 26 further includes a barrel 50 having an inside diameter 24 inches, and length 4 feet, with there being a scrubbing screen means 42 located therein having an outside diameter of 20 inches, and a length of 4 feet, thereby leaving an annulus 38 which measured 2 inches from the exterior surface of the inner screen to the interior surface of the barrel. The screen 42 is preferably a commercially available wedge wire tube having 0.015 inch openings. The free end 52 of the screen 42 is located approximately one inch below inlet end 36 of the barrel, while the discharge end of nozzle 32 is located above inlet end 36 of the barrel. The outlet end 40 of circulation guide 34 is located approximately 2 inches above the desired or design level 18 of media 12, which varies depending upon the compactness of the media 20 during operation as well as the amount of media charged into the vessel; consequently, sometimes the media is slightly above outlet 40 at the beginning of the filtration cycle, and sometimes the media is below the outlet 40 at the end of the cycle. The media selected is 12-20 particle size (screened) walnut shells. Support 54 is a standard 4 inch pipe.
The outlet header 24 is 6 inches in diameter while the individual screens 64 were laterally arranged respective to the header 24, and each is provided with an effective screening length of 2 feet. The screens 64 are provided with 0.015 inch slots. The screens 64 preferably are wedge wire tubes.
As noted, the screens in the above examples are preferably wedge wire tubes having bars connected together in the manner illustrated at 78 in FIG. 9, with there being an 0.015 inch slot between adjacent bars, and the bars being 1/8 inch in thickness. This material is a commercially available product.
The filter media 20 preferably is walnut hulls which passes through a 12 mesh screen and are caught on a 20 or 30 mesh screen, depending upon the characteristics of the removed contaminants.
Feed pump 67 is a 40 horsepower pump designed to deliver 1000 gallons per minute at 50 psi.
12,000 pounds of media 20 in the form of 12-20 walnut shells can be directly or indirectly charged into the lower end of the vessel 12, and all the compressible fluid thereafter exhausted from the upper end of the vessel as flow of liquid occurs at 14. The characteristics of the contaminated liquids were as follows: The inlet water is fresh or salt water containing inert particles of iron sulfide, sand, metal particles, and semi-soluble particles of oil, waxes, paraffins, asphalts, and the like.
After the system had reached equilibrium, the characteristics of the liquid exiting at outlet 24 was found suitable for injection into a downhole formation of a water flood injection well. The system removes the filterable solids and organics up to 1 ppm of a size greater than 1 micron depending on specific characteristics of the filterable contaminants.
The apparatus filters a stream of liquid flowing at a rate of 30,000 barrels per day into inlet 14, with the initial pressure drop measured at sensors 108 and 110 being 3-5 psi ΔP. At the end of 18 hours, the pressure drop across media 20 had increased to 15-25 psi ΔP, at which time the rejuvenation cycle was commenced in the above described manner. The scrubbing cycle was carried out for 20 minutes, with scrubbing action lasting 15 minutes, and with discharge through conduit 44 occurring during the last 14.5 minutes of the 15 minute cycle. During this 14.5 minutes, relative clean makeup water or second order dirty water entered the vessel at 67 flowing at the rate of about 600 gallons per minute into the inlet 14, while a similar amount of very dirty water was discharged at 44. Thereafter, a delay of 3 minutes enables the media to gravitate into a bed, as previously described above, and then valves 58 and 67 were shifted to the appropriate position to provide the closed circuit flow for a time interval of 2 minutes, thereby cleaning up all of the lines flowing from the clean water outlet 24, and setting the bed. The system was then returned to mode 1, or the on stream and filtering mode.
The method of this invention therefore involves five modes of operation as follows:
Mode 1: on stream or filtering for 18 to 24 hours;
Mode 2: scrubbing cycle, 15 minutes;
Mode 3: blowdown cycle, 14.5 minutes of the above 15 minutes;
Mode 4: gravitate bed into position, 3 minutes;
Mode 5: set bed and scavage closed circuit, 2 minutes.
Total rejuvenation time 20 minutes for modes 2, 3, 4, and 5. | A filter system has a filter media comprised of particles of filter material contained within the lower end of a vessel. Liquid flows into the upper end of the vessel and down through the filter media, thereby removing unwanted contaminants from the liquid. When the accumulated contaminant load in the filter media reaches a selected value, the filter media is cleaned of contaminants by vigorously circulating the media within the vessel. This scrubbing action transfers the contaminants from the filter media into the scrub water, and thereby enables the contaminants to be removed from the vessel by discharging the scrub water therefrom. All activity is stopped to enable the media to gravitate back to the bottom of the vessel. The cleaned filter is returned to operation. | 1 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to the filing date of Provisional Application Ser. No. 60/196,161, filed Apr. 11, 2000, the disclosure of which is hereby incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] Aggregates, including for example crushed stone, sand and gravel, are one of the most fundamental components used in construction.
[0003] Approximately fifty percent of aggregates are shipped for highway construction, either as road base or a primary component of asphalt and concrete. Aggregates are also used in commercial and residential construction as base for foundations, concrete and parking lots. Other uses for aggregates, some of which require a high-quality, chemical-grade limestone, include: riprap for erosion control; railroad ballast; flux stone; filter stone; agricultural limestone; production of cement and lime; desulfurization; acid neutralization; animal feed supplements; and plastic and paint fillers. Regardless of the use, the production requirements of stone aggregates are complex because the material must be crushed to multiple sizes, often washed to remove fines and impurities, and sometimes processed further in order to meet the specification for its intended use. Without the physical and chemical properties provided by aggregates, modem construction materials and methods, as well as a multitude of industrial products, would not be possible.
[0004] Product requirements often dictate the percentages of flat particles, elongated particles or flat and elongated particles in coarse aggregates. For example, flat or elongated particles of aggregates for some construction uses may interfere with consolidation and result in harsh, difficult to place materials. Flat particles are defined as those particles that exceed a specified ratio of width to thickness. For example, if the ratio is 3:1, the width cannot exceed three times the thickness. (A specification will give a percentage and then the ratio, such as 20% 3:1, meaning a sample fails the specification if more than 20% of the particles (individual pieces or by mass of the total sample) tested have ratios that exceed 3:1.) Elongated particles are defined as those particles that exceed a specified ratio of length to width. Flat or elongated particles are defined as those particles of aggregate having a ratio of width to thickness or length to width greater than a specified value. Flat and elongated particles of aggregate are defined to be those particles having a ratio of length to thickness (maximum to minimum) greater than a specified value.
[0005] Sieve size is the size of an opening that a particle can pass through. The specification may require that the amount of particles passing through the opening be determined (“percent passing”). Alternatively, the specification may require that the percent of the sample that does not pass through a specified opening be determined (“percent retained”).
[0006] Crushers are conventionally used to crush large aggregate particles (e.g., rocks) into smaller particles. One particular type of crusher is known as a cone crusher. A typical cone crusher includes a frame supporting a crusher head and a mantle secured to the head. A bowl and bowl liner are supported by the frame so that an annular space is formed between the bowl liner and the mantle. In operation, large particles are fed into the annular space between the bowl liner and the mantle. The head, and the mantle mounted on the head, rotate eccentrically about an axis, causing the annular space to vary. As the distance between the mantle and the bowl liner varies, the large particles are impacted and compressed between the mantle and the bowl liner. The particles are crushed and reduced to the desired product size, and then drop down from between the mantle and bowl liner.
[0007] Aggregate is a description of the product based on how much of the product passes (or could be given as how much is “retained on”) a specified number of sieve sizes, or openings. For example, an ASTM (American Society of Testing and Materials) #57, a typical product used in concrete and asphalt construction, is described by using sieve sizes as follows (sieve sizes are square openings):
Sieve Size % Passing 1 ½ inches 100% 100% of the sample must pass through an 1 ½ inch square opening 1 inch 95-100% Between 95 and 100% of the particles must be smaller than 1 inch ½ 25-60% Between 25 and 60% of the particles must be smaller than ½ inch #4 0-10% #4 is close to ¼ inch opening #8 0-5% #8 is close to ⅛ inch opening
[0008] Prior apparatus and methods for measuring individual particles of aggregate of specific sieve size to determine the ratio of width to thickness, length to width, or length to thickness include that disclosed in Standard Test Method for Flat Particles, Elongated Particles or Flat and Elongated Particles in Coarse Aggregate , ASTM Designation D 4791-95, the entire contents of which is incorporated herein by reference. This test method uses a proportional caliper device that consists of a base plate with two fixed posts and a swinging arm mounted between them so that the openings between the swinging arm and the two fixed posts maintain a constant ratio. The axis position can be adjusted to provide the desired ratio of opening dimensions. The axis position must be moved to change the ratio being measured. A complete re-measuring of the particle under test each time a new ratio is selected is thus required. This device is therefore capable of measuring only one ratio at a time and is therefore capable of only determining whether a particle is larger or smaller than a single ratio.
[0009] Additionally, ASTM D 4791 details how to measure flat and elongated particles using a proportional caliper device that determines pass/fail for one ratio at a time. Specifications are based around using the proportional caliper device and specify the ratio and the maximum percent of the sample that can exceed the given ratio. In the “Superpave” asphalt pavement mix 5 design specification, for example, 10% on a 5:1 ratio means that no more than 10% of the aggregate sample can have a maximum dimension greater than five times the minimum dimension. Most aggregate specifications currently (and historically) use 10% on a 5:1 ratio, which is adequate for controlling excessive flat and elongated particles.
[0010] However, describing the flat and elongated particles present in a sample using the percent found at one ratio doesn't give a true picture of the various ratios found within a sample as described later in this paper. A good analogy would be to describe the gradation of an ASTM #57 stone by giving only the percent passing the ½-inch sieve. Without the information on the 1 inch, ¾ inch, ⅜ inch and #4 sieve, a complete picture of the gradation of the sample cannot be determined.
[0011] Without a complete picture of the various particle shapes in a sample, it is difficult to accurately evaluate performance results as determined by the current research efforts concerning particle shape. Several Departments of Transportation (DOT's) and universities are developing automated procedures that determine aggregate particle shapes (Button, 2000), however the equipment costs involved (up to $30,000) make these devices far too expensive to be used in the typical aggregate laboratory. In addition, measurements with the automated devices are still aimed at determining the percent found at one specified ratio rather than gathering Multiple Ratio Analysis data.
[0012] Accordingly, there is still a need for an inexpensive and readily usable arrangement for determining aggregate particle shapes.
SUMMARY OF THE INVENTION
[0013] The present invention is directed to a method and apparatus for compiling data permitting evaluation of aggregate particle shapes.
[0014] In one aspect, the invention includes a method for performing multiple ratio analysis of aggregate particles. This method includes the steps of measuring a first maximum dimension of a particle, measuring a second maximum dimension of a particle in a direction substantially perpendicular to the first maximum dimension, and inputting the first maximum dimension and second maximum dimension into a computer having a processor. Using the computer, a particle ratio of the first maximum dimension to the second maximum dimension for the measured particle is computed and the particle ratio is classified into one of a predetermined plurality of different ratio ranges, each of these plurality of different ratios representative of a different range of particle shapes.
[0015] Another aspect of the invention includes an apparatus for multiple ratio analysis. This apparatus includes a measurement device configured to measure a dimension of an aggregate particle along at least one axis at a time, a computer, and a computer-readable medium bearing an instruction set executable by the computer. The instruction set permits the computer to calculate an aggregate particle ratio for an aggregate particle by determining a ratio of a first maximum dimension and a second maximum dimension of the aggregate particle. The instruction set also permits the computer to classify the aggregate particle ratio into one of a predetermined plurality of different aggregate particle ratio ranges, each of the plurality of different aggregate particle ratios representative of a different range of aggregate particle shapes.
[0016] Still other objects and advantages of the present invention will become readily apparent from the following detailed description, simply by way of illustration of the best modes contemplated of carrying out the invention. As will be realized, the invention is capable of other and different embodiments and its several details are capable of modifications in various obvious respects, all without departing from the invention. Accordingly, the drawings and description are to be regarded as illustrative in nature, and not as restrictive.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] The various features and advantages of the present invention will become more clearly appreciated as a detailed description of a preferred embodiment of the present invention is given with reference to the appended drawings in which:
[0018] [0018]FIG. 1 is a perspective view showing a digital caliper, a laptop personal computer and a manually operated foot switch which are operatively connected/interfaced to enable data to be intermittently uploaded and captured by suitable software loaded in the computer;
[0019] [0019]FIG. 2 is a perspective view showing an enlarged view of the digital caliper depicted in FIG. 1;
[0020] [0020]FIG. 3 is a perspective view showing an operator holding a particle in position between the jaws of the caliper and operating the caliper to lower the upper jaw into measuring contact with the particle under examination;
[0021] [0021]FIGS. 4 and 5 are perspective views showing two different dimensions of a particle being measured between the jaws of the digital caliper;
[0022] [0022]FIG. 6 is a bar graphs which demonstrates a multiple ratio analysis of a limestone in weighted average terms;
[0023] [0023]FIG. 7 is a multiple ratio analysis of fractional sizes depicted in FIG. 1;
[0024] [0024]FIG. 8 is a depiction of a spreadsheet image showing the manner in which color can be used in conjunction with the data which is collected to code the MRA ratios which are developed by the software;
[0025] [0025]FIG. 9 is a bar graph which highlights the small amount of variation which is provided with the embodiment of the invention when used by an experienced operator and one who has no prior exposure to the arrangement;
[0026] [0026]FIG. 10 shows another spreadsheet image which depicts the MRA calculation;
[0027] [0027]FIG. 11 depicts the MRA of 1.5 inch fractions after primary jaw crushing;
[0028] [0028]FIG. 12 depicts the MRA of 1.5 inch basalt fractions after secondary crushing;
[0029] [0029]FIG. 13 depicts the MRA of minus ¾ inch basalt particles after tertiary crushing;
[0030] [0030]FIG. 14 depicts the MRA weighted average comparison of total production circuit;
[0031] [0031]FIG. 15 depicts the MRA weighted average comparison of two apparently identical granites;
[0032] [0032]FIGS. 16 and 17 are MRA of a first and second different groups of granite fractions; and
[0033] [0033]FIG. 18 illustrates a computer system utilizable in accord with the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0034] In view of the above, asphalt pavement design, for example, has focused attention on aggregate particle shape requirements. As disclosed herein, a technique referred to as Multiple Ratio Analysis (MRA) has been developed as a method of categorizing the various particle shapes found in an aggregate sample. Improved definition of the various particle shapes found within the coarse aggregate particles leads to improved mix design procedures for performance optimized combined gradations based on particle shape. MRA analysis also lends itself to optimization of crusher performance and measurement of product consistency during production.
[0035] This MRA technique involves the use of a digital measuring device that easily and more accurately determines the various coarse aggregate particle shapes found in an aggregate sample. More specifically MRA gives an accurate picture of an aggregate sample's particle shapes by evaluating the sample on a plurality of different ratios, such as but not limited to five or more (i.e., <2:1, 2:1 to 3:1, 3:1 to 4:1, 4:1 to 5:1, >5:1), as shown in FIG. 6. Even more information can be gained by examining the MRA of the various size fractions found in the same aggregate sample (FIG. 7).
[0036] FIGS. 1 - 5 show an apparatus which may be used to perform MRA in one embodiment of the present invention. As shown in FIGS. 1 - 5 , this apparatus includes a measurement device or measurement system 100 , such as digital caliper (hereinafter digital caliper 100 or measurement device 100 ), a notebook computer 200 and a foot operated switch 300 . The digital caliper 100 is provided with a read-out 102 which is associated with a measuring device which determines the distance between the upper and lower jaws 104 and 106 of the caliper arrangement. A manually operable handle/knob 108 is provided to control the raising and lowering of the upper jaw 104 until it is in contact with a particle which is under examination.
[0037] Using the measurement device 100 , it is desired to obtain a first measurement along a first maximum dimension of a particle in a manner known to those skilled in the art, as provided in ASTM D4791-99, for example, the entire contents of which are incorporated herein by reference. The first maximum dimension of the particle is the longest dimension of the particle in any direction and is generally defined as the length of the particle. In other words, in a conventional Cartesian coordinate system, the first maximum dimension or length could be arbitrarily assigned to correspond to the X-axis.
[0038] The width is, accordingly, a plane perpendicular to the length (e.g., Y-axis) and the thickness is a plane perpendicular to both the length and the width (e.g., Z-axis). ASTM D4791-99 defines width as the maximum dimension perpendicular to the length and defines thickness as the maximum dimension perpendicular to both the length and the width. As used hereinafter, the term first maximum dimension shall refer to the particle length and the term second maximum dimension shall refer to the lesser of the width or thickness maximum dimensions. Following the first measurement, a second measurement is taken along this second maximum dimension of the particle in accord with the invention. For the vast majority of particles, it is relatively easy to visually determine length, width, and thickness. For the very few particles where width and thickness appear to be the same, an extra measurement may be taken to confirm that the lesser of the maximum of the thickness and width is selected in accord with the invention. However, appropriate tolerances are designed into the selected ratio ranges, whether two, three, five, or ten ratios are represented, so that essentially the same ratio will be calculated for either the width maximum or the thickness maximum and the particle will be assigned to the same ratio grouping regardless of the dimension selected from the two essentially equal width and thickness in the second maximum measurement. Thus, only two measurements are necessary in accord with the present invention, although additional measurement may certainly be taken to provide additional data integrity or for additional data analysis in accord with the invention. For example, the width maximum could also be measured as a third maximum dimension and calculations may be made comparing length to width (ratio A) and width to thickness (ratio B).
[0039] Although arbitrarily designated as first and second measurement, it is to be understood that the measurements could be taken in any order. Further, although it is preferred to obtain the absolute maximum first dimension along the length, width, and thickness, the measurements of the above-noted dimensions are not required to be absolute maximum dimensions. Instead, it is sufficient that the measurements taken are within about 10 to 20% of the relevant length, width, or thickness maximum dimension, as significant useful data in accord with the invention may be obtained therefrom. It is preferred that measurements taken are within at least 5% of the relevant length, width, or thickness maximum dimension.
[0040] Measurements can be made very rapidly with the above-described digital caliper measuring device 100 , notebook computer 200 and foot operated switch 300 combination, which is the preferred embodiment of the invention. As shown in FIGS. 3 - 5 , a technician or operator of the device places the aggregate particle in a desired configuration in the device using the left hand, while using the right hand to rotate the shaft to make the upper platen descend to contact the aggregate particle. A first measurement is taken along the first maximum dimension by pressing the foot operated switch 300 . Following raising of the upper platen to release the aggregate particle, the aggregate particle may be repositioned to take a second measurement along the second maximum dimension, in accord with the invention. Using the above sequence of steps and equipment, the MRA ratios may generally be obtained within about two seconds.
[0041] Alternatively, measurements may be input into the computer 200 using a keyboard, voice data entry device, mouse, switch, touch sensitive display or data bearing carrier wave, such as but not limited to infrared waves. Further, the above example serves as one possible means to implement the measurement scheme of the invention and is capable of alteration in many forms to best suit the needs of the device operator, the particular model of digital caliper utilized.
[0042] In a preferred embodiment, once all of the aggregate particles have been measured and separated into the plurality of ratios, such as by placing the aggregate particles in bins or piles in accord with the designated ratio range, five in the preferred embodiment, the operator weighs the combined aggregate particles for each one of the plurality of ratios and inputs the weight of the combined aggregate particles in the spreadsheet such as by a keyboard, voice data entry device, mouse, switch, touch sensitive display or carrier wave. Thus, the weight of each particle is generally not taken individually, which provides a simple, efficient way to compare total masses of one ratio group to total masses of another ratio group and permits determination of the proportion of the sample in each group by mass in accord with ASTM D 4791-99, § 8.4.3. The computer 200 may then calculate, for example, a weighted average for the total sample, as shown in FIG. 6.
[0043] In another embodiment of the invention, a scale (not shown) may be configured to output aggregate particle weight information to the computer 200 . In one aspect of this embodiment, each measured aggregate particle is placed on the scale following measurement of the desired dimensions. Once the measured weight has stabilized or been dampened to within a threshold tolerance, such as but not limited to +/−1 gram, the scale may then automatically output to the computer the weight data for the aggregate particle. Following measurement of all of the aggregate particles, the computer 200 may then calculate, for example, the weighted average of the total sample or the actual ratio of each individual particle.
[0044] Although the preferred embodiment of the invention utilizes a digital caliper as the measurement device 100 , owing to its combination of simplicity, low cost, and accuracy, the measurement device 100 could include any device capable of determining the required dimensions. Thus, the invention can also include, but is not limited to, laser measurement devices, laser imaging or scanning devices, or acoustic measurement devices such as conventionally known laser interferometers or laser ranging devices, active or passive imaging systems such as CCDs, lasers, or cameras. For example, an active system could include an amplitude-modulated ranger, which transmits a laser signal to a target object and uses the reflected laser signal from the target object to a detector, such as a silicon avalanche photodiode (APD), to determine distance to the object. The optical signal is filtered to pass only the transmitted optical frequency, and the electronic detector signal is filtered to pass only the amplitude modulated frequency. An electronic phase detector then measures the phase difference between the transmitted signal and the received signal, which is proportional to the target object distance. This distance could then be subtracted from a known or measured distance of a flat surface upon which the target object rests to determine a dimension of the target object at the measured point.
[0045] Alternatively, another type of active measurement device 100 could include one or more lasers employing “time-of-flight” measurement of short infrared or near-infrared pulses. In these systems, the actual time of flight from output of the pulse from the laser to receipt of the reflected pulse by the detector is measured and converted into a distance using the known speed of the pulse. This known distance may then be converted into a dimension of the target object at the measured point, as noted above.
[0046] Still further, alternate measurement devices 100 comprising any type of modulated output signal (e.g., a modulated radiation such as focused optical radiation (e.g., laser beam) or radio or sonic signals) may be employed so long the alternate imaging systems can provide, at a minimum, range information to a measured point of the target object. The target object will reflect the radiation and provide a reflected signal which can be detected at either the source of the original radiation or at an adjacent site. The detected radiation will exhibit a phase shift or other characteristic difference, such but not limited to a time-shift, relative to a reference signal derived from the source of the original radiation. In this aspect, the phase shift may be used to determine the distance to the target object in a manner known to those skilled in the art utilizing known information about the system, the output signal, and the received signal. Still further, scannerless imaging systems may be used. Examples of such scannerless imaging systems are described in U.S. Pat. No. 6,088,086 to Muguira et al. and to U.S. Pat. No. 4,935,616 to Scott. These references provide scannerless imaging systems that are capable of providing range information, which may be converted into target object dimensional information and used in accord with the invention.
[0047] Additionally, passive systems could be employed in accord with the invention to obtain the desired range data. For example, cameras or CCDs could be used. One aspect of this involves stereo sculpture, stereo display, or stereo vision wherein three dimensional objects are imaged and re-created from stereo information gathered by a stereo pair including, for example stereo cameras or lasers, in a manner known to those skilled in the art. Thus, topo maps can be created by machines using stereo pairs as input. Moreover, stereo vision image data may be accomplished using a single camera wherein various types of mechanical or electro-optic devices can block the light through parts of the optical path to create field sequential stereo pairs, as discussed, for example, in U.S. Pat. No. 5,028,994 to Miyakawa, et al. titled “Synchronized Three Dimensional Imaging Apparatus”. Thus, the invention contemplates incorporation of any device able to provide target object dimensional information including but not limited to active systems (e.g., lasers outputting laser pulses and receiving a corresponding reflected pulse) and passive systems (e.g., charge coupled devices, CCDs, or camera based systems which passively receive external signals) in any combination. Thus, an entirely active measurement device 100 or system could be used, a combined active and passive measurement device or system 100 could be used, or an entirely passive measurement device or system 100 could be used. Any of these combinations could be achieved in accord with the invention and with techniques known to those skilled in the art.
[0048] Still further, the measurement device or system 100 may comprise a simple fixed single laser, which determines the distance to a single point on the object placed in the laser signal's flight path; a single laser configured to output a scanning beam along one or more axes, as noted above; a single laser utilizing conventional optics and a beam splitter to cause the output laser signal to approach the beam from a plurality of directions; or multiple lasers.
[0049] Although the computer 200 illustrated in FIGS. 1 - 5 is preferably a laptop or notebook computer, or other portable computing device such as a handheld computing device, the computer 200 need only be required to receiving digitized information through a suitable port or interface, process the data, and output data through an appropriate port or interface. As described in more detail below, the port or interface can comprise a hardwired interface or could rely on data transmitted to the device by a carrier wave or signal. The computer 200 is loaded with a suitable programs, such as a spreadsheet or database program or application, or instruction sets or macros capable of capturing the digitized measurement data supplied by the measurement device 100 , and applying predetermined operations therewith. By way of example only, a suitable example of such software is Excel® marked by Microsoft. Additional discussion of the computer system in accord with the invention is provided below.
[0050] The switch 300 , which may be foot operated, hand operated, voice operated, or configured to operate in another manner conducive to obtaining measurements in accord with the invention, is operatively connected with the digital caliper 100 or other measurement device, as well as the computer or computer interface device. In one aspect of the invention, operation of the switch 300 triggers the upload of measurement data from the digital caliper 100 or other measurement device. It is preferred to allow the operator to control output of measurement data to the computer 200 using such a switch to permit the operator to properly orient the aggregate particle, or reorient the aggregate particle, to obtain the proper measurements. The switch may be disposed in a variety of locations in accord with the invention and may assume a variety of forms other than the examples noted above. For example, the switch may be located on the handle/knob 108 in the form of a button or trigger. Alternatively, the switch could include a light beam or light curtain which, when the light beam(s) is broken such as by the movement of a limb, the switch is activated.
[0051] As noted above, the Multiple Ratio Analysis or MRA technique of the present invention provides not only an apparatus for measuring the dimensions of a target object, such as an aggregate particle, but also provides a method of categorizing the various particle shapes found in an aggregate sample. Improved definition of the particle shapes found within a coarse sample of aggregate particles leads to improved mix design procedures for performance optimizing combined gradations based around particle shapes.
[0052] Thus, the MRA technique of the invention utilizes the aforementioned measuring device or system 100 , such as the digital caliper, to quickly and accurately determines the various coarse aggregate particle shapes found in an aggregate sample and provide an accurate picture of an aggregate sample's particle shapes by evaluating the sample on a plurality of different ratios, such as but not limited to five or more (i.e., <2:1, 2:1 to 3:1, 3:1 to 4:1, 4:1 to 5:1, >5:1), as shown in FIG. 6, whereas conventional techniques only evaluate one ratio. The computer 200 and associated software, such as a spreadsheet, use the measurement data to calculate the ratios of interest in accord with the invention and output to the operator and/or another device connected to the computer one or more signals indicative of the calculated ratio or ratios as shown, for example, in FIG. 10.
[0053] To help prevent operator error, the displayed ratios may be color-coded or otherwise differentiated on the spreadsheet display(s). In one embodiment, each of the selected plurality of ratios is assigned an arbitrary color or distinctive symbol or shape, or any combination thereof. These colors and/or shapes may preferably correspond to colors of bins used to receive particles of the respective ratio and/or symbols/shapes used to designate bins receiving particles of the respective ratio. For example, yellow could be assigned to particles having a ratio of <2:1, blue for 2:1 to 3:1, green for 3:1 to 4:1, purple for 4:1 to 5:1, and red for >5:1. Thus, upon entry of the first and second measurements into the computer 200 , the computer would output a signal to a display device, in the form of a color, to tell the technician to place a 1:1 particle in the yellow bin. This relieves the technician of the burden of reading numbers off of the computer 200 display. Likewise, the output signal could comprise an audio message instructing the technician that the particle just measured is a “yellow” particle.
[0054] The results of measurements taken on a sample of aggregate particles by two different operators with this device are shown in FIG. 9. One of the operators had never before measured particle shapes or performed any kind of aggregate testing. Thus, the measurement device 100 and method of the invention may be easily utilized, even by unskilled persons.
[0055] Thus, as shown in FIGS. 11 - 13 , for example, the MRA technique can help identify particle shape issues in the production process by providing a complete picture of the particle shapes at each stage of production. FIGS. 11 - 13 show particles retained on the 1 inch sieve through the #4 sieve at each stage of a production process. The material measured is a hard basalt that is difficult to crush. Extremely hard materials like this tend to “shatter” rather than crush and therefore produce many flat and elongated particles. As can be seen from this example, application of the correct crushing technology to fit the situation can turn flat and elongated particles into cubical particles. Also, particles from the primary and secondary crushers in the following examples are to be benefited by passing through the tertiary crusher before reaching finished product stockpiles. The samples are used to illustrate how well MRA can identify changes occurring at each stage of crushing.
[0056] [0056]FIG. 11 shows particles retained on the 1 inch and smaller sieves from a 6-inch minus (primary) jaw crusher product. FIG. 12 shows the same particle sizes after passing through a secondary high-speed cone crusher. FIG. 13 shows the same particles after the particles pass through another high-speed cone crusher (tertiary). Only particles smaller than ¾″ were allowed to reach finished product stockpiles after this crushing stage. Particles larger than ¾″ are returned to the crushing circuit. FIG. 14 compares the weighted average of all three stages of crushing.
[0057] Thus, MRA analysis of finished products in accord with the invention can be used as a tool for evaluating product consistency in various stages of the production process. Additionally, trending data of aggregate particle size may be used, over time, to monitor the effectiveness of the crushers and crusher wear liners in the production circuit.
[0058] Conventional mix design procedures provide requirements on flat and elongated particles but do not provide enough information about particle shapes to permit modification or optimization of the mix design in accord with the variable of particle shape. For example, the shape may even be used to differentiate between materials. FIG. 15 compares two virtually identical granites based only on their weighted averages. However, when the aggregate particle shape or fractional ratios of the aggregate particles are taken into account, as shown in FIGS. 16 and 17, many differences can be seen. This information can then be used by a mix designer to optimize the combined gradation that best fits the particle shapes found in the aggregates and can be used by a process engineer to optimize the tooling, tooling settings, or process flow to obtained desired results. For example, highly angular aggregates should be blended so that the combined gradation is near the maximum density line, and passes through a predetermined restricted zone. Otherwise the voids in the mineral aggregate (VMA) is too high and flushing problems will occur. Highly cubical aggregates should be combined away from the maximum density line in order to achieve enough VMA. There is an optimum combined gradation for each of the particle shapes. Using the identical combined gradation for cubical and angular particle shapes will produce mixes with very different properties.
[0059] MRA can also be used to identify when certain combined gradations should be used. Rather than force aggregate producers to achieve uniform particle shapes across all geologic types, MRA analysis can be used to identify the particle shapes and therefore the appropriate combined gradation suitable for each material. This will allow aggregate producers to utilize the correct crushing technology to fit the geologic type of material in the deposit and therefore help contain increasing production costs. There is an optimum gradation for each combination of particle shapes, allowing each type of particle shape to be successfully used.
[0060] [0060]FIG. 18 depicts a computer 200 system in accord with the invention. Supporting equipment typically comprises a video color display monitor 210 , a printer 220 , a central processing unit (CPU) 230 , interfacing electronics 240 , and a keyboard or other data entry means 260 . CPU 230 includes a bus 232 or other communication mechanism for communicating information, and one or more processors such but not limited to Intel Pentium III/IV processors coupled with bus 232 for processing information. CPU 230 also includes a main memory 236 , such as a random access memory (RAM) or other dynamic storage device, coupled to bus 232 for storing information and instructions to be executed by the processor(s). Main memory 236 also may be used for storing temporary variables or other intermediate information during execution of instructions to be executed by the processor(s). CPU 230 further includes a read only memory (ROM) 238 or other static storage device coupled to bus 232 for storing static information and instructions for the processor(s). A storage device 270 , such as a magnetic disk or optical disk, is provided and coupled to bus 232 for storing and providing information and instructions.
[0061] CPU 230 may be coupled via bus 232 to monitor 210 , such as a cathode ray tube (CRT), for displaying information to a computer user. Input device or data entry means 260 , including alphanumeric and other keys or a microphone to enable voice activated functions, is coupled to bus 232 for communicating information and command selections to the processor(s). Other types of user input devices may include cursor control, such as a mouse, a trackball, the aforementioned foot operated switch 300 , or cursor direction keys for communicating direction information and command selections to the processor(s) and for controlling cursor movement on display 210 .
[0062] Transmission media for data to and from processor(s) and associated devices, including bus 232 may comprise coaxial cables, metal wire or metal layers and fiber optics. Transmission media can also take the form of acoustic or light waves, such as those generated during radio frequency (RF) and infrared (IR) data communications. CPU 230 also may include a communication interface 280 coupled to bus 232 to provide two-way data communication coupling to a link, such as a network link 282 , by sending and receiving electrical, electromagnetic or optical signals that carry digital data streams representing various types of information. It will be appreciated that various forms of output devices may be operatively connected to the CPU 230 through the transmission media to be controlled thereby.
[0063] The computer 230 is used to process the data obtained by the measurement system 100 output the data in a meaningful form. In accord therewith, this function is provided by computer 230 in response execution by the processor of one or more sequences of instructions contained in main memory 236 . Such instructions may be read into main memory 236 from a computer-readable medium, such as storage device 270 . Execution of the sequences of instructions contained in main memory 236 causes the processor to perform the process steps described herein. In alternative embodiments, hard-wired circuitry may be used in place of or in combination with software instructions and it is to be understood that no specific combination of hardware circuitry and software are required.
[0064] The instructions may be provided in any number of forms such as source code, assembly code, object code, machine language, compressed or encrypted versions of the foregoing, and any and all equivalents thereof. “Computer-readable medium” refers to any medium that participates in providing instructions to the computer 230 for execution and “program product” refers to such a computer-readable medium bearing a computer-executable program. The computer usable medium may be referred to as “bearing” the instructions, which encompass all ways in which instructions are associated with a computer usable medium.
[0065] Computer-readable mediums include, but are not limited to, non-volatile media, volatile media, and transmission media. Non-volatile media include, for example, optical or magnetic disks, such as storage device 270 . Volatile media include dynamic memory, such as main memory 236 . Transmission media include coaxial cables, copper wire and fiber optics, including the wires that comprise bus 232 . Transmission media can also take the form of acoustic or light waves, such as those generated during radio frequency (RF) and infrared (IR) data communications. Common forms of computer-readable media include, for example, a floppy disk, a flexible disk, hard disk, magnetic tape, any other magnetic medium, a CD-ROM, DVD, any other optical medium, punch cards, paper tape, any other physical medium with patterns of holes, a RAM, a PROM, and EPROM, a FLASH-EPROM, any other memory chip or cartridge, a carrier wave as described hereinafter, or any other medium from which a computer can read.
[0066] Various forms of computer readable media may be involved in carrying one or more sequences of one or more instructions to computer 230 for execution. For example, the instructions may initially be borne on a magnetic disk of a remote computer. The remote computer can load the instructions into its dynamic memory and send the instructions over a telephone line using a modem. A modem local to computer 230 can receive the data on the telephone line and use an infrared transmitter to convert the data to an infrared signal. An infrared detector coupled to bus 232 can receive the data carried in the infrared signal and place the data on bus 232 . Bus 232 carries the data to main memory 236 , from which computer 230 retrieves and executes the instructions.
[0067] Computer system 200 also may include a communication interface 218 coupled to bus 202 . For example, communication interface 218 may be an integrated services digital network (ISDN) card or a modem to provide a data communication connection to a corresponding type of telephone line. As another example, communication interface 218 may be a local area network (LAN) card to provide a data communication connection to a compatible LAN. Wireless links may also be implemented. In any such implementation, communication interface 218 sends and receives electrical, electromagnetic or optical signals that carry digital data streams representing various types of information.
[0068] Network link 220 typically provides data communication through one or more networks to other data devices. For example, network link 220 may provide a connection through local network 222 to a host computer 224 or to data equipment operated by an Internet Service Provider (ISP) 226 . ISP 226 in turn provides data communication services through a worldwide packet data communication network 228 , such as the “Internet.” Local network 222 and Internet 228 both use electrical, electromagnetic or optical signals that carry digital data streams. The signals through the various networks and the signals on network link 220 and through communication interface 218 , which carry the digital data to and from computer system 200 , are exemplary forms of carrier waves transporting the information.
[0069] The instructions received by main memory 236 may optionally be stored on storage device 270 either before or after execution by computer 230 . The CPU 230 advantageously accesses memory media including floppy disks, tape drives, and hard disk drives, as previously indicated, may also output control signals to the measurement device or system 100 , particularly if the measurement device includes a laser measurement device. Interface electronics 240 convey and format signals from the measurement system components to the computer 230 and commands from computer 230 to the system components. Interface electronics 240 employs conventional circuitry, such as standard printed circuit cards, and utilize standard data transmission formats.
[0070] Multiple Ratio Analysis is a new concept in describing aggregate particle shapes by identifying the amount of particles found in five different ratios rather than one ratio. In addition, a new low-cost measuring device is provided that accurately and easily determines multiple ratios found within a sample. This allows mixes to be designed by first determining the various particle shapes involved, and then using the correct combined gradation to fit the particle shapes for optimum performance. This common sense approach can be used to address the many different geologic types used for construction aggregates, and help designers with reducing risks and improving performance.
[0071] Only several embodiment of the invention are shown to illustrate its versatility as shown and described in the present disclosure. It is to be understood that the invention is capable of use in various other combinations and environments and is capable of changes or modifications within the scope of the inventive concept as expressed herein. Moreover, although illustrative examples of the method of the present invention were discussed, the present invention is not limited by the examples provided herein and additional variations of the invention are embraced by the claims appended hereto. | A method and apparatus for performing multiple ratio analysis of aggregate particles, wherein the method includes the steps of measuring a first maximum dimension of a particle, measuring a second maximum dimension of a particle in a direction substantially perpendicular to the first maximum dimension, and inputting the first maximum dimension and second maximum dimension into a computer having a processor. Using the computer, a particle ratio of the first maximum dimension to the second maximum dimension for the measured particle is computed and the particle ratio is classified into one of a predetermined plurality of different ratio ranges, each of these plurality of different ratios representative of a different range of particle shapes. An apparatus for multiple ratio analysis includes a measurement device configured to measure a dimension of an aggregate particle along at least one axis at a time, a computer, and a program or instruction set permitting calculation of an aggregate particle ratio for the aggregate particle and classifying this aggregate particle ratio, as noted. | 6 |
FIELD OF THE INVENTION
The present invention relates generally to detection systems in the realm of speaker verification (or speaker identification, authentication or recognition) and in other applications, such as radar detection, fire alarms, visual (face) detection and many others.
BACKGROUND OF THE INVENTION
Generally, the functionality of detection systems is defined by the capability to analyze a certain input sample (for example, a speech recording, a video or radar signal, etc.), compare it to a particular “claimed” or hypothesized pre-stored sample (e.g., a template or model) and to decide whether the observed test sample and the pre-stored sample match or not (i.e., to accept or reject the claim). The detection task can also be extended in a broader sense to cases involving a mixture of input samples, with the objective of detecting a particular claimed target within this mixture.
The quality of detection systems is measured primarily by evaluating two types of error (i.e., the expected values of such errors): “False Alarm Rate”, and “Miss Rate”. Low values of both measurements reflect more accurate systems. Typically, detection systems are trained/optimized according to criteria that minimize the two error rates simultaneously and along all operating points of the detection system. To such criteria belong maximum entropy, linear discriminative analysis, and indirectly, maximum likelihood.
To date, efforts towards such minimization have not yielded sufficiently desirable results. A need has therefore been recognized in connection with providing an arrangement that surpasses the performance hitherto encountered.
SUMMARY OF THE INVENTION
In accordance with at least one presently preferred embodiment of the present invention, for a given operating point range, with an associated detection “cost”, the detection cost is preferably reduced by essentially trading off the system error in the area of interest with areas essentially “outside” that interest. Among the advantages achieved thereby are higher optimization gain and better generalization.
From a measurable Detection Error Tradeoff (DET) curve of the given detection system, a criterion is preferably derived, such that its minimization provably leads to detection cost reduction in the area of interest. The criterion allows for selective access to the slope and offset of the DET curve (a line in case of normally distributed detection scores, a curve approximated by mixture of Gaussians in case of other distributions). By modifying the slope of the DET curve, the behavior of the detection system is changed favorably with respect to the given area of interest.
Experimental observations show that the slope component of this new criterion exhibits significantly better generalization behavior compared to the conventional methods as described herein. The criterion is applicable to any detection system which works on the basis of detection scores that are mixture-Gaussian distributed. An implementation description is exercised herebelow in connection with an existing text-independent speaker verification system as described in Navratil, J., Chaudhari, U. V., Ramaswamy, G. N., “Speaker verification using target and background dependent linear transforms and multi-system fusion,” (Proceedings of EUROSPEECH-01, Aalborg, Denmark, September 2001), where the optimization is applied on the feature space level of each single system, as well as for combining multiple systems.
In summary, the present invention relates, in one aspect, to an apparatus for facilitating detection in a detection system, the apparatus comprising: an input arrangement which accepts input data comprising true target data and non-target data; a detection arrangement which evaluates the input data and derives scores from the input data; and an evaluation arrangement which evaluates the scores and which successively prompts revision of at least one aspect associated with the scores until the scores reach a predetermined quality; wherein the evaluation arrangement is adapted to minimize a criterion associated with a detection error tradeoff relating to the scores.
In an additional aspect, the present invention relates to a method of facilitating detection in a detection system, the method comprising steps of: accepting input data comprising true target data and non-target data; evaluating the input data and deriving scores from the input data; and evaluating the scores and then successively prompting revision of at least one aspect associated with the scores until the scores reach a predetermined quality; wherein the step of evaluating the scores comprises minimizing a criterion associated with a detection error tradeoff relating to the scores.
In a further aspect, the present invention relates to a program storage device readable by machine, tangibly embodying a program of instructions executable by the machine to perform method steps for facilitating detection in a detection system, the method comprising steps of: accepting input data comprising true target data and non-target data; evaluating the input data and deriving scores from the input data; and evaluating the scores and then successively prompting revision of at least one aspect associated with the scores until the scores reach a predetermined quality; wherein the step of evaluating the scores comprises minimizing a criterion associated with a detection error tradeoff relating to the scores.
For a better understanding of the present invention, together with other and further features and advantages thereof, reference is made to the following description, taken in conjunction with the accompanying drawings, and the scope of the invention will be pointed out in the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 schematically illustrates parameter optimization in a detection system.
FIG. 2 schematically illustrates the optimization of a linear combination of multiple detection systems.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
By way of background, the DET curve for assessment of detection systems was introduced in Martin, A. et al., “The DET Curve in Assessment of Detection Task Performance,” (Proceedings of EUROSPEECH-97, Rhodos, Greece, pp. 1895-1898) as an alternative to the Receiver Operating Characteristics (ROC) usually plotted on linear axes, offering a better viewability due to special, nonlinear scaling. The axes of the DET plot are scaled according to the normal error function defined as
Φ ( t ) = ∫ - ∞ t 1 2 π ⅇ - τ 2 2 ⅆ τ
with t denoting the threshold applied on the detection score.
Given a specific detection system that supplies real-valued scores for a trial (i.e., a test sample and a claimed model), the Detection Error Tradeoff Analysis Criterion (DETAC) is formulated for two cases of score distribution types: 1) the Gaussian, and 2) the Gaussian-Mixture distribution.
As regards, Gaussian Distributed Detection Scores, it should be noted that the DET curve generally appears as a straight line for these distributions. Assuming that the impostor (false claims) trial scores are normally distributed with mean μ 1 and standard deviation σ 1 , and the true target scores with μ 2 and σ 2 , the DETAC criterion is formulated in variants of constrained and unconstrained optimization, with an optimization parameter set θ, as follows:
Constrained Minimization of DETAC Slope:
θ*=arg min θ ±R (θ), subject to D (θ)≦0 (1)
Constrained Minimization of DETAC Bias:
θ*=arg min θ D (θ), subject to R (θ)=0 (2)
Unconstrained Minimization of DETAC:
θ*=arg min θ w R ( R (θ)− C R )+ w D ( D (θ)− C D ) (3)
where
R ( θ ) = w R ( σ 1 ( θ ) σ 2 ( θ ) - C R ) ,
is the Sigma-Ratio corresponding to the DET line slope
D ( θ ) = w D ( μ 1 ( θ ) - μ 2 ( θ ) σ 2 ( θ ) - C D )
is the Delta-Term corresponding to the DET line as and
w R , w D ∈R being arbitrary regulator constants and C R , C D ∈R the initial values of the Sigma-Ratio and the Delta-Term respectively.
The minimization (1) aims at reducing or increasing the slope of the DET line depending on the location of the operating point (“+” if the OP requires false alarm rate to be lower than that of the Equal-Error-Rate, “−” otherwise), while keeping the bias constant or smaller than the initial value. The minimization (2) aims at reducing the DET bias while keeping the slope constant. For (1) and (2) the reduction of the objective guarantees a reduction on both error types (False Alarm, Miss) for the given operating area on training data set.
The minimization (3) aims at reducing both weighted terms simultaneously. It represents a compromise between (1) and (2), which can be easily implemented with most optimization software packages. The distribution parameters σ 1,2 μ 1,2 are a function of the optimization set θ. This functional relationship depends on the particular system structure and implementation and has to be determined for each case individually. Later on, two examples for the most common speaker detection systems on the basis of Gaussian Mixture Models (GMM) are described.
In the case of non-Gaussian detection score distributions, the approximation by a mixture of Gaussian densities is used. The two error probabilities are written as a weighted sum of error components, each distributed with a mean and a standard deviation:
P M ( t ) = ∑ i π i e Mi ( t ) = ∑ i π i ∫ - ∞ t N ( τ , μ i , σ i ) ⅆ τ = ∑ i π i Φ ( t - μ i σ i )
(Probability of Miss)
and
P FA ( t ) = ∑ i π i e FA ( t ) = ∑ i π i ∫ t ∞ N ( τ , μ i , σ i ) ⅆ τ = ∑ i π i Φ ( μ i - t σ i )
(Probability of False Alarm).
Let F 0 (Sigma-Ratio, Delta-Term) denote the DETAC objective function for Gaussian distributed scores, i.e. one of the three introduced hereinabove. Then, the DETAC objective function for Gaussian mixture distributions can be defined as
F GM = ∑ i ∈ T _ j ∈ T β ij F 0 ( σ 1 i σ 2 j , μ 1 i - μ 2 j σ 2 j )
where T, T are the true target and the impostor trial sets respectively, β ij are pairwise component weights that sum up to 1. The weights should be proportional to the Bayes error between the components “i” and “j”, and one suitable function type is the Chernoff bound (upper bound on the Bayes error):
β ij =c ij √{square root over (π i π j )} e −u(0.5,σ 1i ,σ 2j ,μ 1i ,μ 2j )
where μ is a distance function, for 0.5 known as the Bhattacharyya distance (see Fukunaga, S., “Statistical pattern recognition,” Academic Press, 2nd Ed., 1990) and c are normalizing constants so that the weights sum up to 1.
The minimization is carried out using F GM as objective and with one of the choices (1)-(3) for F 0 .
The disclosure now turns to an example of a DETAC application in speaker verification.
As far as optimizing the models goes, the system on the basis of GMMs as described in Navratil, supra is preferably used. In this system, each target speaker has a model created in the initial training phase. In the test phase, the logarithmic likelihood-ratio score between the target model and a universal background model (UBM) is calculated. Given a test sequence of d-dimensional feature vectors, it can be shown that the average componentwise log-likelihood-ratio (LLR) can be written in a compact form
trAB+c
where “tr” denotes the matrix trace operator, A is an arbitrary d×d matrix transforming the feature space in each GMM component, B is a precomputed d×d matrix containing the model and the feature information and c is a constant.
Using the training sets T, T , the transform A can be optimized with respect the DETAC defined above, thus improving the detection accuracy of the baseline system. A is a full-rank transform and can be optimized either globally or on a speaker-dependent basis. (This example can be appreciated with reference to FIG. 1 , described in more detail further below.)
As far as the optimization of linear system combinations goes, it should be recognized that combining multiple detection systems is a well known method to improve the overall accuracy. An example of a simple combination is the linear combination of detection scores S output by N systems
s tot = ∑ k = 1 N w k s k
where a set of weights w is used. This set can be optimized by using the following forms of the Sigma-Ratio and Delta-Term of the DETAC:
Sigma - Term : a T S 1 a a T S 2 a Delta - Term : a T ( μ 1 - μ 2 ) a T S 2 a
in which S=cov(s)∈R N×N ;μ∈R N×1 are the covariances and means of the targets and impostor scores formed into N-dimensional vectors s i =[s i1 s i2 . . . s iN ] T , and α∈R N×1 is a projection vector containing the set of linear weights to be optimized.
After the DETAC optimization, the vector a represents the best set of weights with respect to the bias and slope implicit to DETAC, and the total score can be obtained as
s tot =α T s
(This example can be appreciated with reference to FIG. 2 , described in more detail further below.)
It should now be recognized that there are numerous model and system optimization methods available in the technical literature that allow for improving the accuracy of recognition systems (e.g., speaker verification systems). Typically, detection tasks are viewed as a special case of classification between two classes. Hence, most optimization techniques, applied to detection systems, concentrate on reducing the overall error caused by the class overlap in distributions. Some techniques try to achieve this via a naive approach, namely by optimizing each class independently (e.g., Maximum Likelihood techniques) other techniques aim at minimizing the Bayes error (discriminative techniques). (Background information on both types of techniques may be found in Duda R. et al., “Pattern Classification and Scene Analysis”, Wiley, 1973.) It can be shown that the Delta-Term of the DETAC function in (1)-(3) corresponds to some of these discriminative techniques, i.e. its minimization corresponds to minimizing the Bayes error.
However, in accordance with at least one presently preferred embodiment of the present invention, the Sigma-Ratio term of the DETAC has a different objective. Instead of minimizing the overall Bayes error of the classifier (detection system), its minimization leads to changes in the shape of the Bayes error area (class overlap). These changes may result in relative accuracy improvements in certain operating regions of the DET curve, outbalanced by error rate increases in others. Thus, DETAC can also represent a way of reshaping the Bayes error area in a controlled and provable way. From experimental observations, it appears that the process of reshaping the error area is easier to achieve than reducing the area of the error itself, which can be observed as a better generalization behavior of the optimized parameters.
It should be appreciated that while specific references have been made herein to the realm of speaker verification, DETAC can actually be applicable to essentially any detection system (e.g. as described in the “Field of the Invention” and “Background of the Invention” sections), in which some optimization parameters can be identified and their functional relationship to the DETAC parameters μ,σ can be determined or approximated, either analytically or heuristically. Additional conceivable applications include, but are not limited to, a wide range of “two-class” detection systems including biometric detection systems (e.g., not only those that face detection but those that involve fingerprint detection or any of a wide range of other types of bodily detection), automobile alarms, topic detection, language detection and even medical tests, including pregnancy tests.
FIG. 1 schematically illustrates parameter optimization in a detection system using DETAC in accordance with an embodiment of the present invention. Details relating to the different components or steps shown may be appreciated, in non-restrictive and illustrative fashion, from the discussion heretofore. As shown in FIG. 1 , data from a true target trial data set S 2 (indicated at 102 ) and from an imposter trial set S 1 (indicated at 104 ) are preferably input into a detection system 106 which includes model parameters 106 a. Output scores 108 , relating to both sets S 1 and S 2 , then preferably undergo evaluation via DETAC ( 110 ). If needed, model parameters 106 a will be updated (preferably in accordance with DETAC as described heretofore) and this cycle may preferably repeat itself until the output scores 108 reach or exceed a predetermined quality as discussed heretofore.
FIG. 2 schematically illustrates the optimization of a linear combination of multiple detection systems in accordance with an embodiment of the present invention. Again, details relating to the different components or steps shown may be appreciated, in non-restrictive and illustrative fashion, from the discussion heretofore. As shown in FIG. 2 , data from a true target trial data set S 2 (indicated at 202 ) and from an imposter trial set S 1 (indicated at 204 ) are preferably input into several detection systems 1 , 2 , . . . N (indicated at 206 , 208 and 210 ). In this case, a corresponding weighting factor (w 1 , w 2 , . . . wN; indicated at 212 , 214 and 216 ) associated with each system will be applied to output scores from each system. The weighted scores, relating to both sets S 1 and S 2 , then preferably undergo evaluation via DETAC ( 110 ). If needed, the weights w 1 , w 2 , . . . wN (at 212 , 214 , 216 ) will be updated (preferably in accordance with DETAC as described heretofore) and this cycle may preferably repeat itself until a combined final score (at 218 ) reaches or exceeds a predetermined quality as discussed heretofore.
It should be understood that the “impostor data” indicated at 104 and 204 in FIGS. 1 and 2 , respectively, may also be generally construed as “non-target data” in a wide variety of applications not only in speaker verification but in many others, such as those referred to heretofore.
It is to be understood that the present invention, in accordance with at least one presently preferred embodiment, includes an input arrangement which accepts input data comprising true target data and non-target data, a detection arrangement which evaluates the input data and derives scores from the input data, and an evaluation arrangement which evaluates the scores and which successively prompts revision of at least one aspect associated with the scores until the scores reach a predetermined quality. Together, the input arrangement, detection arrangement and evaluation arrangement may be implemented on at least one general-purpose computer running suitable software programs. These may also be implemented on at least one Integrated Circuit or part of at least one Integrated Circuit. Thus, it is to be understood that the invention may be implemented in hardware, software, or a combination of both.
If not otherwise stated herein, it is to be assumed that all patents, patent applications, patent publications and other publications (including web-based publications) mentioned and cited herein are hereby fully incorporated by reference herein as if set forth in their entirety herein.
Although illustrative embodiments of the present invention have been described herein with reference to the accompanying drawings, it is to be understood that the invention is not limited to those precise embodiments, and that various other changes and modifications may be affected therein by one skilled in the art without departing from the scope or spirit of the invention. | In detection systems, such as speaker verification systems, for a given operating point range, with an associated detection “cost”, the detection cost is preferably reduced by essentially trading off the system error in the area of interest with areas essentially “outside” that interest. Among the advantages achieved thereby are higher optimization gain and better generalization. From a measurable Detection Error Tradeoff (DET) curve of the given detection system, a criterion is preferably derived, such that its minimization provably leads to detection cost reduction in the area of interest. The criterion allows for selective access to the slope and offset of the DET curve (a line in case of normally distributed detection scores, a curve approximated by mixture of Gaussians in case of other distributions). By modifying the slope of the DET curve, the behavior of the detection system is changed favorably with respect to the given area of interest. | 6 |
BACKGROUND OF THE INVENTION
This invention relates to a new process for making vicinal epoxides.
Vicinal epoxides are valuable chemical intermediates and monomers useful in making epoxy adhesives and various heat- and solvent-resistant polymers. A well-known process for making vicinal epoxides from olefins involves the oxidation of the olefinic double bond with aqueous chlorine to form the chlorohydrin and reaction of the chlorohydrin with a base to make the epoxide. However, a major disadvantage of this process is the production of an equivalent of HCl from the aqueous oxychlorination step and another equivalent of inorganic chloride from the reaction of the base with the chlorohydrin intermediate. In the case of epichlorohydrin, the conventional preparation uses the same chemistry with the added initial step of chlorinating propylene to allyl chloride which produces an additional equivalent of HCl.
Ethylene oxide is prepared by oxidizing ethylene with molecular oxygen over a silver catalyst. However, this method is not applicable to other olefins because of low selectivity and the formation of by-products. Another method using oxygen involves oxidizing a hydrocarbon such as isobutane or isopropylbenzene with air to the corresponding tertiary hydroperoxide and then reacting the hydroperoxide with an olefin in the presence of a transition metal catalyst. A disadvantage of this process is the formation of co-product alcohol which must be solid or recycled.
Hydrogen peroxide and peroxy acids are other reagents which have been used to epoxidize olefins. Chemical and economic disadvantages of such methods have precluded their use on a large scale.
It is known that cyclic carbonates can be decomposed to form epoxides in the presence of various catalysts. Such a process particularly directed to the preparation of propylene oxide by decomposition of propylene carbonate in the presence of a sulfonium or phosphonium halide or any of certain metal salts is described in U.S. Pat. No. 4,069,234.
SUMMARY OF THE INVENTION
It has now been found that vicinal epoxides of various kinds, not only the simple alkylene and cycloalkylene oxides, but also their aromatic and halogen-substituted derivatives, can be made in good yield by heating an unsymmetrical β-haloalkyl carbonate of the formula ##STR2## in the presence of a small but effective amount of a quaternary ammonium or phosphonium salt at a temperature of about 25° C.-250° C. The products of this decomposition are CO 2 , the halide R 5 X, and the epoxide of the formula ##STR3## wherein X is Cl or Br, each of R 1 , R 2 , R 3 , and R 4 is hydrogen, a hydrocarbon group, --CH 2 X, or R 1 and R 2 together form an alkylene group of 3-6 carbon atoms, and R 5 is an alkyl group, preferably a lower alkyl group.
DETAILED DESCRIPTION OF THE INVENTION
The term hydrocarbon group as used above to define R 1 , R 2 , R 3 , and R 4 includes alkyl groups of one to about 20 carbon atoms, cycloalkyl and alkylcycloalkyl groups of 5-10 carbon atoms, and aromatic hydrocarbon groups of 6-10 carbon atoms. R 5 is preferably a lower alkyl group as noted and is most preferably a methyl or ethyl group.
As can be seen from the above description, this process produces two useful products, the alkyl halide R 5 X and the epoxide, assuming CO 2 to be a waste product. The structure of the starting β-haloalkyl carbonate, therefore, is normally designed to produce not only the desired epoxide, but also a particular useful alkyl halide which has a boiling point sufficiently different from the epoxide to facilitate easy and complete separation of these two products.
The decomposition reaction takes place in the presence of the quaternary salt catalyst at some rate at any temperature from about room temperature to about 250° C., but for normally practical reaction times, the decomposition is preferably carried out at about 150°-250° C. Reaction times can range from 0.001 hour to about 10 hours depending on the structure of the carbonate, the temperature, and the nature and amount of the catalyst.
Substantially any quaternary ammonium or phosphonium salt can catalyze the decomposition reaction. Preferably, these salts have the general formula R 4 AY where each R is a hydrocarbon moiety; A is a quaternized nitrogen or phosphorus atom; and Y is an inert (i.e., inert in this process) neutralizing anion which may be inorganic, e.g., chloride, bromide, iodide, bicarbonate, sulfate, or the like; or Y may be an organic ion such as formate, acetate, benzoate, phenate, or bisphenolate. The R groups may be alkyl, aryl, alkaryl, aralkyl, or cycloalkyl. Also, two R groups may combine to form a heterocyclic ring. Illustrative quaternary salt catalysts are tetrabutylammonium bromide, benzyltriethylammonium chloride, N-methylpyridinium chloride, N,N-dibutylmorpholinium iodide, N-propylpyrrolium chloride, tetrabutylphosphonium bromide, tributylmethylphosphonium formate, tetrapropylphosphonium bisulfate, and corresponding ammonium and phosphonium salts with these and other such inorganic and organic neutralizing anions as described above.
Although any significant amount of such a quaternary salt will catalyze the decomposition reaction to some extent, for practical reasons in batch operations, it is preferred to use about 0.1-10 mole percent of the salt based on the carbonate. More quaternary salt catalyst can be used but the excess confers little added advantage and may in fact be disadvantageous.
In a mode of the invention particularly adapted to continuous operation, one or more R groups may be pendant methylene groups from a resin matrix so that the quaternary salt is a salt form of a strong base anion-exchange resin such as DOWEX® 21K, DOWEX® 11, DOWEX® MSA-1, or other such commercially available ion-exchange resins or the phosphonium equivalents of such quaternary ammonium-substituted resins. In such a continuous operation of the process, the β-haloalkyl carbonate starting material is passed at an appropriate flow rate through a bed of the strong base anion resin maintained at a suitable temperature within the limits previously defined.
A reaction solvent or diluent is usually of no advantage and the process is ordinarily run in the absence of such an inert additive. In some cases, however, a solvent may be of some advantage. Inert solvents suitable for use include hydrocarbons such as toluene, xylene, and decane; glycol diethers such as dimethyloxy ethane, substituted amides such as N,N-dimethylformamide, and cyclic compounds such as tetrahydrofuran and sulfolane.
In the preparation of higher boiling epoxides particularly, separation of the epoxide product may be facilitated by running the reaction under appropriately reduced pressure or by passing a stream of nitrogen or other inert gas through or over the reaction mixture.
The β-haloalkyl alkyl carbonate starting materials for this process can be prepared by any of several generally known procedures. Pechukas, U.S. Pat. No. 2,518,058 describes the reaction of an epoxide with a haloformate to make a corresponding β-haloalkyl alkyl carbonate. These mixed carbonate esters can also be made by the acid-catalyzed transesterification reaction of a halohydrin with a dialkyl carbonate. For example, 2-chloroethyl methyl carbonate is produced by the reaction of diemthyl carbonate with ethylene chlorohydrin and 1-chloro-2-propyl ethyl carbonate can be made by reacting diethyl carbonate with 1-chloro-2-propyl alcohol. Variations of this method can be used to make particular halogenated alkyl carbonate esters. Corresponding monohalo- and dihalopropyl carbonates, for example, can be made by first reacting allyl alcohol with a dialkyl carbonate and then adding hydrogen halide or halogen to the olefinic double bond in the allyl alkyl carbonate product.
EXAMPLE 1
A mixture of 4.57 g of 1-chloro-2-propyl methyl carbonate (contained 20-30 percent of the 2-chloro-1-propyl isomeric ester) and 0.034 g of tetrabutylphosphonium bromide in a 10 ml reaction flask was heated by an oil bath at 180° C.-185° C. for 2 hours. The flask was equipped with a magnetic stirrer, a condenser, and a receiver plus a trap, each of the latter containing 10 g of chloroform cooled to -60° C. After 2 hours of heating, the residue in the reaction flask amounted to 0.23 g of material which contained less than 5 percent starting carbonate. The receiver and trap had gained a total of 2.5 g of reaction products which were determined by nuclear magnetic resonance spectroscopic and chromatographic analysis to be a mixture of propylene oxide and methyl chloride, some methyl chloride having been lost because of its high volatility. The conversion of chloropropyl methyl carbonate was nearly 100 percent and the analyses indicated a yield of about 95 percent of the theoretical for propylene oxide.
EXAMPLES 2-3
The procedure of Example 1 was repeated twice using 0.027 g of tetrabutylammonium chloride and 0.037 g of tetrabutylammonium iodide respectively in place of the phosphonium salt catalyst. In each case, the yield of propylene oxide was 97-99 percent of the theoretical amount but the conversion of starting carbonate was relatively low, about 20 percent and 25 percent respectively.
EXAMPLE 4
The procedure of the above examples was repeated using 0.5 g of DOWEX® MSA-1 ion-exchange resin as the catalyst. The resin contained 40-50 percent water. This resin is a strong base anion resin consisting of a macroporous cross-linked styrene polymer matrix having pendant quaternary ammonium chloride functionalities. After 2.5 hours of heating time, about 99 percent of the carbonate had been decomposed to form 95 percent of the theoretical quantity of propylene oxide.
EXAMPLES 5-11
Other alkyl 1-chloro-2-propyl carbonates (containing 20-30 percent of the corresponding 2-chloro-1-propyl ester) were heated for 2 hours as described above to produce propylene oxide using different tetrabutylphosphonium salts as catalysts. Each carbonate was used in a quantity of 0.03 g mole. The results are summarized in Table I.
TABLE I______________________________________Example Alkyl Phosphonium Catalyst % %No. group Salt Wt. g. Conv. Sel.______________________________________5 ethyl bromide 0.034 2-3 996 ethyl bicarbonate 0.032 5-6 997 ethyl formate 0.030 35-37 998 ethyl bisphenate.sup.b 0.075 37-38 999 ethyl bisphenate.sup.b 0.215 98 96 10.sup.a n-propyl bisphenate.sup.b 0.215 99 95 11.sup.a isopropyl bisphenate.sup.b 0.215 39 93______________________________________ .sup.a Heating time was 6 hours. .sup.b Monosalt of Bisphenol A complexed with one molecule of the free bisphenol.
EXAMPLE 12
A mixture of 4.16 g of 2-chloroethyl methyl carbonate and 0.034 g of tetrabutylphosphonium bromide was heated at 180° C. for 3 hours in the apparatus previously described. A carbonate conversion of 99.7 percent was obtained with an 89 percent yield of ethylene oxide.
EXAMPLE 13
In the same way, a mixture of 5.49 g of 2-bromoethyl methyl carbonate and 0.034 g of tetrabutylphosphonium bromide was heated for 6 hours at 200° C. to produce a carbonate conversion of 100 percent and an 88 percent selectivity to ethylene oxide and methyl bromide.
EXAMPLE 14
Similarly, a mixture of 2.92 g of 1-chloro-2-hexyl methyl carbonate (containing 22 percent of the 2-chloro-1-hexyl isomer) and 0.024 g of tetrabutylphosphonium formate was heated at 200° C.-205° C. for 2 hours to produce an isolated yield of 98 percent of the theoretical quantity of 1,2-epoxyhexane.
EXAMPLE 15
A mixture of 3.34 g of 1-chloro-2-octyl methyl carbonate (containing 21 percent of the corresponding 2-chloro-1-octyl ester) and 0.024 g of tetrabutylphosphonium formate was heated as above at 200° C.-205° C. for 2 hours at reduced pressure (200 mm Hg). An isolated yield of 96 percent of theory of 1,2-epoxyoctane was collected in the receiver.
EXAMPLE 16
A mixture of 2.89 g of 2-chlorocyclohexyl methyl carbonate and 0.039 g of tetrabutylphosphonium salt of Bisphenol A (as used in Examples 8-11) was heated at 200° C.-205° C. for 1.5 hours. A yield of 1.34 g of 1,2-epoxycyclohexane was collected in the receiver.
EXAMPLE 17
In a procedure similar to that used in Example 15, a mixture of 3.89 g of 2-bromo-1-phenylethyl methyl carbonate and 0.024 g of tetrabutylphosphonium formate was heated at 180° C. for 2 hours at 50 mm Hg absolute pressure. The product condensed in the receiver was 1.58 g of a mixture containing 40 percent styrene oxide and 60 percent phenylacetaldehyde.
EXAMPLE 18
The reduced pressure technique of Examples 15 and 17 was followed in heating a mixture of 5.61 g of 1,3-dichloro-2-propyl methyl carbonate and 0.078 g of the tetrabutylphosphonium Bisphenol A salt used in Examples 8-11 and 16. After 2 hours at 195° C.-200° C. and 100 mm Hg absolute pressure, 2.85 g of 88 percent pure epichlorohydrin had condensed in the receiver.
EXAMPLE 19
To a 4-neck 50 ml reaction flask equipped with a mechanical stirrer, addition funnel, distillation head, and nitrogen inlet there was added 0.24 g of tetrabutylphosphonium formate and the flask was heated to 185° C.-190° C. with a stream of 30 ml/min. of nitrogen passing through while 2.81 g of 2,3-dichloro-1-propyl methyl carbonate was added over a period of 30 minutes. Analyses of 1.4 g of condensed effluent in the receiver cooled by solid CO 2 and 0.47 g of residue indicated a 90-95 percent conversion of carbonate with a 50-60 percent yield of epichlorohydrin. | Vicinal epoxides are prepared by decomposing a β-haloalkyl carbonate of the general formula ##STR1## in the presence of a quaternary ammonium or phosphonium salt. | 2 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a device for processing a card clothing mounted on a card clothing carrier, particularly an all-steel sawtooth card carrier, with at least one processing tool and a guiding device serving for guiding the processing tool along a predetermined path.
2. Description of the Related Art
Devices of this type are used, for example, for maintaining and starting the operation of cards and carding machines. A card is used in fiber processing for cleaning and parallelizing individual fibers. For this purpose, a card is equipped with a drum and a plurality of so-called flats. The drum referred to is an approximately circular cylindrical cylinder which is equipped on its outer surface with a clothing generally formed of a sawtooth wire extending in a coil shape, wherein the circular cylindrical cylinder serving as the carrier is rotatable about its cylinder axis. Referred to as the flats are fiber processing elements which extend approximately parallel to the cylinder axis of the drum, wherein the fiber processing elements are equipped on its side facing the drum clothing with a clothing composed, for example, of sawtooth wire sections or card wires. For fiber processing, the drum is rotated and the drum takes along the fibers to be processed, wherein the fibers are parallelized and cleaned as a result of the cooperation of the drum clothing and the flat clothings. Fiber processing tools which are similar to the drum of a card and which also are usually called drums are used in carding machines which are used for manufacturing or processing worsted yarns, synthetic fibers, non-woven fabrics, cotton wool, etc.
During this fiber processing, a significant wear and also a significant contamination of the drum clothing occurs. For this reason, it is necessary to regularly regrind and/or clean the drum clothing. Usually used for regrinding the drum clothing are grinding devices which can be secured to the card frame and extend essentially in the direction of the cylinder axis of the drum, wherein the grinding devices can grind the clothing mounted on the circular cylindrical or roll-shaped carrier of the drum during a rotation of the drum. In view of the fact that the drum of a card has in the longitudinal direction of the cylinder axis usually a width of at least 1.5 meters and the drum of a carding machine may have a length of up to 5 meters, grinding elements are usually used which can be moved back and forth along a guiding device extending parallel to the cylinder axis of the drum, so that the entire width of the drum can be processed using a relatively small grinding element.
Devices of the type described last are disclosed, for example, in DE-A-196 05 635. With respect to a construction, the operation and the assembly of a grinding device suitable for regrinding a drum clothing, the disclosure content of this document is hereby incorporated into this description by express reference.
Even though it is possible to carry out a reliable and effective processing of all-steel sawtooth card clotting, using the grinding devices known from the cited document, it has been found that the assembly of the known processing devices regularly poses significant problems with respect to the generally very narrow space available in the area of a card and particularly in the area of a carding machine.
In view of these problems in the prior art, the invention is based on the object of providing a device for processing a clothing mounted on a clothing carrier which can be easily mounted at the location of use while ensuring a satisfactory operation.
According to the invention, this object is met by a further development of the known processing devices which is essentially characterized in that the guiding device has at least two guiding elements which are adjustable between a work position and a transport position, wherein the guiding elements extend in the work position along a longer portion of the predetermined path than in the transport position.
This solution of the object of the invention is based on the finding that the principal difficulty in the assembly of the known processing devices is in the transport of this processing device to the location of use, because the guiding devices of the processing device must have a length which corresponds approximately to the length of the predetermined path. This length of the guiding device constructed, for example, in the form of a guiding rail, may be up to 4.5 m in a processing device which can be used for regrinding the drum of a carding machine, so that a transport of these processing devices is hardly possible particularly in view of the narrow space available in factory buildings.
In the further development of the known processing device according to the present invention, this problem is solved by dividing the guiding device which predominantly determines the dimensions of the processing device into at least two guiding elements, so that the total length of the processing device is reduced for transporting purposes to at least about half. Consequently, a simple transport of the processing device according to the invention to the location of use is made possible. At the location of use itself, the processing device according to the invention can then be adjusted in a simple manner into the work position in which the guiding elements extend along the total predetermined path, i.e., for example, along the total width of the drum of a carding machine in the direction of the drum axis over 2.5 to 5 meters, so that a complete processing of the clothing is made possible.
Even though the processing device according to the invention may also have two guiding elements which are completely separated from each other in the transport position it has been found particularly advantageous for the transport and the assembly if the guiding elements are still connected to each other even in the transport position because this ensures that the individual guiding elements are always assigned to the corresponding guiding elements. In this connection, it has been found particularly advantageous structurally as well as for ensuring a high operational reliability if the guiding elements are connected to each other through a joint preferably in the form of a flap-type hinge having a hinge axis extending perpendicularly of the predetermined path because the individual joint elements, such as the individual hinge flaps, can be attached particularly simply to the guiding elements and the use of a hinge having an axis extending perpendicularly of the predetermined path already ensures an alignment in a plane of the individual guiding elements formed, for example, by guiding rails. The assembly can be further simplified if the individual guiding elements each have an end face extending approximately perpendicularly of the predetermined path, wherein these end faces rest against each other in the work position and are arranged next to each other in the same plane in the transport position.
For ensuring a particularly high operational safety in the work position, the processing device according to the invention is advantageously equipped with at least one stabilizing element for stabilizing the guiding elements in the work position wherein the stabilizing element can be secured to at least one of the guiding elements. Such a stabilizing element may be constructed, for example, in the form of a stabilizing rail extending over the joint which connects the two guiding elements with each other. A particularly good stabilization is achieved if the stabilizing element has an approximately T-shaped cross-section in a sectional plane extending perpendicularly of the predetermined path because this ensures a particularly high geometrical moment of inertia of the stabilizing element.
As already mentioned above, it is particularly advantageous if the stabilizing element extends in the work position over the joint connecting the guiding elements because this ensures a protection of the joint, on the one hand, and an unintentional pivoting movement of the guiding elements about the joint axis can be reliably prevented, on the other hand. For this purpose, in accordance with a particularly advantageous further development of the invention, the stabilizing element is provided with at least one spacer member by means of which the stabilizing element can be secured to at least one of the guiding elements while forming an intermediate space serving for receiving at least one of the components of the joint or hinge.
A particularly secure locking of the guiding elements in the work position can be achieved if the stabilizing element and/or the hinge has at least one coupling area preferably extending along the predetermined path for effecting a positively connecting engaging connection with a coupling area of the guiding element of complimentary construction, because this makes it possible to reliably prevent a tilting motion of the two guiding elements about a tilting axis extending transversely of the hinge axis. The coupling areas can be realized structurally in a particularly simple manner if they are constructed in the form of grooves formed in the guiding elements and being in alignment with each other in the work position wherein corresponding coupling ledges of the stabilizing element and/or the joint engage in the grooves.
The above-described locking of the guiding elements in the work position can be ensured without influencing the operability of the processing tool if the joint and/or the stabilizing element is arranged on a side of the guiding device located opposite the work position of the clothing to be processed, wherein the guiding device is realized, for example, in the form of a guiding rail having an approximately square cross-section.
Event though the device according to the invention can also advantageously be used in those processing devices in which the processing tool is moved automatically along the predetermined path by the rotating motion of the clothing mounted in the shape of a coil on a circular cylindrical carrier, as, for example, when using a cleaning tool with cleaning blades extending into the clothing lanes formed between the individual coils of the clothing, it has been found particularly advantageous especially in devices for regrinding a clothing if the processing tool is coupled through a traction member preferably in the form of a toothed belt extending around a drive roller and a guide roller to a drive device serving for moving the processing tool along the redetermined path. In this connection, for avoiding an excessive elongation of the traction member when adjusting the processing device according to the invention between the work position and the transport position, it has been found particularly advantageous, if the traction member is releasably fastened to the processing tool.
For simplifying the assembly of such a processing device, it has been found advantageous if the traction member is fastened for this purpose to a fastening element of the processing tool which is releasably connected to a processing element of the processing tool. In the case of an adjustment from the work position into the transport position it is then possible to separate the fastening element together with the traction member from the processing element and it can simultaneously also be ensured that the fastening element with the traction member fastened thereto and separated from the processing element is guided along a guide means formed in the guiding elements, so that an uncontrolled movement of the traction member separated from the processing tool is prevented.
For this purpose, the processing device according to the invention may additionally include a limiting element which can be secured relative to the guiding device and is movable preferably along the predetermined path for limiting the movement of the fastening element of the processing tool separated from the processing element along the predetermined path. The just-described guidance of the fastening element separated from the processing element can be realized in a particularly simple manner if at least one of the guiding elements has a guiding groove extending along the predetermined path for receiving a guiding portion of the processing tool because this guiding groove can also be utilized for guiding the fastening element. IN the embodiment of the invention described last, the fastening element may have a stop area for preventing the fastening element from completely penetrating into the guiding groove after the fastening element has been separated from the processing element. Such a fastening element may have, for example, an approximately T-shaped cross-section in a plane extending perpendicularly of the predetermined path with a leg received in the guiding groove and a leg resting on both sides of the guiding groove against a guiding surface of the guiding element.
A particularly compact construction of the device according to the invention can be achieved if the guiding groove opens into a hollow space extending in the guiding element in the direction of the predetermined path and serving for receiving the traction member. Such a guiding element can be realized, for example, in the form of a hollow aluminum section.
The various features of novelty which characterize the invention are pointed out with particularity in the claims annexed to and forming a part of the disclosure. For a better understanding of the invention, its operating advantages, specific objects attained by its use, reference should be had to the drawing and descriptive matter in which there are illustrated and described preferred embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWING
In the drawing:
FIG. 1 is a partially sectional side view of a processing device according to the invention;
FIG. 2 is a view of the processing device shown in FIG. 1 in the direction indicated by arrow A in FIG. 1; and
FIG. 3 is a sectional view of the processing device shown in FIG. 1 along the sectional plane B—B indicated in FIG. 1
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The processing device illustrated in the drawing is composed essentially of a processing tool in its totality indicated by 10 and a grinding head 12 and a carriage 14 and of a guiding device in its totality denoted by 20 .
The guiding device 20 is composed of two guiding rails 22 and 24 which are connected to each other through a joint 40 formed in the form of a flap-type hinge.
As illustrated particularly clearly in FIG. 3, each of the guide rails 22 and 24 is constructed in the from of a hollow aluminum section. IN the work position of the processing device according to the invention illustrated in FIGS. 1 and 2, the processing tool 10 can be moved back and forth in the directions indicated by double arrow P. For this purpose, the carriage 14 is coupled to a traction member in the form of a toothed belt 18 which extends around a drive roller and a guide roller. The toothed belt is received in a hollow space 28 extending through the guide rails 22 and 24 in the longitudinal direction thereof. For guiding the movement of the carriage in the directions indicated by arrow P, the carriage is equipped with a guiding area which is received in a groove 26 (see FIG. 3) of the guide rails 22 and 24 which leads into the hollow space 28 . With respect to the construction of the grinding head 12 , reference is made to the description in DE-A-196 05 653.
In the work position of the processing device according to the invention shown in FIGS. 1 and 2, the guide rails 22 and 24 rest against each other with end faces 23 and 25 extending perpendicularly of the directions of movement of the processing tool indicated by double arrow P, so that the guiding grooves 26 formed in the guiding rails 22 and 24 and the hollow spaces 28 are in alignment with each other. As shown particularly clearly in FIG. 3, the guiding rails 22 and 24 have an essentially square cross-section, wherein, in addition to the guiding groove 26 , provided in each of the side surfaces of the guiding rails 22 and 24 are always two grooves 30 , 32 , 34 and 36 with an essentially T-shaped cross-section and extending in the longitudinal direction of the guiding rails, wherein additional elements of the processing device according to the invention are secured in the grooves, such as, a limiting element 38 (see below) or a stabilizing element 50 (see below).
The flap-type hinge which connects the two guiding rails to each other is arranged on the side of the guiding rails 22 and 24 facing away from the grinding head 12 and the guiding groove 26 . The hinge 40 includes a first hinge flap 42 secured to the guiding rail 22 and a second hinge flap 44 secured to the guiding rail 24 . At their ends facing each other, the hinge flaps 42 and 44 are equipped with receiving areas 43 and 45 for receiving a hinge pin 46 . The receiving area 45 provided at the hinge flap 44 is arranged between the receiving areas 43 arranged at the hinge flap 42 . The hinge pin 46 and, thus, also the hinge axis extend in a direction extending perpendicularly of the longitudinal direction of the guiding rails 22 and 24 , so that the guiding rails 22 and 24 can be folded together from the work position shown in FIGS. 1 and 2 by a pivoting movement, such that the end faces 23 and 25 which rest against each other in FIGS. 1 and 2 are located in a plane in the folded-up state and the total arrangement composed of the guiding rails 22 and 24 now only has approximately half the length as compared to the work position illustrated in FIGS. 1 and 2.
As is particularly clear from looking at FIGS. 1 and 3 together, the hinge flaps 42 and 44 are mounted by screws 47 at fastening ledges 48 received in the grooves 34 arranged in the sides of the guiding rails 22 and 24 facing away from the guiding groove 26 .
For securing the guiding rails 22 and 24 in the work position illustrated in FIGS. 1 and 2, the processing device according to the invention is equipped with a stabilizing element denoted in its totality by 50 and releasably fastened to the guiding rails 22 and 24 . The stabilizing element 50 extends approximately in the longitudinal direction of the guiding rails 22 and 24 and has an essentially T-shaped cross-section, as particularly clearly illustrated in FIG. 3 . One of the legs of the stabilizing element 50 extends approximately parallel to the limiting surface of the guiding rails 22 and 24 provided with the grooves 34 and located opposite the guiding groove 26 , while the other leg 54 extends starting from the center of this leg in a direction extending perpendicularly thereto away from the guiding rails 22 and 24 .
The stabilizing element 50 is also secured by means of screws 58 to the fastening ledges 48 received in the grooves 34 . For providing an intermediate space serving for receiving the flap-type hinge 40 , spacer members 56 are arranged at the outer edges of the leg 52 of the stabilizing element 20 on the side facing the guiding rails 22 and 24 , wherein the screws 58 extend through the spacer members 56 . For reliably locking the stabilizing element 5050 relative to the guiding rails 22 and 24 , at least one of the spacer members 56 is equipped on its side facing the grooves 34 with a guiding ledge received in the end area of the groove 34 . The hinge flaps 42 and 44 are also equipped with guiding webs received in the end areas of the grooves 34 .
For adjusting the processing device according to the invention from the work position illustrated in FIGS. 1 and 2 into a transport position, initially the stabilizing element 50 is removed together with the spacer members 56 by loosening the screws 56 from the guiding rails 22 and 24 . The toothed belt 18 is then separated from the carriage 14 . For this purpose, the carriage 14 is equipped with a fastening element 16 mounted on the toothed belt 18 through a screw 17 , wherein the fastening element 16 , in turn, is mounted through a screw 15 on the remainder of the processing tool. The fastening element 16 has in a direction extending perpendicularly of the direction of movement of the carriage 14 indicated by the double arrow P a greater width than the guiding groove 26 . This prevents the fastening element 16 together with the toothed belt 18 from falling into the hollow space extending in the guiding rails 22 and 24 after the carriage 14 has been separated. In addition, a movement of the fastening element 16 along the predetermined path indicated by the double arrow P is limited by a limiting element 38 received in the guiding grooves 30 .
After separating the stabilizing element 50 and the toothed belt 18 , the guiding rails 22 and 24 can be tilted about the hinge axis of the hinge 40 or can be folded together in order to reach a transport position.
The invention is not limited to the embodiment explained with the aid of the drawing. Rather, it is also contemplated to use the guiding device illustrated in FIGS. 1 through 3 in connection with a cleaning tool which partially surrounds the guiding rails 22 and 24 and rests against guiding surfaces of these guiding rails 22 and 24 and which can be moved in the directions indicated by the double arrow P. The processing device according to the invention may also have more than only one processing tool in order to achieve in this manner a complete processing of the clothing in a particularly short time and with particularly short distances of moving the individual processing tools. Moreover, instead of the flap-type hinge illustrated in the drawing, other joints can be used for connecting the individual guiding rails 22 and 24 .
While specific embodiments of the invention have been shown and described in detail to illustrate the inventive principles, it will be understood that the invention may be embodied otherwise without departing from such principles. | A device for processing a card clothing mounted on a card clothing carrier, particularly an all-steel sawtooth card clothing carrier, has at least one processing tool and a guiding device for guiding the processing tool along a predetermined path. The guiding device has at least two guiding elements which can be adjusted between a work position and a transport position. The guiding elements extend in the work position along a longer portion of the predetermined path than in the transport position. | 3 |
RELATED APPLICATIONS
[0001] This application is based on Provisional Application Serial No. 60/314,744 filed on Aug. 24, 2001, entitled “Retractable Structures Comprised of Interlinked Panels.”
BACKGROUND OF THE INVENTION
[0002] Structures that transform in size or shape have numerous applications in many fields. My prior patent, U.S. Pat. No. 5,024,031, hereby incorporated by reference as if fully disclosed herein, teaches methods for constructing transformable truss-structures in a variety of shapes. The teachings therein have been used to build structures for diverse applications including architectural uses, public exhibits and educational toys.
[0003] One particular embodiment disclosed in U.S. Pat. No. 5,024,031 is a retractable structure that expands from a compact ring of links to form a self-supporting structural dome. In its most basic embodiment, such a structure is made entirely of a latticework of links. The structure would be comprised of structural elements only, and the structural dome, when extended, retains a somewhat skeletal appearance. As an extension of that embodiment, a method was also disclosed to incorporate panel elements that may be attached to the outward side of structure, thereby creating a substantially smooth, continuous covering that covers the entire dome in its extended position (See FIGS. 28-33 of U.S. Patent No. 5,024,031).
[0004] Such an arrangement can be improved upon. Since the panel elements are separate pieces from the structural member themselves, they add additional elements that may negatively affect the structural integrity of the structure. Additional elements would also raise the cost to build and maintain such a structure. A further concern is that when building a large structure, the panel elements may catch the wind and cause them to be dislodged from the structural elements.
BRIEF SUMMARY OF THE INVENTION
[0005] In accordance with the present invention, a retractable structure is presented that incorporates an additional useful feature. I have discovered a way to construct such retractable structures whereby the links are themselves panel elements. Thus, the structural members themselves form a continuous surface, leading to a more economical, structurally sound and cleaner design.
[0006] Such links can be assembled to form planer and three-dimensional structures. In their planar embodiments, retractable structures according to this invention may be comprised exclusively of panels hinged together. In their three-dimensional embodiments, whether conical, hemispherical or other shapes, panels are connected to one another via small hub elements.
[0007] This discovery represents a significant improvement over the earlier invention, and offers the promise of building of practical architectural structures with retractable features.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] [0008]FIG. 1 shows a typical panel-link with three pivot points.
[0009] [0009]FIG. 2 shows a tongs linkage comprised of eight separate panel-links in its extended position, forming a wedge-shaped surface.
[0010] [0010]FIG. 3 shows the same linkage in a partially retracted position, its edges lying along the lines of a similar angle to that in FIG. 1.
[0011] [0011]FIG. 4 shows the same linkage in a fully retracted position, its edges lying along the lines of a similar angle to that in FIG. 1.
[0012] [0012]FIGS. 5, 6, and 7 show perspective views of the same linkage in its extended, partially retracted and fully retracted positions respectively.
[0013] [0013]FIG. 8 shows a structural arch to which twelve extended tongs-linkages have been attached, said linkages also being joined to one another, to form a semi-circular planar surface.
[0014] [0014]FIG. 9 shows the same structure wherein all twelve tongs-linkages have been fully retracted into the structural arch, thereby providing a large semi-circular opening.
[0015] [0015]FIG. 10 shows a perspective view of the planar arch structure in its extended position.
[0016] [0016]FIGS. 11 and 12 show perspective views of the planar arch structure in its partially retracted and fully retracted positions respectively.
[0017] [0017]FIG. 13 shows two planar tongs-linkages about to be joined to one another by six hub elements.
[0018] [0018]FIG. 14 shows same two linkages joined together by the hub elements.
[0019] [0019]FIG. 15 shows a sectional view revealing an angled relationship between the two linkages.
[0020] [0020]FIG. 16 shows a perspective view of a retractable conical structure comprised of twenty planar tongs-linkages, shown here in its extended position, each linkage being joined to one another by hub elements, thereby forming a complete ring.
[0021] [0021]FIG. 17 shows the same structure in elevation view.
[0022] [0022]FIGS. 18 and 19 show perspective views of the same structure in its partially retracted and fully retracted positions.
[0023] [0023]FIG. 20 shows a plan view of a curved tongs-linkage in its extended position.
[0024] [0024]FIG. 21 shows an elevation view of the same linkage.
[0025] [0025]FIGS. 22, 23 and 24 show perspective views of the curved tongs-linkage in its extended, partially retracted and fully retracted states respectively.
[0026] [0026]FIG. 25 shows a perspective view of a retractable domed structure in its extended position.
[0027] [0027]FIG. 26 shows an elevation view of the domed structure.
[0028] [0028]FIGS. 27 and 28 show the same retractable dome in its partially retracted and fully retracted positions respectively.
[0029] [0029]FIG. 29 shows a panel-link that is constructed of a frame with a sheet material to provide an infill, along with a linear link.
[0030] [0030]FIG. 30 shows a tongs linkage in its extended position, whereby the linkage is comprised of four panel-links and four linear links.
[0031] [0031]FIG. 31 shows the tongs linkage in a partially retracted position, the slide elements having moved along the supporting structure.
[0032] [0032]FIG. 32 shows the tongs linkage in its fully retracted position so that it is fully retracted to within the supporting structure.
[0033] [0033]FIG. 33 shows a semi-circular retractable structure consisting of twelve tongs linkages.
[0034] [0034]FIG. 34 shows a stationary supporting arch and a supporting track.
[0035] [0035]FIG. 35 shows the retractable structure and supporting structure together.
[0036] [0036]FIGS. 36 and 37 show the structure in its partially extended and fully retracted position respectively.
[0037] [0037]FIG. 38 shows an elevation view of the same retractable structure.
DETAILED DESCRIPTION OF THE INVENTION
[0038] In FIG. 1 is shown a typical panel-link element 8 which has a polygonal profile. Panel link element 8 has one central pivot 7 and two end-pivots 5 and 9 . A single panel-link element is the most basic element in the structure. Two panel-link elements can be pivotally connected to each other by their central pivots to form a link-pair.
[0039] A plurality of these link-pairs can be pivotally connected to each other by their end-pivots to form a structure that can extend like a pair of extendable tongs (hence, a “tongs linkage”.) FIG. 2 shows such a tongs linkage 20 which is comprised of eight panel-links 2 , 4 , 6 , 8 , 10 , 12 , 14 and 16 . Links 6 and 8 are pivotally joined together via pivot 7 to form a link-pair. Similarly links 2 and 4 are joined, as are links 10 and 12 , as are links 14 and 16 . Each link-pair is itself joined to a neighboring pair via two pivots. Linkage 20 is shown in an extended position whereby a triangle-shaped surface is formed. A line 22 passes through one end-pivot each of all of the panel-links. A second line 24 passes through the other end-pivot of the panel-links.
[0040] In FIG. 3 linkage 20 is shown in a partially retracted position. A line 23 passes through one end-pivot each of the eight panel-links and a second line 24 passes through the other end-pivot. The angle formed between lines 23 and 24 is identical to the angle formed between lines 21 and 22 .
[0041] In FIG. 4 linkage 20 is shown in a fully retracted position. A line 25 passes through one end-pivot each of the eight panel-links and a second line 26 passes through the other end-pivot. The angle formed between lines 25 and 26 is identical to the angle formed between lines 21 and 22 .
[0042] [0042]FIG. 5 shows a perspective view of linkage 20 in an extended position. Link-pair 14 , 16 lies in an offset plane from link-pair 10 , 12 which itself lies in an offset plane from link-pair 6 , 8 . This last link-pair is itself offset from link-pair 2 , 4 . FIG. 6 shows a perspective view of linkage 20 in a partially retracted position. The offsets between adjacent link-pairs allow them to slide over one another without interference. FIG. 7 shows linkage 20 in its fully retracted position whereby all of the panel-links are stacked over one another.
[0043] [0043]FIG. 8 shows a semi-circular retractable structure 60 which is comprised of 12 tongs-linkages 20 , 30 , 32 , 34 , 36 , 38 , 40 , 42 , 44 , 46 , 48 and 50 each one of which is pivotally joined to its neighboring linkage via those end pivots which lie in along a line. Shown in its extended position, structure 60 forms a semi-circular solid wall. Structure 60 is further comprised of a stationary arch 52 which supports the linkages. Linkage 20 is attached to arch 52 via two sliding connections 27 and 28 . Similarly all of the remaining linkages are attached to arch 52 by sliding connections. Structure 60 is further comprised of a linear track 60 which supports tongs linkages 20 and 50 along their unattached edges. FIG. 9 shows structure 60 in its fully retracted position whereby the linkages have retracted to overlap arch 52 thereby providing a semi-circular opening. FIGS. 10,11 and 12 shows perspective views of structure 60 in its extended, partially retracted and fully retracted positions respectively.
[0044] [0044]FIG. 13 shows two tongs-linkages 70 and 71 in proximity to five hub elements 72 , 73 , 74 , 75 and 76 . FIG. 14 shows linkages 70 and 71 joined to one another via those same five hub elements. FIG. 15 shows a sectional view of the joined tongs-linkages revealing an angular relationship between them, said angle being formed by the hub elements. FIG. 16 shows a retractable structure 80 having a conical form which is comprised of twenty tongs linkages 70 , 71 and 81 through 98 (consecutively). Each tongs linkage is connected to two of its neighboring linkages via adjoining hub elements. For example linkage 70 is joined to linkage 71 via hub elements 72 , 73 , 74 , 75 and 76 . Structure 80 is further comprised of a base support 79 . Each tongs linkage is joined to base support 79 via two sliding connections.
[0045] [0045]FIG. 17 shows an elevation view of structure 80 . FIG. 18 shows a perspective view of structure 80 in a partially retracted position. FIG. 19 shows structure 80 in a fully retracted position.
[0046] [0046]FIG. 20 shows a tongs linkage 100 which is comprised of twelve panel-links and 14 hub elements. Linkage 100 is shown in its extended position forming a continuous triangular shaped surface. Link-pair 121 , 122 is joined to link-pair 123 , 124 via hub elements 102 , 112 . Link-pair 123 , 124 is joined in turn to link-pair 125 , 126 via hub elements 103 , 113 . Similarly each successive link-pair is joined to its neighboring pair by a pair of hub elements. Linkage 100 is shown in elevation view in FIG. 21. It may be seen to have a curved profile, this curvature being introduced by the various hub elements. FIG. 22 shows a perspective view of linkage 100 in its extended position. The edges of the panel-links may be seen to lie in planes 140 and 141 . Likewise, the center-planes of the hub elements lie in planes 140 and 141 .
[0047] [0047]FIG. 23 shows linkage 100 in a partially retracted position. The center-planes of the hub elements lie in planes 142 and 143 . The angle formed between planes 142 , 143 is identical to the angle formed between 140 , 141 . FIG. 24 shows linkage 100 in its fully retracted position. The center-planes of the hub elements lie in planes 144 and 145 . The angle formed between planes 144 , 145 is identical to the angle formed between 140 , 141 . FIG. 25 shows a retractable structure 110 , which is a dome, in its fully extended position. Structure 110 is comprised of 24 linkages which are similar to linkage 100 , each linkage being connected to its neighbor by adjoining hub elements. Structure 110 is supported by a base 115 to which each of the 24 linkages are attached by sliding connections.
[0048] [0048]FIG. 26 shows structure 110 in elevation view. FIGS. 27 and 28 show structure 110 in its partially retracted and fully retracted positions respectively.
[0049] [0049]FIG. 29 shows panel-link 123 that is constructed of framing elements 140 that connect the three pivots, and border the polygonal profile. Link 123 is further comprised of an infill 141 which is a sheet material attached to frame 140 . Also shown in FIG. 29 is a linear link 124 which has three pivots.
[0050] [0050]FIG. 30 shows a tongs linkage in its extended position, whereby the linkage is comprised of four panel-links and four linear links. Link-pairs are made up of one panel-link and one linear link respectively. For example panel-link 123 is joined to linear link 124 by their central pivots. In its extended position the four panel-links form a triangular-shaped surface that is one layer thick. The linear links serve to synchronize the motion of the linkage, but do not provide covering themselves. Also shown in FIG. 30 is a stationary supporting structure 134 to which two links 127 and 128 are joined via slide elements 130 and 132 respectively.
[0051] [0051]FIG. 31 shows the tongs linkage in a partially retracted position, the slide elements having moved along the supporting structure. FIG. 32 shows the tongs linkage in its fully retracted position so that it is fully retracted to within the supporting structure. FIG. 33 shows a retractable structure 100 consisting of twelve tongs linkages which are attached to one another by their end pivots. Structure 200 is shown in its extended position whereby a continuous surface is formed having a semi-circular profile.
[0052] [0052]FIG. 34 shows a stationary supporting arch 220 and a supporting track 210 . FIG. 35 shows the retractable structure 200 attached to supporting structure 220 by a series of slide connections. Track 210 supports the edges of those linkages that lie on the border of the semi-circle.
[0053] [0053]FIGS. 36 and 37 show the structure 200 in its partially extended and fully retracted position respectively. Finally, FIG. 38 shows an elevation view of the retractable structure 200 .
[0054] It will be appreciated that the instant specification, drawings and claims set forth by way of illustration and not limitation, and that various modification and changes may be made without departing from the spirit and scope of the present invention. | This invention discloses tongs-linkage, which, in its extended position, provides an essentially triangular-shaped surface, whereby the links of the tongs-linkage are themselves the panels that form the surface. Such assemblies may be planar, or, by use of intermediate hub elements, may form a surface with curvature. As such an assembly is compressed, the panel-links slide over one another, compressing down to a compact stack. Such tongs-linkages may be joined to similar linkages by pivots lying along their respective edges thereby forming extended structural surfaces. Surfaces that are planar, cone-shaped and doubly-curved surfaces of revolution are disclosed. In each case when the structure is retracted it compresses down to a compact linear element or ring. | 4 |
FIELD OF INVENTION
The present invention is related to the use of certain diterpenes (that are not taxol) as antitumor agents. More specifically, the present invention relates to the drugs, 10-deacetyltaxol and cephalomannine and their antineoplastic activities against cancerous cells.
BACKGROUND
Taxol isolated from the bark of the Western yew, "Taxus brevifolia", is a complex diterpene. During isolation of taxol from plant material, members of other taxanes have been collected and identified. Examples of these taxanes include 10-deacetyltaxol, baccatin III, 10-deacetylbaccatin III, and cephalomannine. Unfortunately, numerous studies indicate that taxol is highly cytotoxic, and the other taxanes such as 10-deacetyltaxol, cephalomannine, 10-deacetylbaccatin III and baccatin III have less cytotoxic effects than taxol. Although U.S. Pat. No. 4,206,221 reports that cephalomannine had significant cytotoxic effective against leukemia cells of the strain P388. The industry has focused of research and development taxol and has virtually ignored the other taxanes.
Taxol's and presumably other taxane derivatives mechanism of action is based on taxol's unique capacity to stabilize microtubulin assembly which leads to microtubule bundling and abnormal spindle aster formation. Once microtubules are stabilized, the cells lose their capacity to undergo dynamic reorganization of their microtubular network and normal mitoses. These changes impact upon mitogenic signaling from the membrane, intracellular transport of metobolites, and ordered movement of chromosomes associated with cell proliferation; all of which lead to cell death.
The use of 10-deacetyltaxol and cephalomannine as agents having antineoplastic properties has been discounted by the industry because of taxol's superior cytotoxic effect. However, taxol has certain draw-backs not associated with cephalomannine and 10-deacetyltaxol. Taxol is insoluble in water. Thus, to have clinical usefulness taxol must be placed in a carriers such as a polyoxyethylated castor oil (cremophår).
Taxol shows some toxic effects, but severe allergic reactions have resulted from carriers administered in conjunction with taxol to compensate for taxol's low water solubility. To solve taxol's water solubility problems the industry has attempted to create water soluble derivatives of taxol. The industry has ignored the taxanes such as 10-deacetyltaxol and cephalomannine which are significantly more water soluble then taxol because of their slightly lower cytotoxicity. Surprisingly the present invention evidences that 10-deacetyltaxol and cephalomannine showed 91% and 94.6% cell kill respectively on certain cell lines while taxol evidenced 94.3% cell kill at the same concentration and exposure time. Plus the carriers necessary for administration of 10-deacetyltaxol and cephalomannine in vivos cause less severe allergic reactions because the carriers are not formulated to compensate for material that is totally insoluble in H 2 O.
There remains a need for antineoplastic agents which achieve high levels of cell kill but are more water soluble then taxol. 10-deacetyltaxol and cephalomannine of the present invention are significantly more water soluble then taxol. Many of the limitations presented by taxol are greatly reduced by using 10-deacetyltaxol and cephalomannine.
SUMMARY OF THE INVENTION
An object of the present invention is to provide as drugs, taxanes, which are more water soluble then taxol and which have significant antineoplastic properties.
Another object of the present invention is to provide transdermal patches for having cephalomannine or 10-deacetyltaxol as a drug application to melanoma and to systemic delivery.
Still a further object of the present invention is to provide a method of testing the cytotoxicity effects of the present invention on a patient's tumor cell prior to patient treatment.
Still a further object of the present invention is to provide a method of determining the optimal drug scheduling and dosing for treatment of a patient's tumor.
Yet another object of the present invention is to provide a systemic treatment of neural tumors.
One form of the present invention provides a method for assessing the sensitivity of a patient's tumor cells to cephalomannine and 10-deacetyltaxol prior to selecting cephalomannine or 10-deacetyltaxol as a method of treating the tumor cells. The method comprises the following steps removing from the patient, a sample of tumor cells, establishing tumor cell line culturing the tumor cells in a medium, contacting selected concentrations of cephalomannine and/or 10-deacetyltaxol with the cultured tumor cells whereby forming treated cells and performing an assay on the treated cells to assess viability of the cells to cephalomannine and 10-deacetyltaxol and selecting concentrations of cephalomannine and 10-deacetyltaxol for in vivos application based on the viability of the cells. The method also can including the step of incubating the cells in the medium in 5% CO 2 in air. And the step of solubilizing the cells in alcohol. The tumor cells can be neural tumor cells. The assay for assessing the viability of the tumor cells is preferably the MTT assay. However other procedures for analysizing the viability of the tumor cells can be employed.
The present invention also teaches a method of treating malignancy by a transdermal patch adapted to be placed on the skin of a patient. This treatment method comprising the steps of preparing a formulation containing a carrier material and at least one of the drugs cephalomannine and 10-deacetyltaxol in therapeutic amounts, contacting the formulation with the transdermal patch to form a drug supplying transdermal patch, and next applying said drug supplying transdermal patch to the skin of the patient having the malignancy. The preferred type of malignancy for this method is melanoma but other malignancies can be treated in this manner. The carrier material can be polyethylene glycol, a cyclodextrine, or liposomes.
In its broadest form the present invention teaches a method of treating a patient's malignancy with a nontaxol taxane. The method includes the steps of assaying the malignancy with at least one nontaxol taxane, which is formed by nature, to determine the sensitivity of the malignancy to the taxane. The next step is treating the malignancy with a therapeutic amount of the taxane whereby the malignancy is subjected to the cytotoxic effect of said taxane. The preferred nontaxol taxane is 10-deacetyltaxol or cephalomannine.
This method more specifically includes the step of preparing a formulation of the nontaxol taxane, which is formed by nature, with a pH adjusted polyoxyethylated castor oil. This formulation can be intravenously administered to the patient having the malignancy. The present invention is applicable to nonhuman patient's and human patients.
DETAILED DESCRIPTION
The following compounds, 10-deacetyltaxol, 10-deacetylbaccatin III, baccatin III and cephalomannine were tested for in vitro activity against two glioblastoma multiform (Sample 1 and 2) and two neuroblastoma (Sample 3 and 4) cell lines and the compounds activity was compared with that of taxol. 10-deacetyltaxol and cephalomannine were found to have significant cytotoxic effects on neural tumors. Cephalomannine, 10-deacetyltaxol have cytotoxic effects that are therapeutically useful.
CELL CULTURE
All human cell lines except Sample 4 (which was obtained from the American Type Culture collection, 12301 Park Lawn Drive, Rockville, Md.), were established and cultured as described in L., Helson C.: Establishment of a new cell line, VA-N-BR, from a primitive neuroblastoma tumor of the abdomen; Anticancer Research 12:467-472, 1992. Different methods of culturing the human cell lines are known to those of skill in the art. The method of establishing a cell line for stock cells is listed a an example and is not intended to limit the scope of the present invention.
This is a specific example of establishing a cell line from which stock cells were generated from a neuroblastoma originating in the abdomen of a six year old male. One small serosal tumor specimen was extracted in surgery from the patient and was minced and suspended in Eagle's™ (commercially available) minimal essential medium supplemented by 15% heat activated fetal bovine serum and incubated at 37° C. in a humidified atmosphere of 5% carbon dioxide in air.
TUMOR CELL CULTURE
On the seventh day of incubation the flasks contained small round highly refractile tumor cells layered out upon and between attached fibroblasts. The cultured medium was supplemented every four to six days for three weeks. After three weeks the monolayer of tumor cells and fibroblasts were harvested with trypsin 0.25% --EDTA 0.1% and placed in fresh medium. By the thirteenth week the the tumor cells grew in the absence of fibroblasts. Tumor cells were harvested with trypsin, EDTA and the stock cells were seeded in microwells.
CYTOTOXICITY ASSAYS
The cytotoxic effects of taxol, 10-deacetyltaxol, cephalomannine, baccatin III and 10-deacetylbaccatin III were determined in tumor cells growing as attached monolayers. Stock cells in 25 cm 2 flasks were incubated in medium (Dubelccos Modified Eagles's Medium and 10% fetal bovine serum) at 37° C. in 5% CO 2 in air for five days. The medium specified is listed as an example and is not intended to limit the scope of the invention. Various mediums can be employed. Medium was renewed on the sixth day and on the seventh day the cells were detached into a single cell suspension with trypsin/EDTA, counted, and aliquots plated at 3,000-5,000 cells in 0.1 ml fresh media in each well of a 96 well microtiter plate (Becton-Dickinson Labware, 2 Bridewate Lane, Lincoln Park, N.J.). Within 24 hours the cells formed attached monolayers. Research grade taxol was obtained from three sources: Cal Biotech, Inc., La Jolla, Calif. from the National Cancer Institute, and from NaPro BioTherapeutics, Boulder, Colo. as a 99.2% purified product. The taxol from NaPro was compared with taxol supplied by the NCI using HPLC. Cephalomannine was obtained as an 87% purified product containing 1.4% taxol. The cephalomannine did not contain any 10-deacetyltaxol. 10-deacetyltaxol was obtained as an 80% purified product and contained 4.5% taxol. The 10-deacetyltaxol did not contain any cephalomannine. Baccatin III was obtained as a 95% purified product. 10-deacetylbaccatin III was obtained as a 95% purified product. These taxanes were obtained from NaPro BioTherapeutics, Inc., Boulder, Colo. All compounds were solubilized in 95% alcohol to 100 μg/ml. Then the compounds were further diluted with complete media to 0.2-20 μg/ml. Various concentrations of freshly diluted taxanes were added to replicate wells in 0.1 ml volumes. After one hour or 24 hours depending on the length of the experiment at 37° C. the media was aspirated and replaced by drug free media in both treated and control wells.
CELL VIABILITY (MTT).
Viability of the cell lines five days after exposure to drugs was determined by the MTT assay following published procedures Carmichael J., DeGraff WG, Gazdor AP et al: Evaluation of tetrazolium-based semi-automated colormetric assay: Assessment of chemosensitivity testing. Cancer Research 47:936-942, 1987. Six replicate wells for control and for each test concentration were used in every experiment. Each experiment was done three separate times. The MTT, 3-(4,5-dimethythiazol-2-yl)-2,5-diphenyl-tetrazolium bromide (thiazolyl blue), assay depends on the cellular reduction of MTT by viable cells to a blue formazan product which is then measured spectrophometrically. (This is commercially available from Signa Chemical Company, St. Louis, Mo.) 0.1 mgr# (50 μl of 2# mg/ml) of MTT was added to each well and incubated at 37° C. for 4 hours. The plates of wells were then flipped to remove excess material and DMSO (dimethyl sulfoxide) was added to solubilize the formazancrystals and the plates were shaken on a rotary shaker for 10 minutes. The plates were then read for absorbance with a scanning multiwell spectrophotometer (ELISA Reader, Botek Instruments) at a wavelength of 570 nm. The following data resulted.
TABLE I______________________________________Toxicity as percent control A B C* ug/ml 1h 24h 1h 24h 1h 24h______________________________________3 0.1 73 84 37 75 35 71 1.0 90 92 85 88 76 88 10.0 94.3 94.5 94.6 92.3 91 934 0.1 14 0 0 0 0 0 1.0 53 51 0 8 0 9 10.0 76 57 0 52 0 381 0.1 11 4 0 0 0 0 1.0 45 33 20 24 41 22 10.0 54 33 70 54 64 412 0.1 57 66 38 59 39 61 1.0 75 27 62 65 64 69 10.0 74 76 76 78 73 73______________________________________ A. Taxol B. Cephalomannine C. 10deacetyltaxol *Sample
Chromatographic and other chemicals analysis revealed the NCI taxol was essentially identical to the product from NaPro BioTherapeutics, Inc., hence, no cytotoxicity studies were performed with the NCI material. Concentration of 0.1 μg/ml to 10.0 μg/ml taxol for 1 or 24 hours caused a range of dose related toxicities which were consistent over three separate experiments (Table I). Depending on the concentration and cell line a range of 0% to 94.6% cell kill was observed. Sample 3 was consistently the most sensitive, and Sample 4 the most resistant cell line (Table I). Baccatin III and 10-deacetylbaccatin III were not toxic. Both cephalomannine and 10-deacetyltaxol were 33-53% less cytotoxic than taxol at equal concentrations and exposure durations. The order of sensitivity to the three drugs exhibited in four cell lines remained consistent and independent of the duration of exposure within the concentrations used.
DISCUSSION
These experiments offer the first evidence that taxol, cephalomannine, and 10-deacetyltaxol cause cytopathic effects in cultured human and neural tumor cell lines. It is not surprising that clinical neuropathy following taxol has been reported, since interference with microtubular assembly can impact upon transport of trophic substances such as nerve growth factor, which is normally transported via the microtubular network and ultimately nerve function.
The cytotoxic profile of 10-deacetyltaxol is different from taxol since it is more polar and water soluble. Clinical use of these drugs in patient or animals with central and peripheral nerve tumors through systemic application or intravenous application would result in cytotoxic effects with less side effects associated with taxol's water insolubility. 10-deacetyltaxol's use in highly malignant glial tumors characterized by neovascularization and enhanced drug permeability should not be an obstacle except possibly for drug penetration to disseminated tumor cells in the brain which are protected by the blood brain barrier. This phenomenon may somewhat limit tumor cell eradication in some patients.
These in vitro data indicate taxol, cephalomannine, and 10-deacetyltaxol can affect survival of peripheral neuroblastoma and central malignant glioma tumor cell lines. The refractory neuroblastoma cell line of Sample 4 and the very sensitive Sample 3 cell line were obtained from bone marrow metastases of heavily pre-treated patients. The Sample 4 cell line expresses 10-fold greater drug resistance than the Sample 3 cell line. Most probably this is due to its high expression of Multiple Drug Resistance (MDR) 1 since the specific target determining susceptibility to taxol is the microtubule, and the drug must reach this target in sufficient amounts to initiate cytopathic changes. Other determinants of taxol resistance such as differences in drug microtubule reactions may not be required to explain this difference.
In conclusion, unexpectedly, cephalomannine, and 10-deacetyltaxol exert considerable cytotoxic effects on neuroblastoma and glial tumors. These two compounds appear to be slightly less cytotoxic than taxol, hence they may in certain instances demand higher concentrations to equal taxol's effect on tumored tissues; however, they often offer a better toxicity profile in the clinical setting.
The following method can be employed to determine the toxicity profile of the selected compound to the patient's malignancy. First as noted above, the patient's tumor cells should be established and the cephalomannine and 10-deacetyltaxol should be contacted with the cultured cells. Next the MTT assay should be run and analyzed to determine the sensitivity of the tumor cells to the drug. This data should be used to determine appropriate patient dosages of the selected drug. The exposure duration of the drug to the cells can be varied to determine the appropriate scheduling of the dosages to the patient. When the drug is used in vivos the patient should be closely monitored to determine if there are any allergic reactions to the drugs.
Cephalomannine and 10-deacetyltaxol exhibit more water solubility then does taxol. Therefore some of the carrier materials which maybe highly successful for administration of cephalomannine and 10-deacetyltaxol can be selected to avoid inducing acute hypersensitivity reactions. Carrier materials such as polyethylene glycol (PEG), cyclodextrine and liposomes are candidates for a injection carrier for a cephalomannine or a 10-deacetyltaxol formulation. Likewise, cremophar can also be employed although it often limits the clinical usefulness of the drug. PEG, cyclodextrines and liposomes maybe especially useful as carrier material in cephalomannine and 10-deacetyltaxol formulation which are applied by a transdermal patch to a patient having a malignancy. A patch maybe used for systemic administration of cephalomannine and 10- deacetyltaxol or alternatively it may be placed directly on the malignancy. By way of example direct skin patch application to the tumor may be a successful method of treating melanoma.
Accordingly, the present invention has been described with some degree of particularity directed to the preferred embodiment of the present invention. It should be appreciated, though, that the present invention is defined by the following claims construed in light of the prior art so that modifications or changes may be made to the preferred embodiment of the present invention without departing from the inventive concepts contained herein. | A method for assessing the sensitivity of a patient's tumor cells to cephalomannine and 10-deacetyltaxol in order to treat those tumor cells involves the removal of a sample of the tumor cells and establishing a cell line therefrom. Cells from the cell line are cultured and then contacted with varying concentrations of cephalomannine or 10-deacetyltaxol to form treated cells. The treated cells are assessed to determine the cytotoxic effect of the cephalomannine and/or the 10-deacetyltaxol and, where cytotoxic response is exhibited, a therapeutic dosage is formulated using the selected concentration of cephalomannine or 10-deacetyltaxol and a carrier material. The method is particularly useful for neural and glial tumor cells. | 6 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a method and apparatus for securing cables into the ground by means of an improved earth anchor. Earth anchors depend upon the weight of the earth above the anchor and the sheer strength of undisturbed soil which lies above extensions of the anchor. The holding strength is dependent upon the size of the anchor, the depth and the amount of undisturbed earth that secures the anchor.
Earth anchors are used for securing guy lines for transmission poles, logging towers and drilling platforms. They may also be used for any other purpose that requires securing an object to the ground.
2. Description of the Prior Art
In earth anchors known in the art, many complex mechanical devices have been used to drive extensions into undisturbed soil. Many do not achieve a high percentage of earth penetration because the extension plates are small. The prior art anchors fail to utilize the side walls of the hole to absorb the reaction to the thrust during insertion of an extension, and as a result require extensive torques which must be applied from the surface.
U.S. Pat. No. 3,778,944 shows an extension which requires rotation of a rod 13. This device produces less than 75% of a surface increase.
U.S. Pat. No. 3,628,337 has small extension members and is therefore limited in strength.
U.S. Pat. Nos. 825,587 and 1,643,769 extend plates by means of gears and a torque rod that extends to the surface. Substantially all of the extension apparatus must remain with the anchor.
U.S. Pat. No. 1,026,402 shows an anchor which requires the extensions to be driven outwardly by means of a wedge driven down.
U.S. Pat. No. 362,774 shows extensions which are driven by a conical wedge pulled upward.
U.S. Pat. No. 2,660,276 is similar to U.S. Pat. No. 3,628,337 and the extensions are small in area.
U.S. Pat. No. 1,994,520 drives the extensions outward by means of vertical impact.
U.S. Pat. No. 1,546,327 depends upon a vertical force to drive the extensions outward.
SUMMARY OF THE INVENTION
This invention differs from the prior art in that it utilizes a hydraulic jack which is manually placed in the hole to push the extensions into the soil. By this technique it is possible to achieve increases in load bearing surface as much as 250%, which is far more than that shown in any of the prior art patents discussed above.
This anchor is much larger than those shown in the art. The anchor therefore includes a flux limiter and a cable attachment means which aids in distributing the heavy loads. The anchor of this invention, because of its larger size and high load bearing surface, can be mounted in shallow holes and therefore in locations where there is a subsurface rock or water condition.
The cable is attached to the anchor assembly at a plurality of locations in order to distribute the load and decrease stress in the assembly.
The strength to weight ratio is substantially improved by the flex limiter and the cable attachment at a plurality of points.
The installation of this anchor is with commonly available hand tools such as wrenches and a hydraulic jack. Once installation is complete, the tools are removed from the hole.
The method of this invention includes excavation of a hole slightly larger than the base plate to a depth of three to five feet, placement of thrust washers in the bottom of the hole with the slots aligned with the long axis of the hole and open toward the center, positioning of a base plate on the bottom of the hole above the thrust washers, placement of a first extending plate between base plate flanges on top of the base plate with the extending plate jack lug extending upwards; attachment of the cable to the jack lug extension, positioning the wall bearing plate and jack in position, jacking the extension plate into the undisturbed soil, installing a second extension plate, attachment of eye bolts to the plates and the thrust washers on each side of the base plate, attachment of the cables to the eye bolts and backfilling the hole.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows the assembly completed with the cable loops in place.
FIG. 2 shows the base plate and extension plate in the hole with the jack and the wall bearing plate in place.
FIG. 3 shows the jack, with an extension in place after the thrust plate has been inserted into undisturbed soil, but without the cable attached to the lug.
DESCRIPTION OF THE PREFERRED EMBODIMENT
A. THE APPARATUS
The extending plate anchor assembly of FIG. 1 includes a base plate 10 which is a rectangle of approximately the size of the hole to be excavated. The base plate 10 has flanges 12 and 14 which extend upwardly from the base plate. Flanges 12 and 14 stiffen the base plate and provide a guide channel which is used during the jacking of extensions 16 and 18 into place. The base plate also includes slots 20 and 22 which are open at the center end in order to permit insertion of eye bolt assemblies 24 and alignment of the extension plates 16, 18.
Thrust washers 26 are initially placed in the hole with centers pointing in the same direction as slots 20 and 22 and towards the center of the hole. These thrust washers are attached to the eye bolt assemblies upon final assembly and serve to distribute the eye bolt forces over a large area of the base plate 10.
The extension plates 16, 18 have upwardly extending flanges 28 and 30 which stiffen the plates when force is applied to the cable assembly 32. The upwardly extending flanges also serve to guide the extension plate through the soil during insertion.
The extension plates 16, 18 have jack lug extensions 34 with holes 36 for receiving cable shackles 38. The jack lug extensions are adapted to receive the end of a jack 40 as shown in FIG. 2.
A cable 32 is attached to the eye bolt assembly 24 and the cable shackle 38. As can be seen in FIG. 1, when the cable 42 is drawn tight, the load is distributed to two points on each side of the assembly. This reduces stress and flexure of the completed anchor assembly.
A flex limiter 44 is placed across each end of the base plate 10 after the eye bolts 24 are tightened. These flex limiters become functional only when high loads are placed on cable 42, causing base plate 10 to flex, moving flanges 12 and 14 apart.
Assembly is commenced as shown in FIG. 2 where jack 40 is placed between the jack lug 34 and a wall bearing plate 46 which is placed on the opposite side of the hole. When the jack 40 is extended, extension plate 16 moves into the soil. If the travel of the extension plate exceeds the travel of the jack, then jack extensions 48 as shown in FIG. 3 may be used to finally place the extensions in the soil. The extensions are inserted until the jacking lug becomes embedded in the soil.
In the preferred embodiment, the jack 40 is a hydraulic cylinder or a porta power cylinder. Obviously any other mechanical or pneumatic jack may be employed which will conveniently fit into the hole. The pump may be a hand pump or any other source of hydraulic power.
During insertion of the extension plates, it may be necessary to temporarily bolt the extension plates lightly to the base plate in order to maintain alignment and prevent excessive cocking. This stop bolt is not shown and is removed after the plate insertion step.
At final assembly the thrust washers 26 are rotated so that their slots 27 are at an angle to slots 20 and 22 of the base 10 in order to provide for even load distribution.
B. THE METHOD OF ANCHORING
The method of anchoring basically utilizes a jack against an extension plate which acts against the side of a hole in the ground and a system for locking the base plate and extension plates together after insertion.
The method involves excavation of a hole which is slightly larger than the base plate 10, placing thrust washers 26 in the hole with their open ends facing the center, placing the base plate 10 in the hole, placing the extension plate 16 on the base plate between flanges 12 and 14, placing a jack 40 and wall plate 46 in the hole as shown in FIG. 2, attaching a cable to the jack lug 34 by shackle 38, extending the jack 40 until the jack lug 34 is flush with the side of the hole, repeating the extension plate-jacking procedure on the opposite side of the hole, removal of the jack 40 attachment of eye bolts 24 and cable 32, thereby securing the cable and locking the plate assembly together, and backfilling the hole.
From the above description it can be seen that this invention provides an inexpensive, strong and easy to install earth anchor apparatus and method. | An apparatus and method for installing an extending plate earth anchor using extension plates, a hydraulic jack which works against the side of the wall, and techniques for load stress distribution are shown and described. | 4 |
The invention relates to an electromedical implant for intracardial coronary therapy, having the features recited in the classifying portion of claim 1 .
BACKGROUND OF THE ART
The electrotherapeutic treatment of cardiac arrhythmias by means of implantable cardiac pacemakers has become established as a powerful, versatile, comparatively low-risk and reliable form of treatment. Electromedical implants of that kind include numerous functional individual components which are necessary for long-lasting therapeutic treatment of the heart, which is suited to the physiological factors involved and which is as trouble-free as possible. Those components can be systematically divided into components which are disposed in a housing of the implant and components which are arranged outside the housing. The latter involve for example sensors for physiological parameters and the electrodes, by way of which a pacemaker pulse is transmitted to the atrium or ventricle myocardium. The implant housing in contrast accommodates functional components such as a battery, a circuit, telemetric means and the like.
The electromedical implant is to have a service life which is as long as possible and good compatibility. Under some circumstances those two aspects can be in conflict. Thus on the one hand the implant should be of the minimum possible structural size so that it is not perceived as troublesome by the patient after the implantation operation or indeed give rise to unwanted physiological reactions. On the other hand the battery for a long service life must be of the maximum possible capacity, which in a practical context means that the battery generally fills up markedly more than 80% of the internal space of the housing. There is therefore always the need for making the optimum possible use of the available space.
As intracardial therapy in the meantime has developed into a standard procedure which has proved its worth worldwide millions of times, it is appropriate for cost reasons to automate the process for production of the implants. The construction of current electromedical implants can in that respect be described in simplified terms as follows. All functional components such as the battery, the circuit, the telemetry unit or the like are disposed in mutually juxtaposed relationship in the implant housing. The implant housing itself is generally of a flat, elongate contour with rounded-off edges and is generally formed from two half-shell portions with a kind of snap-action mechanism comprising interengaging edges. Then, in the opened condition, the conventional arrangement with functional components mounted in mutually juxtaposed relationship on an inner base surface of the half-shell portions can be clearly seen. It will be noted that such an arrangement suffers from the disadvantage that, in assembly of the individual components, it is necessary to operate on a plurality of production axes. That makes automation more difficult and leads to increased costs. In addition the available space cannot be put to optimum use, for example because generally an expensive and complicated electrical contacting means for contacting the power-consuming components with the battery additionally has to be fitted.
U.S. Pat. No. 6,026,325 to Weinberg et al. discloses an electromedical implant having a circuit whose electronic components are arranged in stacked relationship. The individual electronic components of such a circuit are disposed perpendicularly to the heightwise extent of the implant housing on parallel substrate planes. The circuit and the further functional components such as a battery and capacitors are mounted in conventional manner in mutually juxtaposed relationship on the base surface of the implant housing.
U.S. Pat. No. 6,251,124 to Youker et al. describes a cardiac pacemaker in which a plurality of capacitors is arranged in a plurality of substrate planes in the housing. All further functional components—disposed beside the capacitors—are arranged on the inner base surface of the housing.
Furthermore, WO 99/06107 discloses a cardiac pacemaker whose circuit includes a memory unit comprising memory chips stacked in mutually superposed relationship. That is intended to minimize the structural space required for an electrical connection between the individual memory chips. As in the above-mentioned specifications, the stacked arrangement is limited to selected partial structures of the functional components of the implant.
SUMMARY OF THE INVENTION
An aspect of the present invention is to make better use of the structural space available in the housing and to optimize the construction of the implant from the point of view of a production process which can be automated and is as simple as possible.
The invention emanates from an electromedical implant for intracardial coronary therapy comprising an implant housing and functional components of the implant disposed in said housing wherein the functional components comprise a circuit and a battery and wherein the battery has a flat side, an underside and a peripherally extending narrow side and the battery is arranged with its underside on an inner base surface of the implant housing and the circuit is disposed adjacent to a flat side of the battery.
In a first advantageous configuration of the invention the circuit includes a component carrier with fitment set, on the top side of which the individual electronic components of the circuit are mounted. An underside of the component carrier and thus the circuit is arranged adjacent to the flat side of the battery. Advantageously, the circuit is fixedly mounted to the flat side of the battery, for example by means of known adhesive processes. In the depicted arrangement accordingly the flat circuits which are embodied on conventional component carriers are fixed directly on the battery, in which respect a mounting direction of battery and circuit is retained. It will be self-evident that an electrical connection to the voltage source between the battery and the circuit only needs to be of small dimensions and, in contrast to conventional electrical connections, does not have to be made by way of a joining procedure but can also be implemented in a direct plug-in configuration. Accordingly a short discrete join is possible, without discrete elements.
During discharge of the battery a slight increase in the volume of the battery occurs, as a consequence of the underlying electrochemical reaction. That discharge-induced swelling of the battery must be compensated when there is a fixed connection between the battery and the circuit as otherwise there is a threat of mechanical damage to the circuit. In a further advantageous embodiment of the invention for that purpose disposed between the flat side of the battery and the underside of the circuit are structures with which it is possible to compensate for the discharge-induced swelling of the battery. Those structures include free spaces between the battery and the circuit or joining elements which permit a relative movement of the circuit with respect to the battery.
In a further advantageous configuration of the invention the underside of the component carrier and thus the circuit is arranged adjacent to an inward side of the implant housing. The electronic components of the circuit then face in the direction of the battery. If the inward side of the half-shell portion is suitably structured the half-shell portion can function at the same time as the component carrier for the electronic components. At any event, it is possible to forego the structures for compensation of the discharge-induced swelling of the battery. In production of the implant, in a common production step, the circuit is introduced into the implant and the housing closed.
It is further advantageous if there is provided a mounting element which accommodates the circuit. The relative orientation of the fitment set or components of the circuit with respect to the battery can then be adapted to the respective requirements involved. Accordingly, the electronic components can face either in the direction of the battery or in the direction of the housing. The mounting element can be introduced into the implant without a mechanical join to the battery or only at the periphery thereof so that the mechanical stresses which occur as a consequence of the discharge-induced variation in volume cannot be diverted to the circuit.
In addition, it has proven to be advantageous if the battery does not fill all the internal base surface of the implant housing. The remaining free spaces are used in such a way that, after mounting of the constituent parts, electronic components of a great structural height project into those free spaces. The aim here is to ensure the best possible utilization of space with a small overall structural height without having to make cuts in terms of functionality.
The battery which is suitable for such single-axis construction of the electromedical implant is to be as flat as possible in terms of its contour, as the circuit and optionally further functional component parts are to be arranged adjacent to its flat side. In this connection, the use of electrochemical energy storage systems based on lithium and manganese dioxide has proven to be particularly advantageous. The equipment components of the circuit are preferably also of the minimum possible structural height.
A further preferred configuration of the invention provides that the adjacent flat sides of the battery and the circuit have a mutually matched heightwise profile. The aim here is to minimize the overall height of the two component parts which are stacked one upon the other. Thus, in regions in which electronic components of the circuit of a relatively great structural height are disposed, the battery is of a smaller structural height than in the other regions. If further or all functional component parts disposed in the implant housing are stacked one upon the other, then the above-described matching in respect of the heightwise profile can also be applied to those component parts.
A further preferred embodiment of the invention is one in which the implant housing comprises two half-shell portions and one thereof is at the same time a constituent part of the battery housing. In that way it is possible to eliminate a housing half-shell portion.
In a further development of the last-mentioned concept of the invention, both half-shell portions at the same time also form the battery housing. In this case the circuit and all further functional component parts of the implant must hermetically sealed with respect to the electrolyte of the battery. It is possible in that way to eliminate two half-shell portions and the utilization of structural space in the arrangement can be further optimized.
Further preferred embodiments of the invention are set forth by the other features recited in the appendant claims.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is described in greater detail hereinafter in embodiments with reference to drawings in which:
FIGS. 1 a through 1 d are diagrammatic plan and side views of batteries for an electromedical implant,
FIGS. 2 a and 2 b are two diagrammatic plan views onto a half-shell portion of an implant housing with a battery arranged on the internal base surface,
FIG. 3 is a sectional view of a circuit arrangement in the implant in accordance with a first variant,
FIG. 4 is a sectional view of a circuit arrangement in the implant in accordance with a second variant,
FIGS. 5 a and 5 b show two sectional views of alternative arrangements of the circuit with a mounting element,
FIG. 6 shows a sectional view of a further alternative circuit arrangement in the implant with a free space in the region of the implant housing,
FIGS. 7 a and 7 b show two sectional views of alternative arrangements with a heightwise profile which is matched as between the battery and the circuit,
FIGS. 8 a through 8 f show perspective detail views of six alternative lead-through ducts for producing an electrical connection,
FIGS. 9 a and 9 b show a partly sectional view and a detail view on an enlarged scale through the battery, circuit and a structure for compensating for discharge-induced variations in volume,
FIGS. 10 a and 10 b show perspective side views of two joining elements for compensating for discharge-induced variations in volume in the open and closed form,
FIG. 11 is a sectional view of an arrangement in which the battery housing replaces a half-shell portion of the implant housing,
FIG. 12 shows a sectional view of an implant housing in which the battery housing replaces both half-shell portions of the implant housing, and
FIG. 13 shows an illustration of the single-axis production process of an electromedical implant.
DETAILED DESCRIPTION OF THE INVENTION
The mode of operation and the area of use of electromedical implants are generally known. By virtue of an appropriate selection of functional components, all stimulation and diagnostic functions which are necessary for each individual case can be integrated into such an electromedical implant. It will be noted that in the present case only the arrangement according to the invention of the functional components in the implant housing is of significance. Therefore only the structural features, which are necessary to the invention, of the individual functional components and their relative position with respect to each other are described in the examples hereinafter.
FIGS. 1 a through 1 d are greatly simplified side and plan views showing the contours of two alternative embodiments of a battery 10 . In this example the battery 10 is of an oval basic shape. While having the same base surface, that is to say the same lengthwise and widthwise dimensions, the two batteries 10 differ only in respect of their heightwise profile. The battery 10 illustrated in FIGS. 1 a and 1 b has a narrow side 10 . 1 which extends therearound at a constant height as well as a flat side 10 . 2 and an underside 10 . 3 with a flat contour, thus affording a homogenous heightwise profile. In contrast the battery 10 shown in FIGS. 1 c and 1 d involves a heightwise profile in which a first portion 12 of the narrow side 10 . 1 and the flat side 10 . 2 is of a smaller height than a second portion 14 . The conditions under which the use of one or other alternative embodiment of the battery 10 is appropriate will be discussed in greater detail hereinafter.
The battery itself is in particular an electrochemical cell based on lithium/manganese oxide elements. Batteries 10 of that kind are distinguished by their particularly high energy density and also their flexible design so that they are suitable as a flat unit or sandwich unit. FIGS. 2 a and 2 b show the relative position of two batteries 10 involving different base shapes in a half-shell portion 16 of an implant housing 18 . As will be clearly apparent the battery 10 in each case does not take up an entire internal base surface 18 . 1 of the half-shell portion 16 . Rather, free spaces 20 of differing sizes remain, and the use thereof will also be discussed in greater detail hereinafter.
A highly diagrammatic sectional view in FIG. 3 shows an electromedical implant including two functional component parts, namely the battery 10 and a circuit 22 . The circuit 22 includes all electronic components 24 which are necessary for the functional logic of the implant and which are arranged in the form of an equipment set on a component carrier 26 with a circuit board. The electronic components 24 are preferably SMT-units which are produced in per se known manner from the point of view of a structural height which is as small as possible. An electrical connection between the battery 10 and the circuit 22 can be produced by the lead-through duct 28 indicated here. The circuit 22 is now fitted with its underside 22 . 1 onto the flat side 10 . 2 of the battery 10 , in such a way that electrical contact is produced and the circuit 22 is arranged in adjacent relationship to the flat side 10 . 2 of the battery 10 —possibly being fixed by adhesive means. Then the implant housing 18 is closed by a second half-shell portion 30 being put onto the first half-shell portion 16 . The two half-shell portions 16 , 30 are for that purpose preferably in the form of snap-action shell portions with mutually interengaging edges.
In an arrangement which is an alternative to FIG. 3 the circuit 22 is arranged with its underside 22 . 1 in adjacent relationship to an inward side 30 . 1 of the second half-shell portion 30 ( FIG. 4 ). The equipment set of the circuit 22 then faces in the direction of the battery 10 . An electrical connection is in turn made by way of the lead-through duct 28 when the two half-shell portions 16 , 30 of the implant housing 18 are brought together. The inward side 30 . 1 of the second half-shell portion 30 can possibly be suitably structured to carry the electronic components 24 of the circuit 22 . Thus for example a component carrier can be introduced directly into the inward side 30 . 1 of the half-shell portion 30 .
The following is to be noted in regard to the dimensioning of the individual constituent parts of the variants in FIGS. 3 and 4 : an overall thickness of the battery 10 in all of the regions in opposite relationship to the circuit 22 is preferably <3.9 mm, a component height of all electronic components 24 is preferably <2 mm and the thickness of the component carrier 26 is <0.25 mm. Finally the battery 10 and the circuit 22 preferably extend over >85%, in particular over >90%, particularly preferably over >95%, of the overall housing volume. The circuit 22 preferably extends over >80% in particular over >90% and particularly preferably over >95% of the flat side of the battery 10 .
FIGS. 5 a and 5 b show the circuit 22 and the battery 10 in a stacked arrangement which is in principle the same, as in FIGS. 3 and 4 . However, the circuit 22 does not bear directly against the battery 10 or the half-shell portion 30 but is accommodated by a mounting element 32 . The mounting element 32 has structures which are suitable for that purpose and in which the component carrier 26 can be clamped. The specific design configuration of the structures must be adapted to the respective structural aspects involved. Measures of that nature are adequately known to the man skilled in the art so that they will not be discussed in greater detail here. After accommodating the circuit 22 the mounting element 32 is arranged in adjacent relationship with the battery 10 , in which case the component mounting side thereof faces selectively in the direction of the half-shell portion 30 ( FIG. 5 a ) or in the direction of the battery 10 ( FIG. 5 b ). Such a mounting element 32 affords the advantage that stresses which can occur in the region of the battery 10 as a consequence of variations in volume are not transmitted directly to the circuit 22 and there result in mechanical damage. In addition, this arrangement affords options in terms of joining technologies which are suited to single-axis mounting operations.
If the battery 10 does not occupy the entire base surface of the half-shell portion 16 of the implant housing 18 and thus free spaces 20 remain, it is possible to embody the alternative arrangement of the component parts of the implant, as is diagrammatically shown in FIG. 6 . In accordance with that arrangement electronic components 24 of particularly great structural height are placed on the circuit 22 in such a way that they project into the free spaces 20 , after the two component parts have been assembled.
With a differing structural height in respect of the electronic components 24 of the circuit 22 , two further alternative possible design options present themselves for such a single-axis arrangement of the component parts ( FIGS. 7 a and 7 b ). Both alternatives are based on a battery 10 with heightwise profile as has already been described with reference to FIG. 1 b . As shown in FIG. 7 a the contour of the circuit 22 including the component carrier 26 is adapted to the heightwise profile of the battery 10 . The electronic components 24 of the greatest structural height are obviously disposed in the region 12 of the battery 10 which involves the smallest heightwise extent ( FIG. 7 a ). Alternatively, as shown in FIG. 7 b , a circuit 22 with a flat component carrier 26 is arranged in adjacent relationship with the half-shell portion 30 , more specifically in such a way that the highest electronic components 24 , after the mounting procedure, are arranged above the region 12 of the battery 10 which is of the smallest structural height.
FIGS. 8 a through 8 f show a total of six alternative embodiments of a lead-through duct 28 which can be used to produce the electrical connection between the battery 10 and the circuit 22 . The ducts 28 can be soldered on during an SMT-mounting process as constituent parts of the circuit 22 . It is necessary in each individual case to decide at what locations ultimately a soldering operation is to be effected or what orientation individual elements of the duct 28 have relative to the position of the component parts to be connected therewith. It will be noted that in principle the single-axis construction of the functional component parts permits a marked simplification in the electrical circuitry as only small distances have be bridged. That affords savings of material and gains in terms of structural space. The ducts 28 which are set forth by way of example are electrically connected to the circuit 22 by way of nail heads ( FIG. 8 a ), adaptors ( FIGS. 8 b and 8 c ), bent pins ( FIGS. 8 d ), flattened pins ( 8 e ) or conventional solder joins ( 8 f ). In accordance with the variants in FIGS. 8 b and 8 c , it is possible to forego bonding joining processes for producing the electrical connection. It will be appreciated that for that purpose it is possible to provide electrical plug elements of varying configurations, which engage into each other when the implant is assembled. Here too the description will not go into these aspects in greater depth as such plug elements are sufficiently known to the man skilled in the art and have to be adapted to the respective functional and structural requirements involved, from one case to another.
When the circuit 22 is fixedly connected to the battery 10 , measures must be taken to prevent damage to the circuit 22 as a consequence of a gradual variation in volume of the battery 10 . Such a variation in volume results from the electrochemical reactions which take place during the discharge process in the battery 10 . To compensate for the discharge-induced swelling of the battery 10 , special structures 34 are arranged between the flat side 10 . 2 of the battery 10 and the underside 22 . 1 of the circuit 22 . FIGS. 9 a and 9 b —in part as a detail view on an enlarged scale—show a view in section through the battery 10 and the circuit 22 in the region of the structures 34 . They are in the form of free spaces between the battery 10 and the circuit 22 , into which parts of the battery 10 can penetrate in the discharge process and the increase in volume which is related thereto. Those structures 34 can be an integral constituent part of the component carrier 26 , for example etched copper structures, and they can be inexpensively produced using standard procedures in production of the component carrier.
As an alternative thereto, it is also possible to provide between the battery 10 and the circuit 22 joining elements 36 as are shown in FIGS. 10 a and 10 b prior to and after mounting of the component parts. The joining elements 36 involve a male and a female contour which, when the component parts are stacked in mutually superposed relationship, engage one into each other and hold the component parts at a defined spacing. It will be appreciated that it is possible here to have recourse to a large number of alternative embodiments of the joining elements 36 , as are sufficiently known from the state of the art. The only essential criterion in regard to the joining elements 36 is that they permit a relative movement of the two component parts with respect to each other. For automation reasons the illustration snap-action connection particularly presents itself in that respect.
FIG. 11 diagrammatically shows a further alternative arrangement with a single-axis component construction. In its broad outlines it corresponds to the arrangement of the circuit 22 and the battery 10 , which has already been described with reference to FIG. 3 . It will be noted that in this case a battery housing 38 is used at the same time to form the lower half-shell portion of the implant housing 18 . For that reason, at least in that region, the battery housing 38 is made from a biocompatible material, in particular titanium. In that way it is possible to forego one of the two half-shell portions of the implant housing 18 and the resulting structural space can be used for the functional component parts. In addition, a production step is eliminated from the production process, namely the step of placing the battery 10 in one of the half-shell portions of the implant housing 18 . When turning over a seam between the battery housing 38 and the half-shell portion 30 , if necessary (for example because of a thermal loading in the joining procedure), it is possible to implement subsequent filling of the battery 10 with electrolyte or activation in some other manner by way of an additional filling opening, whereby it is possible to determine the moment in time of the commencement of energy-consuming operation of the implant.
In an extension of the last embodiment FIG. 12 is a diagrammatic sectional view of an electromedical implant in which the implant housing 18 is completely replaced by the battery housing 38 . All functional component part—in this case the illustrated circuit 22 with its electronic components 24 —are disposed within the battery 10 and to protect them have to be hermetically sealed in relation to the electrolyte of the battery 10 . Sealing of the circuit 22 can be effected for example by a dipping process with inert resins/dipping lacquers. The dried resins/dipping lacquers form a protective layer through which the electrolyte cannot pass or which it cannot attack. It is possible in that way to eliminate two housing half-shell portions.
FIG. 13 is intended to illustrate once again by way of example the single-axis mounting of the functional component parts during manufacture of an implant (as indicated by an arrow). Firstly the battery 10 , then the circuit 22 and finally the half-shell portion 30 are respectively fitted into or onto the half-shell portion 16 , in each case from the same approach direction. That substantially simplifies automation and enhances the degree of precision in terms of placement of the individual components. The arrangement and the mounting sequence may vary.
The implants produced in the above-described manner are intended to correspond in their dimensions to the dimensions of known implants. They are therefore of an overall height of between 5 and 7 mm. Of that, the metal case of the implant housing 18 including applied films for insulation and the free space for fixing of the component parts occupies between about 0.6 and 0.9 mm. In embodiments in which the battery 10 has a heightwise profile ( FIGS. 7 a and 7 b ) the thickness of the battery generally varies between 1.5 and 4.5 mm, with the remaining structural space being used for the circuit 22 .
List of references
10
battery
10.1
narrow side of the battery 10
10.2
flat side of the battery 10
10.3
underside of the battery 10
12
portion of low structural height
14
portion of larger structural height
16
lower half-shell portion
18
implant housing
18.1
internal base surface
20
free space
22
circuit
22.1
underside of the circuit 22
24
electronic components
26
component carrier
28
lead-through duct
30
upper half-shell portion
30.1
inward side of the upper half-shell portion 30
32
mounting element
34
structures for compensation of discharge-induced swelling
36
joining element
38
battery housing | The invention concerns an electromedical implant for intracardial coronary therapy comprising an implant housing in which functional component parts of the implant, namely a circuit, a battery and the like, are disposed. It is characterized in that the battery ( 10 ) has a flat side ( 10.2 ), an underside ( 10.3 ) and a peripherally extending narrow side ( 10.1 ) and the battery ( 10 ) is arranged with its underside ( 10.3 ) on an internal base surface ( 18.1 ) of the implant housing ( 18 ) and the circuit ( 22 ) is arranged in adjacent relationship with a flat side ( 10.2 ) of the battery ( 10 ). | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority under 35 U.S.C. §119 to Korean Patent Application No. 10-2013-0014392 filed on Feb. 8, 2013, in the Korean Intellectual Property Office, the disclosure of which is incorporated herein by reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to thienopyrimidinone derivatives as antagonists that act on metabotropic glutamate receptor subtype 1 to show pharmacological activity against metabotropic glutamate receptor-related diseases, including pain, such as neuropathic pain and migraine, psychiatric diseases, such as anxiety disorder and schizophrenia, urinary incontinence, and neurodegenerative diseases, such as Parkinson's disease and Alzheimer's disease. The present invention also relates to methods for preparing the compounds, and pharmaceutical compositions containing the compounds as active ingredients.
[0004] 2. Description of the Related Art
[0005] Glutamate is an important excitatory neurotransmitter in the central nervous system. Synaptic stimulation of glutamate is transmitted through the activities of two receptor types: ionotropic glutamate receptors and metabotropic glutamate receptors. The former receptors are ligand-gated cation channels, and the latter receptors are G-protein-coupled receptors (GPCRs). Metabotropic glutamate receptors are divided into three groups on the basis of their structural similarity, pharmacology, and signaling mechanisms. The three groups are further subdivided into a total of eight subtypes according to their splicing variants. The group I receptors are divided into mGluR1 and mGluR5. The subtypes mGluR1 and mGluR5 activate phospholipase C (PLC) via a Gq/11 protein, resulting in release of calcium via phosphoinositide (PI) hydrolysis. The group II receptors (mGluR2 and mGluR3) and the group III receptors (mGluR4, mGluR5, mGluR6, and mGluR7) are negatively coupled to adenyl cyclase (AC) via a Gi/o protein, inhibiting cAMP formation.
[0006] Approximately 70 million Americans suffer from pain. The annual medical expenses for pain treatment and related social costs in the United States are estimated to be 100 billion dollars. Neuropathic pain has numerous etiologies and causes complex and chronic pain conditions. A total of about 18 million Americans, including about 4 million Americans suffering from diabetic pain, are afflicted with neuropathic pain. Various neurological diseases including pain, psychiatric diseases and neuritic diseases are associated with glutamate release. mGluR1, a glutamate receptor, is present on the primary afferent nerve terminals and is abundantly distributed in the pain process-related nervous tissues of the CNS. Thus, mGluR1 is reported to be closely associated with the treatment of pain [Annu. Rev. Pharmacol. Toxicol. 1989, 29, 365; Trends Neurosci. 2011, 24, 550; Expert Opin. Ther. Targets 2002, 6, 349; Neuron 1992, 9, 259].
[0007] Various experiment results have revealed that mGluR1 antagonism relieves neuropathic pain. It was reported that the injection of selective mGluR1 antibodies relieves allodynia and hyperalgesia in animal models, and the administration of selective mGluR1 antagonists after administration of Group I mGluR agonists to induce spontaneous pain relieves the pain [Prog. Neurobiol. 1999, 59, 55; Neuro-Report 1996, 7, 2743; J. Neurosci. 2001, 21. 3771].
[0008] Many efforts have been made to date to develop mGluR1 antagonists. However, there is still a need for mGluR1 antagonists that are selective for mGluR1, have good pharmacokinetic profiles, have good absorption, distribution, metabolism and excretion (ADME) properties, and are effective against metabotropic glutamate receptor-related diseases, including pain, such as neuropathic pain and migraine, psychiatric diseases, such as anxiety disorder and schizophrenia, urinary incontinence, and neurodegenerative diseases, such as Parkinson's disease and Alzheimer's disease.
SUMMARY OF THE INVENTION
[0009] It is an object of the present invention to provide novel compounds as mGluR1 modulators that are effective against metabotropic glutamate receptor-related diseases, including pain, such as neuropathic pain and migraine, psychiatric diseases, such as anxiety disorder and schizophrenia, urinary incontinence, and neurodegenerative diseases, such as Parkinson's disease and Alzheimer's disease.
[0010] Specifically, it is an object of the present invention to provide thienopyrimidinone derivatives having novel structures and pharmaceutically acceptable salts thereof.
[0011] It is a further object of the present invention to provide methods for preparing thienopyrimidinone derivatives from 4-aryl-3-amino-2-alkoxycarbonylthiophenes, which are prepared from arylmethylcyanides through three steps.
[0012] It is another object of the present invention to provide pharmaceutical compositions acting on mGluR1, each of the compositions including at least one of the thienopyrimidinone derivatives and pharmaceutically acceptable salts thereof as an active ingredient.
[0013] It is still another object of the present invention to provide drugs for the prevention and treatment of pain, such as neuropathic pain and migraine, psychiatric diseases, such as anxiety disorder and schizophrenia, urinary incontinence, and neurodegenerative diseases, such as Parkinson's disease and Alzheimer's disease, each of the drugs including at least one of the thienopyrimidinone derivatives and pharmaceutically acceptable salts as an active ingredient.
[0014] According to one aspect of the present invention, there is provided a thienopyrimidinone derivative effective as a compound that acts on mGluR1 to show efficacy against metabotropic glutamate receptor-related diseases, including pain, such as neuropathic pain and migraine, psychiatric diseases, such as anxiety disorder and schizophrenia, urinary incontinence, and neurodegenerative diseases, such as Parkinson's disease and Alzheimer's disease, wherein the thienopyrimidinone derivative is represented by Formula 1:
[0000]
[0015] wherein R1 represents an aryl group, R2 represents an alkyl or aryl group, and R3 represents a hydrogen atom, a hydroxyl group, an alkyl group, or an alkylamine group.
[0016] According to another aspect of the present invention, there is provided a method for preparing the thienopyrimidinone derivative.
[0017] According to yet another aspect of the present invention, there is provided a pharmaceutical composition including the thienopyrimidinone derivative.
[0018] The thienopyrimidinone derivative of Formula 1 or pharmaceutically acceptable salt thereof according to the present invention exhibits excellent activity as compounds acting on mGluR1, thus being useful as a therapeutic or prophylactic agent for metabotropic glutamate receptor-related diseases, including pain, such as neuropathic pain and migraine, psychiatric diseases, such as anxiety disorder and schizophrenia, urinary incontinence, and neurodegenerative diseases, such as Parkinson's disease and Alzheimer's disease.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] These and/or other aspects and advantages of the invention will become apparent and more readily appreciated from the following description of the embodiments, taken in conjunction with the accompanying drawings of which:
[0020] FIGS. 1 to 6 show the structures of compounds according to embodiments of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0021] Aspects and embodiments of the present invention will now be described in more detail.
[0022] In one aspect, the present invention provides a thienopyrimidinone derivative represented by Formula 1:
[0000]
[0023] wherein R1 is phenyl which is unsubstituted or substituted with one to five substituents selected from halogen, substituted or unsubstituted stannyl, phenyl, alkylphenyl, alkoxyphenyl, benzodioxolyl, and naphthalenyl groups, R2 is selected from substituted or unsubstituted phenyl, substituted or unsubstituted C 1 -C 7 alkyl, substituted or unsubstituted C 3 -C 10 cycloalkyl, pyranyl, hydropyranyl, naphthalenyl, hydronaphthalenyl, substituted or unsubstituted piperidinyl, acetyloxy, allyl, and vinyl, and R3 is selected from hydrogen, C 1 -C 7 alkyl, substituted or unsubstituted amino, and hydroxy; or a pharmaceutically acceptable salt thereof.
[0024] In the case where R3 is a hydroxyl group, tautomeric isomerism (tautomerism) may occur. In this case, the thienopyrimidinone derivative of Formula 1 may also exist in a tautomeric form represented by Formula 2:
[0000]
[0025] wherein R1 and R2 are as defined in Formula 1, and R3′ is oxygen.
[0026] It is therefore to be understood that the tautomeric form of Formula 2 is within the scope of the present invention.
[0027] In one embodiment, R1 is selected from substituted or unsubstituted phenyl, substituted or unsubstituted naphthalenyl, and substituted or unsubstituted benzodioxolyl.
[0028] The substituted phenyl may be phenyl in which some or all of the hydrogen atoms are replaced by substituents selected from halogen, C 1 -C 7 alkyl, halogenated C 1 -C 7 alkyl, C 1 -C 7 alkoxy, halogenated C 1 -C 7 alkoxy, substituted or unsubstituted stannyl, and phenyl.
[0029] The substituted stannyl may be alkylstannyl substituted with one to three C 1 -C 7 alkyl groups.
[0030] The substituted naphthalenyl may be naphthalenyl in which some or all of the hydrogen atoms are replaced by substituents selected from halogen, C 1 -C 7 alkyl, C 1 -C 7 alkoxy, unsubstituted stannyl, C 1 -C 7 alkylstannyl, C 1 -C 7 dialkylstannyl, C 1 -C 7 trialkylstannyl, and phenyl.
[0031] The substituted benzodioxolyl may be benzodioxolyl in which some or all of the hydrogen atoms are replaced by substituents selected from halogen, C 1 -C 7 alkyl, C 1 -C 7 alkoxy, unsubstituted stannyl, C 1 -C 7 alkylstannyl, C 1 -C 7 dialkylstannyl, C 1 -C 7 trialkylstannyl, and phenyl.
[0032] In a further embodiment, (i) R2 may be selected from substituted or unsubstituted phenyl, substituted or unsubstituted benzonitrile, substituted or unsubstituted C 1 -C 7 alkyl, allyl, vinyl, substituted or unsubstituted C 3 -C 10 cycloalkyl, substituted or unsubstituted pyranyl, substituted or unsubstituted hydropyranyl, substituted or unsubstituted naphthalenyl, substituted or unsubstituted hydronaphthalenyl, substituted or unsubstituted furanyl, substituted or unsubstituted hydrofuranyl, substituted or unsubstituted piperidinyl, and substituted or unsubstituted C 3 -C 10 heterocycloalkyl; or (ii) R2 may have a C 1 -C 7 alkyl group through which a group selected from substituted or unsubstituted phenyl, substituted or unsubstituted benzonitrile, substituted or unsubstituted C 1 -C 7 alkyl, allyl, vinyl, substituted or unsubstituted C 3 -C 10 cycloalkyl, substituted or unsubstituted pyranyl, substituted or unsubstituted hydropyranyl, substituted or unsubstituted naphthalenyl, substituted or unsubstituted hydronaphthalenyl, substituted or unsubstituted furanyl, substituted or unsubstituted hydrofuranyl, substituted or unsubstituted piperidinyl, and substituted or unsubstituted C 3 -C 10 heterocycloalkyl is linked to the corresponding nitrogen atom of the thienopyrimidinone ring.
[0033] The substituted phenyl may be phenyl in which some or all of the hydrogen atoms are replaced by substituents selected from halogen, C 1 -C 7 alkyl, halogenated C 1 -C 7 alkyl, C 1 -C 7 alkoxy, halogenated C 1 -C 7 alkoxy, hydroxy, nitro, vinyl, and allyl.
[0034] The substituted benzonitrile may be benzonitrile in which some or all of the hydrogen atoms are replaced by substituents selected from halogen, C 1 -C 7 alkyl, halogenated C 1 -C 7 alkyl, C 1 -C 7 alkoxy, halogenated C 1 -C 7 alkoxy, hydroxy, nitro, vinyl, and allyl.
[0035] The substituted C 1 -C 7 alkyl may be C 1 -C 7 alkyl in which one to three hydrogen atoms of the alkyl are replaced by substituents selected from halogen, C 1 -C 7 alkyl, halogenated C 1 -C 7 alkyl, C 1 -C 7 alkoxy, halogenated C 1 -C 7 alkoxy, hydroxy, nitro, vinyl, allyl, C 3 -C 10 cycloalkyl, furanyl, and hydrofuranyl.
[0036] The substituted C 3 -C 10 cycloalkyl may be C 3 -C 10 cycloalkyl substituted with substituents selected from halogen, C 1 -C 7 alkyl, halogenated C 1 -C 7 alkyl, C 1 -C 7 alkoxy, halogenated C 1 -C 7 alkoxy, hydroxy, nitro, vinyl, allyl, and C 1 -C 7 alkyl.
[0037] The substituted pyranyl may be pyranyl in which some or all of the hydrogen atoms are replaced by substituents selected from halogen, C 1 -C 7 alkyl, halogenated C 1 -C 7 alkyl, C 1 -C 7 alkoxy, halogenated C 1 -C 7 alkoxy, hydroxy, nitro, vinyl, and allyl.
[0038] The hydropyranyl may be dihydropyranyl or tetrahydropyranyl, and the substituted hydropyranyl may be hydropyranyl in which some or all of the hydrogen atoms are replaced by substituents selected from halogen, C 1 -C 7 alkyl, halogenated C 1 -C 7 alkyl, C 1 -C 7 alkoxy, halogenated C 1 -C 7 alkoxy, hydroxy, nitro, vinyl, and allyl.
[0039] The substituted naphthalenyl may be naphthalenyl in which some or all of the hydrogen atoms are replaced by substituents selected from halogen, C 1 -C 7 alkyl, halogenated C 1 -C 7 alkyl, C 1 -C 7 alkoxy, halogenated C 1 -C 7 alkoxy, hydroxy, nitro, vinyl, and allyl.
[0040] The hydronaphthalenyl may be selected from dihydronaphthalenyl, tetrahydronaphthalenyl, hexahydronaphthalenyl, and heptahydronaphthalenyl, and the substituted hydronaphthalenyl may be hydronaphthalenyl in which some or all of the hydrogen atoms are replaced by substituents selected from halogen, C 1 -C 7 alkyl, halogenated C 1 -C 7 alkyl, C 1 -C 7 alkoxy, halogenated C 1 -C 7 alkoxy, hydroxy, nitro, vinyl, and allyl.
[0041] The substituted furanyl may be furanyl in which some or all of the hydrogen atoms are replaced by substituents selected from halogen, C 1 -C 7 alkyl, halogenated C 1 -C 7 alkyl, C 1 -C 7 alkoxy, halogenated C 1 -C 7 alkoxy, hydroxy, nitro, vinyl, and allyl.
[0042] The hydrofuranyl may be dihydrofuranyl or tetrahydrofuranyl, and the substituted hydrofuranyl may be hydrofuranyl in which some or all of the hydrogen atoms are replaced by substituents selected from halogen, C 1 -C 7 alkyl, halogenated C 1 -C 7 alkyl, C 1 -C 7 alkoxy, halogenated C 1 -C 7 alkoxy, hydroxy, nitro, vinyl, and allyl.
[0043] The substituted piperidinyl may be (i) piperidinyl in which some or all of the hydrogen atoms are replaced by substituents selected from halogen, C 1 -C 7 alkyl, halogenated C 1 -C 7 alkyl, C 1 -C 7 alkoxy, halogenated C 1 -C 7 alkoxy, hydroxy, nitro, vinyl, and allyl, or (ii) piperidinyl in which a substituent selected from C 1 -C 7 alkyl, halogenated C 1 -C 7 alkyl, C 1 -C 7 alkoxy, halogenated C 1 -C 7 alkoxy, vinyl, and allyl is bonded to the nitrogen atom of the piperidine ring.
[0044] The C 3 -C 10 heterocycloalkyl may be heterocycloalkyl in which one or two heteroatoms selected from N, O and S, and three to ten carbon atoms are bonded together to form a ring; and the substituted C 3 -C 10 heterocycloalkyl may be heterocycloalkyl in which some or all of the hydrogen atoms are replaced by substituents selected from halogen, C 1 -C 7 alkyl, halogenated C 1 -C 7 alkyl, C 1 -C 7 alkoxy, halogenated C 1 -C 7 alkoxy, hydroxy, nitro, vinyl, and allyl.
[0045] In one embodiment, the substituted phenyl in R1 is phenyl substituted with one to five substituents selected from halogen, substituted or unsubstituted stannyl, phenyl, alkylphenyl, alkoxyphenyl, benzodioxolyl, and naphthalenyl; the substituted stannyl in R1 is stannyl substituted with one to three C 1 -C 7 alkyl groups; the alkylphenyl in R1 is phenyl substituted with C 1 -C 7 alkyl; the alkoxyphenyl in R1 is phenyl substituted with C 1 -C 7 alkoxy; and the substituted phenyl in R2 is phenyl substituted with one to five substituents selected from halogen, C 1 -C 7 alkyl, halogenated C 1 -C 7 alkyl, C 1 -C 7 alkoxy, halogenated C 1 -C 7 alkoxy, hydroxy, nitro, vinyl, allyl, and benzonitrile.
[0046] In a further embodiment, the substituted C 1 -C 7 alkyl in R2 is C 1 -C 7 alkyl substituted with at least one substituent selected from C 3 -C 10 cycloalkyl, furanyl, and hydrofuranyl; the hydrofuranyl is dihydrofuranyl or tetrahydrofuranyl; the substituted C 3 -C 10 cycloalkyl in R2 is C 3 -C 10 cycloalkyl substituted with C 1 -C 7 alkyl; the hydropyranyl in R2 is dihydropyranyl or tetrahydropyranyl; the hydronaphthalenyl in R2 is selected from dihydronaphthalenyl, tetrahydronaphthalenyl, hexahydronaphthalenyl, and heptahydronaphthalenyl; and the substituted piperidinyl in R2 is piperidinyl substituted with at least one C 1 -C 7 alkyl group.
[0047] The phenyl substituted with benzonitrile is phenyl substituted with a substituent having any one of the structures of Formulae 3 to 5:
[0000]
[0048] wherein each asterisk (*) indicates a position where phenyl is bonded.
[0049] The substituted amino in R3 is amino substituted with one or two C 1 -C 7 alkyl groups.
[0050] In another embodiment, R1 is selected from phenyl, 2-fluorophenyl, 3-fluorophenyl, 4-fluorophenyl, 2-chlorophenyl, 3-chlorophenyl, 4-chlorophenyl, 2-bromophenyl, 3-bromophenyl, 4-bromophenyl, 2-iodophenyl, 3-iodophenyl, 4-iodophenyl, 2-trimethylstannylphenyl, 3-trimethylstannylphenyl, 4-trimethylstannylphenyl, 2-methylphenyl, 3-methylphenyl, 4-methylphenyl, 2-methoxyphenyl, 3-methoxyphenyl, 4-methoxyphenyl, 3,4-dimethoxyphenyl, 4-benzodioxolyl, 5-benzodioxolyl, 1-naphthalenyl, and 2-naphthalenyl.
[0051] In another embodiment, R2 is selected from phenyl, 2-fluorophenyl, 3-fluorophenyl, 4-fluorophenyl, 2-chlorophenyl, 3-chlorophenyl, 4-chlorophenyl, 2-bromophenyl, 3-bromophenyl, 4-bromophenyl, 2-iodophenyl, 3-iodophenyl, 4-iodophenyl, 2-methoxyphenyl, 3-methoxyphenyl, 4-methoxyphenyl, 3,4-dimethoxyphenyl, 3,5-dimethoxyphenyl, 2-hydroxyphenyl, 3-hydroxyphenyl, 4-hydroxyphenyl, 2-methylphenyl, 3-methylphenyl, 4-methylphenyl, 2,5-dimethylphenyl, 2,6-dimethylphenyl, 3,4-dimethylphenyl, benzonitrile, 2-trifluoromethylphenyl, 3-trifluoromethylphenyl, 4-trifluoromethylphenyl, 2-trifluoromethoxyphenyl, 3-trifluoromethoxyphenyl, 4-trifluoromethoxyphenyl, 2-nitrophenyl, 3-nitrophenyl, 4-nitrophenyl, 2-vinylphenyl, 3-vinylphenyl, 4-vinylphenyl, butyl, allyl, cyclobutyl, cyclopentyl, cyclohexyl, cyclooctyl, cyclopropylmethyl, cyclohexylmethyl, 4-methylcyclohexyl, tetrahydropyran-4-yl, 1,2,3,4-tetrahydronaphthalen-1-yl, tetrahydrofuran-2-ylmethyl, 1-methylpiperidin-4-yl, isobutyl, neopentyl, 2-methylcyclohexyl, 3-methylcyclohexyl, 4-ethylcyclohexyl, and acetyloxy.
[0052] In another embodiment, R3 is selected from hydrogen, methyl, and dimethylamino.
[0053] In another embodiment, the thienopyrimidinone derivative is any one of the following compounds:
3,7-diphenylthieno[3,2-d]pyrimidin-4(3H)-one; 3-(2-fluorophenyl)-7-phenylthieno[3,2-d]pyrimidin-4(3H)-one; 3-(3-fluorophenyl)-7-phenylthieno[3,2-d]pyrimidin-4(3H)-one; 3-(4-fluorophenyl)-7-phenylthieno[3,2-d]pyrimidin-4(3H)-one; 3-(2-chlorophenyl)-7-phenylthieno[3,2-d]pyrimidin-4(3H)-one; 3-(3-chlorophenyl)-7-phenylthieno[3,2-d]pyrimidin-4(3H)-one; 3-(4-chlorophenyl)-7-phenylthieno[3,2-d]pyrimidin-4(3H)-one; 3-(3-bromophenyl)-7-phenylthieno[3,2-d]pyrimidin-4(3H)-one; 3-(4-bromophenyl)-7-phenylthieno[3,2-d]pyrimidin-4(3H)-one; 3-(2-methoxyphenyl)-7-phenylthieno[3,2-d]pyrimidin-4(3H)-one; 3-(3-methoxyphenyl)-7-phenylthieno[3,2-d]pyrimidin-4(3H)-one; 3-(4-methoxyphenyl)-7-phenylthieno[3,2-d]pyrimidin-4(3H)-one; 3-(3,4-dimethoxyphenyl)-7-phenylthieno[3,2-d]pyrimidin-4(3H)-one; 3-(3,5-dimethoxyphenyl)-7-phenylthieno[3,2-d]pyrimidin-4(3H)-one; 3-(4-hydroxyphenyl)-7-phenylthieno[3,2-d]pyrimidin-4(3H)-one; 7-phenyl-3-(o-tolyl)thieno[3,2-d]pyrimidin-4(3H)-one; 7-phenyl-3-(m-tolyl)thieno[3,2-d]pyrimidin-4(3H)-one; 7-phenyl-3-p-tolylthieno[3,2-d]pyrimidin-4(3H)-one; 3-(4-ethylphenyl)-7-phenylthieno[3,2-d]pyrimidin-4(3H)-one; 3-(2,6-dimethylphenyl)-7-phenylthieno[3,2-d]pyrimidin-4(3H)-one; 3-(2,5-dimethylphenyl)-7-phenylthieno[3,2-d]pyrimidin-4(3H)-one; 3-(3,4-dimethylphenyl)-7-phenylthieno[3,2-d]pyrimidin-4(3H)-one; 3-(4-oxo-7-phenylthieno[3,2-d]pyrimidin-3(4H)-yl)benzonitrile; 4-(4-oxo-7-phenylthieno[3,2-d]pyrimidin-3(4H)-yl)benzonitrile; 7-phenyl-3-(3-trifluoromethyl)phenyl)thieno[3,2-d]pyrimidin-4(3H)-one; 7-phenyl-3-(4-(trifluoromethyl)phenyl)thieno[3,2-d]pyrimidin-4(3H)-one; 7-phenyl-3-(4-trifluoromethoxy)phenyl)thieno[3,2-d]pyrimidin-4(3H)-one; 3-(4-nitrophenyl)-7-phenylthieno[3,2-d]pyrimidin-4(3H)-one; 7-phenyl-3-(3-vinylphenyl)thieno[3,2-d]-pyrimidin-4(3H)-one; 7-phenyl-3-(4-vinylphenyl)thieno[3,2-d]pyrimidin-4(3H)-one; 3-(4-fluorophenyl)-7-(2-fluorophenyl)thieno[3,2-d]pyrimidin-4(3H)-one; 3-(4-chlorophenyl)-7-(2-fluorophenyl)thieno[3,2-d]pyrimidin-4(3H)-one; 7-(2-fluorophenyl)-3-(4-methoxyphenyl)thieno[3,2-d]pyrimidin-4(3H)-one; 7-(2-fluorophenyl)-3-(4-hydroxyphenyl)thieno[3,2-d]pyrimidin-4(3H)-one; 7-(2-fluorophenyl)-3-(3-hydroxyphenyl)thieno[3,2-d]pyrimidin-4(3H)-one; 7-(2-fluorophenyl)-3-(m-tolyl)thieno[3,2-d]pyrimidin-4(3H)-one; 3-(3-chlorophenyl)-7-(2-fluorophenyl)thieno[3,2-d]pyrimidin-4(3H)-one; 7-(2-fluorophenyl)-3-(3-vinylphenyl)thieno[3,2-d]pyrimidin-4(3H)-one; 3-(7-(2-fluorophenyl)-4-oxothieno[3,2-d]pyrimidin-3(4H)-yl)benzonitrile; 3-(4-chlorophenyl)-7-(3-fluorophenyl)thieno[3,2-d]pyrimidin-4(3H)-one; 7-(3-fluorophenyl)-3-(4-methoxyphenyl)thieno[3,2-d]pyrimidin-4(3H)-one; 3-(4-chlorophenyl)-7-(4-fluorophenyl)thieno[3,2-d]pyrimidin-4(3H)-one; 7-(4-fluorophenyl)-3-(4-methoxyphenyl)thieno[3,2-d]pyrimidin-4(3H)-one; 7-(2-chlorophenyl)-3-(4-chlorophenyl)thieno[3,2-d]pyrimidin-4(3H)-one; 7-(2-chlorophenyl)-3-(4-methoxyphenyl)thieno[3,2-d]pyrimidin-4(3H)-one; 7-(3-chlorophenyl)-3-(4-chlorophenyl)thieno[3,2-d]pyrimidin-4(3H)-one; 7-(3-chlorophenyl)-3-(4-methoxyphenyl)thieno[3,2-d]pyrimidin-4(3H)-one; 3,7-bis(4-chlorophenyl)thieno[3,2-d]pyrimidin-4(3H)-one; 7-(4-chlorophenyl)-3-(4-methoxyphenyl)thieno[3,2-d]pyrimidin-4(3H)-one; 7-(2-bromophenyl)-3-(4-chlorophenyl)thieno[3,2-d]pyrimidin-4(3H)-one; 7-(2-bromophenyl)-3-(4-methoxyphenyl)thieno[3,2-d]pyrimidin-4(3H)-one; 7-(2-iodophenyl)-3-(4-methoxyphenyl)thieno[3,2-d]pyrimidin-4(3H)-one; 3-(4-methoxyphenyl)-7-(2-(trimethylstannyl)phenyl)thieno[3,2-d]pyrimidin-4(3H)-one; 3-(4-chlorophenyl)-7-(o-tolyl)thieno[3,2-d]pyrimidin-4(3H)-one; 3-(4-methoxyphenyl)-7-(o-tolyl)thieno[3,2-d]pyrimidin-4(3H)-one; 3-(4-chlorophenyl)-7-(m-tolyl)thieno[3,2-d]pyrimidin-4(3H)-one; 3-(4-methoxyphenyl)-7-(m-tolyl)thieno[3,2-d]pyrimidin-4(3H)-one; 3-(4-chlorophenyl)-7-(p-tolyl)thieno[3,2-d]pyrimidin-4(3H)-one; 3-(4-methoxyphenyl)-7-(p-tolyl)thieno[3,2-d]pyrimidin-4(3H)-one; 3-(4-chlorophenyl)-7-(2-methoxyphenyl)thieno[3,2-d]pyrimidin-4(3H)-one; 7-(2-methoxyphenyl)-3-(4-methoxyphenyl)thieno[3,2-d]pyrimidin-4(3H)-one; 3-(4-chlorophenyl)-7-(3-methoxyphenyl)thieno[3,2-d]pyrimidin-4(3H)-one; 7-(3-methoxyphenyl)-3-(4-methoxyphenyl)thieno[3,2-d]pyrimidin-4(3H)-one; 3-(4-chlorophenyl)-7-(4-methoxyphenyl)thieno[3,2-d]pyrimidin-4(3H)-one; 3,7-bis(4-methoxyphenyl)thieno[3,2-d]pyrimidin-4(3H)-one; 3-(4-chlorophenyl)-7-(3,4-dimethoxyphenyl)thieno[3,2-d]pyrimidin-4(3H)-one; 7-(3,4-dimethoxyphenyl)-3-(4-methoxyphenyl)thieno[3,2-d]pyrimidin-4(3H)-one; 7-(benzo[d][1,3]dioxol-5-yl)-3-(4-chlorophenyl)thieno[3,2-d]pyrimidin-4(3H)-one; 7-(benzo[d][1,3]dioxol-5-yl)-3-(4-methoxyphenyl)thieno[3,2-d]pyrimidin-4(3H)-one; 3-(4-chlorophenyl)-7-(naphthalen-1-yl)-3,4-dihydrothieno[3,2-d]pyrimidin-4(3H)-one; 3-(4-methoxyphenyl)-7-(naphthalen-1-yl)-3,4-dihydrothieno[3,2-d]pyrimidin-4(3H)-one; 3-(4-chlorophenyl)-7-(naphthalen-2-yl)-3,4-dihydrothieno[3,2-d]pyrimidin-4(3H)-one; 3-(4-methoxyphenyl)-7-(naphthalen-2-yl)-3,4-dihydrothieno[3,2-d]pyrimidin-4(3H)-one; 3-(4-methoxyphenyl)-2-methyl-7-phenylthieno[3,2-d]pyrimidin-4(3H)-one; 3-(4-chlorophenyl)-7-phenylthieno[3,2-d]pyrimidin-2,4(1H,3H)-dione; 3-(4-chlorophenyl)-2-(dimethylamino)-7-phenylthieno[3,2-d]pyrimidin-4(3H)-one; 3-butyl-7-phenylthieno[3,2-d]pyrimidin-4(3H)-one; 3-allyl-7-phenylthieno[3,2-d]pyrimidin-4(3H)-one; 3-cyclobutyl-7-phenylthieno[3,2-d]pyrimidin-4(3H)-one; 3-cyclopentyl-7-phenylthieno[3,2-d]pyrimidin-4(3H)-one; 3-cyclohexyl-7-phenylthieno[3,2-d]pyrimidin-4(3H)-one; 3-cyclooctyl-7-phenylthieno[3,2-d]pyrimidin-4(3H)-one; 3-(cyclopropylmethyl)-7-phenylthieno[3,2-d]pyrimidin-4(3H)-one; 3-(cyclohexylmethyl)-7-phenylthieno[3,2-d]pyrimidin-4(3H)-one; 3-((1R,4R)-4-methylcyclohexyl)-7-phenylthieno[3,2-d]pyrimidin-4(3H)-one; 7-phenyl-3-(tetrahydro-2H-pyran-4-yl)thieno[3,2-d]pyrimidin-4(3H)-one; (R)-7-phenyl-3-(1,2,3,4-tetrahydronaphthalen-1-yl)thieno[3,2-d]pyrimidin-4(3H)-one; (S)-7-phenyl-3-(1,2,3,4-tetrahydronaphthalen-1-yl)thieno[3,2-d]pyrimidin-4(3H)-one; (S)-7-phenyl-3-((tetrahydrofuran-2-yl)methyl)thieno[3,2-d]pyrimidin-4(3H)-one; (R)-7-phenyl-3-((tetrahydrofuran-2-yl)methyl)thieno[3,2-d]pyrimidin-4(3H)-one; 3-(1-methylpiperidin-4-yl)-7-phenylthieno[3,2-d]pyrimidin-4(3H)-one; 3-isobutyl-7-phenylthieno[3,2-d]pyrimidin-4(3H)-one; 3-neopentyl-7-phenylthieno[3,2-d]pyrimidin-4(3H)-one; 3-(2-methylcyclohexyl)-7-phenylthieno[3,2-d]pyrimidin-4(3H)-one; 3-(3-methylcyclohexyl)-7-phenylthieno[3,2-d]pyrimidin-4(3H)-one; 3-(4-ethylcyclohexyl)-7-phenylthieno[3,2-d]pyrimidin-4(3H)-one; (1R,4R)-4-(4-oxo-7-phenylthieno[3,2-d]pyrimidin-3(4H)-yl)cyclohexyl acetate; 3-butyl-7-(2-fluorophenyl)thieno[3,2-d]pyrimidin-4(3H)-one; 3-allyl-7-(2-fluorophenyl)thieno[3,2-d]pyrimidin-4(3H)-one; 3-cyclobutyl-7-(2-fluorophenyl)thieno[3,2-d]pyrimidin-4(3H)-one; 3-cyclopentyl-7-(2-fluorophenyl)thieno[3,2-d]pyrimidin-4(3H)-one; 3-cyclohexyl-7-(2-fluorophenyl)thieno[3,2-d]pyrimidin-4(3H)-one; 3-cyclooctyl-7-(2-fluorophenyl)thieno[3,2-d]pyrimidin-4(3H)-one; 3-(cyclopropylmethyl)-7-(2-fluorophenyl)thieno[3,2-d]pyrimidin-4(3H)-one; 3-(cyclohexanemethyl)-7-(2-fluorophenyl)thieno[3,2-d]pyrimidin-4(3H)-one; 7-(2-fluorophenyl)-3-((1R,4R)-4-methylcyclohexyl)thieno[3,2-d]pyrimidin-4(3H)-one; 3-cycloheptyl-7-phenylthieno[3,2-d]pyrimidin-4(3H)-one; 3-cycloheptyl-7-(2-fluorophenyl)thieno[3,2-d]pyrimidin-4(3H)-one; 3-(2,3-dihydro-1H-inden-2-yl)-7-phenylthieno[3,2-d]pyrimidin-4(3H)-one; 3-(4-isopropylcyclohexyl)-7-phenylthieno[3,2-d]pyrimidin-4(3H)-one; 7-phenyl-3-(4-propylcyclohexyl)thieno[3,2-d]pyrimidin-4(3H)-one; 3-(4-(tert-butyl)cyclohexyl)-7-phenylthieno[3,2-d]pyrimidin-4(3H)-one; (1r,4r)-4-(7-(2-fluorophenyl)-4-oxothieno[3,2-d]pyrimidin-3(4H)-yl)cyclohexyl acetate; 7-(2-fluorophenyl)-3-isobutylthieno[3,2-d]pyrimidin-4(3H)-one; 7-(2-fluorophenyl)-3-neopentylthieno[3,2-d]pyrimidin-4(3H)-one; 3-cyclooctyl-7-(o-tolyl)thieno[3,2-d]pyrimidin-4(3H)-one; and 3-cycloheptyl-7-(o-tolyl)thieno[3,2-d]pyrimidin-4(3H)-one.
[0171] In another aspect, the present invention provides a pharmaceutical composition for treating a brain disease, including at least one of the thienopyrimidinone derivatives according to the embodiments of the present invention or a pharmaceutically acceptable salt thereof as an active ingredient.
[0172] In one embodiment, the brain disease is selected from pain, a psychiatric disease, urinary incontinence, Parkinson's disease, and Alzheimer's disease.
[0173] In a further embodiment, the pain is neuropathic pain or migraine, and the psychiatric disease is anxiety disorder or schizophrenia.
[0174] The pharmaceutical composition of the present invention may be formulated into a dosage form suitable for oral or parenteral administration by compounding the thienopyrimidinone compound of Formula 1 or 2 or pharmaceutically acceptable salt thereof with one or more suitable additives selected from carriers, auxiliaries and diluents. The formulation may be carried out by a suitable technique known in the art. For oral administration, the pharmaceutical composition of the present invention may be in the form of tablets, capsules, solutions, syrups, etc. For parenteral administration, the pharmaceutical composition of the present invention may be in the form of intraperitoneal, subcutaneous, intramuscular, transdermal injectables, etc.
[0175] The daily effective dose of the pharmaceutical composition according to the present invention as an mGluR1 modulator is in the range of 0.01 to 1000 mg/day for an adult patient depending on the age, body weight, sex, mode of administration, general health, and severity of disease. The daily dose of the pharmaceutical composition may be administered in a single dose or in divided doses at regular time intervals according to the judgment of the physician or pharmacist.
[0176] In another aspect, the present invention provides a method for preparing the thienopyrimidinone derivative of Formula 1 or 2.
[0177] Specifically, the method of the present invention includes (a) formylating an aryl acetonitrile 2 to afford an aryl hydroxyacrylonitrile 3, (b) methylating the compound 3 to afford an aryl methoxyacrylonitrile 4, (c) forming a thiophene ring from the aryl methoxyacrylonitrile to synthesize a thiophene derivative 5, and (d) synthesizing the thienopyrimidinone derivative 1 from the thiophene derivative, as depicted in Reaction Scheme 1:
[0000]
[0178] In one embodiment, in step (d), (i) the thienopyrimidinone derivative 1 is directly synthesized from the thiophene derivative, (ii) the thiophene derivative is amidated to synthesize a compound 6 and a pyrimidinone ring is formed to synthesize the thienopyrimidinone derivative 1, or (iii) the thiophene derivative is reacted with an isocyanate to synthesize a thienopyrimidinedione derivative 7 and an amine is introduced to prepare the thienopyrimidinone derivative 1.
[0179] Specifically, the aryl acetonitrile 2 is formylated to afford the aryl hydroxyacrylonitrile 3. The formylation may be carried out using a base. Examples of suitable bases include NaH and NaN(SiMe 3 ) 2 . The formyl group may be introduced using an alkyl formate. Examples of suitable alkyl formates include ethyl formate and methyl formate. General organic solvents may be used in the formylation, and specific examples thereof include tetrahydrofuran, dioxane, N,N-dimethylformamide, acetonitrile, and dichloromethane. The formylation is preferably carried out at a temperature of −20° C. to 80° C. for 1 to 24 hours.
[0180] The aryl hydroxyacrylonitrile 3 is methylated to afford the aryl methoxyacrylonitrile 4. The methylation may be carried out using a base. Examples of suitable bases include NaH and NaN(SiMe 3 ) 2 . The methyl group may be introduced using various methylation reagents, such as methyl iodide and dimethyl sulfate. General organic solvents may be used in the methylation, and specific examples thereof include tetrahydrofuran, dioxane, N,N-dimethylformamide, acetonitrile, and dichloromethane. The methylation is preferably carried out at a temperature of 0° C. to 100° C. for 1 to 24 hours.
[0181] The thiophene derivative 5 including a thiophene ring is synthesized from the aryl methoxyacrylonitrile 4. The thiophene derivative 5 may be synthesized using various bases, such as NaOMe, MaOEt and KOtOBu. Specifically, the aryl methoxyacrylonitrile 4 is reacted with an alkyl thioglycolate, such as methyl thioglycolate, at 50 to 150° C. with stirring for 12 to 36 hours. After completion of the reaction, the reaction mixture is extracted with an organic solvent and purified by column chromatography to obtain the thiophene compound 5. General organic solvents may be used in the reaction, and specific examples thereof include methanol, ethanol, tetrahydrofuran, dioxane, N,N-dimethylformamide, acetonitrile, and dichloromethane.
[0182] The target compound 1 can be prepared from the thiophene compound 5 by the following three methods. According to the first method, the compound 5 is mixed with a triethyl orthocarboxylate, such as triethyl orthoformate or triethyl orthoacetate, an amine, and acetic acid, and the mixture is heated with stirring to obtain the thienopyrimidinone compound 1. The reaction is desirably carried out at about 1 to about 5 atm and a temperature of 50 to 200° C. for 12 to 36 hours.
[0183] According to the second method, the compound 5 is amidated to synthesize the compound 6 and a pyrimidinone ring is formed to synthesize the thienopyrimidinone derivative 1. The amide compound 6 is prepared by reacting the thiophene compound 5 with an amine in the presence of a Lewis acid, such as trimethylaluminum. Starting from −20 to 15° C., the reaction temperature is raised with stirring. The compound 6 is then mixed with a triethyl orthocarboxylate, such as triethyl orthoformate or triethyl orthoacetate, and acetic acid. The mixture is heated with stirring to afford the thienopyrimidinone compound 1. According to the third method, the thiophene compound 5 is reacted with an isocyanate to prepare the thienopyrimidinedione 7, which is then aminated by a suitable method known in the art to synthesize the thienopyrimidinone compound 1 having R3 including the amine.
[0184] Specifically, the thienopyrimidinone compound 7 is chlorinated with N,N-diethylaniline and phosphoryl chloride (phosphorus oxychloride) by a method known in the art to obtain an intermediate. The intermediate is reacted with an amine in the presence of a base to obtain the thienopyrimidinone compound 1 as the target compound. The amine is included in the thienopyrimidinone compound 1.
[0185] In yet another aspect, the present invention provides a method for treating or preventing a brain disease. Specifically, the method includes administering to a mammal in need of such treatment at least one of the target compounds according to the embodiments of the present invention or the pharmaceutical composition including at least one of the target compounds.
[0186] That is, the present invention provides the medical use of the thienopyrimidinone compound of Formula 1 or pharmaceutically acceptable salt thereof or the pharmaceutical composition for the prevention and treatment of diseases.
[0187] Specifically, the present invention includes the medical use of the thienopyrimidinone compound as an mGluR1 modulator for the prevention and treatment of pain, such as neuropathic pain and migraine, psychiatric diseases, such as anxiety disorder and schizophrenia, urinary incontinence, and neurodegenerative diseases, such as Parkinson's disease and Alzheimer's disease.
[0188] The pharmaceutically acceptable salt of the thienopyrimidinone derivative of Formula 1 or 2 according to the present invention may be formed by any suitable method known in the art. For example, suitable pharmaceutically acceptable acid addition salts may also be formed through the addition of a non-toxic inorganic acid or organic acid. Examples of suitable non-toxic inorganic acids include hydrochloric acid, hydrobromic acid, sulfonic acid, amidosulfuric acid, phosphoric acid, and nitric acid. Examples of suitable non-toxic organic acids include acetic acid, propionic acid, succinic acid, glycolic acid, stearic acid, lactic acid, tartaric acid, citric acid, para-toluenesulfonic acid, and methanesulfonic acid.
[0189] A more detailed explanation of the substituents used to define the thienopyrimidinone derivative of Formula 1 or 2 according to the present invention will be provided below.
[0190] The term “aryl” is intended to include phenyl, substituted phenyl, naphthyl, and benzodioxazole groups. The term “alkyl” is intended to include straight, branched and cyclic carbon chains having 1 to 12 carbon atoms. Preferred alkyl groups are, for example, methyl, ethyl, n-propyl, isopropyl, allyl, n-butyl, isobutyl, tert-butyl, neopentyl, cyclobutyl, cyclopentyl, cyclohexyl, cycloheptyl, cyclooctyl, cyclopropylmethyl, cyclohexylmethyl, methylcyclohexyl, ethylcyclohexyl, propylcyclohexyl, isopropylcyclohexyl, tert-butylcyclohexyl, tetrahydronaphthyl, heteroalkyl (e.g., tetrahydrofurfuryl and N-methylpiperidinyl), hydroxycyclohexyl, oxocyclohexyl, and tetrahydropyranyl groups. The term “alkoxy” refers to an alkyl group attached to oxygen wherein the alkyl is as defined above.
[0191] The present invention will be explained in more detail with reference to the following examples, including formulation examples and experimental example. However, these examples are not to be construed as limiting or restricting the scope and spirit of the invention. It is to be understood that based on the teachings of the present invention including the following examples, those skilled in the art can readily practice other embodiments of the present invention whose specific experimental data are not available.
[0192] Although there are differences in the structures and physical properties of the substituents depending on the kind of the substituents, the reaction principles and conditions of the Examples Section can also be applied to compounds including substituents that are not described in the Examples Section. Therefore, it is obvious that those skilled in the art can easily prepare the compounds including substituents based on the disclosure of the Examples Section and the common knowledge in the art.
EXAMPLES
Example 1
3-Hydroxy-2-phenylacrylonitrile
[0193] Phenylacetonitrile (10 g, 85.4 mmol) and methyl formate (67 ml) were dissolved in TIIF (250 ml) in a reaction vessel, and then NaH (2.6 g, 106.7 mmol) was added thereto at 0° C. The solution was stirred at room temperature for 12 hr. After completion of the reaction, the reaction mixture was washed with distilled water and acidified with 1 N HCl to adjust the pH to 5 or less. Thereafter, the resulting solution was extracted with dichloromethane. The organic layer was dried over anhydrous Na 2 SO 4 , followed by filtration. The filtrate was concentrated under reduced pressure to give 12.3 g (84.7 mmol, quant.) of the title compound.
[0194] 1 H NMR (300 MHz, CDCl 3 ) δ 7.44-7.32 (m, 5H)
Example 2
3-Methoxy-2-phenylacrylonitrile
[0195] 3-Hydroxy-2-phenylacrylonitrile (12.3 g, 84.7 mmol) was dissolved in dry THF (100 ml) in a reaction vessel, and then NaH (4.1 g, 169.4 mmol) was slowly added thereto. The mixture was stirred at room temperature for 2 hr. Thereafter, dimethyl sulfate (13.7 ml, 144.0 mmol) was added, followed by stirring at 40° C. for 12 hr. After completion of the reaction, the reaction mixture was washed with distilled water and concentrated under reduced pressure. The concentrate was diluted with EtOAc and extracted with EtOAc together with distilled water. The organic layer was dried over anhydrous MgSO 4 and filtered. The filtrate was concentrated under reduced pressure to give 17.9 g (112.5 mmol, quant.) of the title compound.
[0196] 1 H NMR (300 MHz, CDCl 3 ) δ 7.40-7.28 (m, 5H), 4.00 (s, 3H)
Example 3
Methyl 3-amino-4-phenylthiophene-2-carboxylate
[0197] 3-Methoxy-2-phenylacrylonitrile (17.9 g, 112.5 mmol) was dissolved in NaOMe (5 M in MeOH, 31.5 ml, 157.5 mmol), and then methyl thioglycolate (16 ml, 180.0 mmol) was added thereto. The mixture was heated with stirring at 65° C. for 24 hr. After the completion of the reaction was confirmed by thin layer chromatography (TLC), the reaction mixture was cooled to room temperature and filtered through Celite. The filtrate was washed with distilled water and extracted with dichloromethane. The organic layer was dried over anhydrous MgSO 4 and filtered. The filtrate was distilled under reduced pressure, and the concentrate was purified by silica gel column chromatography (EtOAc:Hex=1:5) to give 5.1 g (21.9 mmol, 26% yield in three steps) of the title compound.
[0198] 1 H NMR (300 MHz, CDCl 3 ) δ 7.49-7.39 (m, 5H), 7.25 (s, 1H), 5.64 (br, 2H), 3.88 (s, 3H)
Example 4
3-Amino-N-(4-methoxyphenyl)-4-phenylthiophene-2-carboxamide
[0199] p-Anisidine (29 mg, 0.24 mmol) was dissolved in toluene (2 ml) in a reaction vessel, and trimethylaluminum (2 M in TIIF, 0.12 ml) was added thereto at 0° C. After stirring for 10 min, to the mixture was added methyl 3-amino-4-phenylthiophene-2-carboxylate (50 mg, 0.21 mmol). The resulting mixture was heated to reflux at 120° C. for 16 hr. The completion of the reaction was confirmed by TLC. The reaction mixture was allowed to cool to room temperature, extracted with EtOAc, dried over anhydrous MgSO 4 , and concentrated under reduced pressure. The concentrate was purified by silica gel column chromatography (hexane:EtOAc=5:1) to give (57 mg, 0.18 mmol, 84% yield) of the title compound.
[0200] 1 H NMR (300 MHz, CDCl 3 ) δ 7.47-7.37 (m, 7H), 7.16 (s, 1H), 7.07 (brs, 1H), 6.93-6.89 (m, 2H), 5.86 (brs, 2H), 3.81 (s, 3H)
Compound 1: 3,7-Diphenylthieno[3,2-d]pyrimidin-4(3H)-one
[0201] Methyl 3-amino-4-phenylthiophene-2-carboxylate (100 mg, 0.43 mmol), triethyl orthoformate (1 ml), aniline (76 mg, 0.81 mmol), and acetic acid (0.1 ml) were placed in a pressure bottle. The mixture was heated with stirring at 160° C. for 18 hr. After the completion of the reaction was confirmed by TLC, the reaction mixture was cooled to room temperature and solidified with diethyl ether and EtOAc to give 42 mg (0.14 mmol, 33% yield) of the title compound as a final product.
[0202] 1 H NMR (400 MHz, CDCl 3 ) δ 8.53 (s, 1H), 8.51 (s, 1H), 8.01 (d, J=7.2 Hz, 2H), 7.63-7.55 (m, 5H), 7.52 (t, J=7.6 Hz, 2H), 7.42 (t, J=7.4 Hz, 1H)
Compound 2: 3-(2-Fluorophenyl)-7-phenylthieno[3,2-d]pyrimidin-4(3H)-one
[0203] In the same manner as the synthesis of Compound 1, methyl 3-amino-4-phenylthiophene-2-carboxylate (100 mg, 0.43 mmol), triethyl orthoformate (1.0 ml), 2-fluoroaniline (88.6 mg, 0.8 mmol), and acetic acid (0.12 ml) were used to give 36 mg (0.11 mmol, 26% yield) of the title compound.
[0204] 1 H NMR (400 MHz, CDCl 3 ) δ 8.12 (s, 1H), 7.91 (s, 1H), 7.84 (d, J=1.4 Hz, 2H), 7.53-7.30 (m, 7H)
Compound 3: 3-(3-Fluorophenyl)-7-phenylthieno[3,2-d]pyrimidin-4(3H)-one
[0205] In the same manner as the synthesis of Compound 1, methyl 3-amino-4-phenylthiophene-2-carboxylate (50 mg, 0.21 mmol), triethyl orthoformate (0.47 ml), 3-fluoroaniline (44.3 mg, 0.4 mmol), and acetic acid (0.06 ml) were used to give 8.1 mg (0.025 mmol, 12% yield) of the title compound.
[0206] 1 H NMR (300 MHz, CDCl 3 ) δ 8.17 (s, 1H), 7.91 (s, 1H), 7.85-7.82 (m, 2H), 7.60-7.38 (m, 5H), 7.42-7.21 (m, 2H)
Compound 4: 3-(4-Fluorophenyl)-7-phenylthieno[3,2-d]pyrimidin-4(3H)-one
[0207] In the same manner as the synthesis of Compound 1, methyl 3-amino-4-phenylthiophene-2-carboxylate (76 mg, 0.33 mmol), triethyl orthoformate (0.66 ml), 4-fluoroaniline (0.058 mg, 0.61 mmol), and acetic acid (0.08 ml) were used to give 68.5 mg (0.021 mmol, 64% yield) of the title compound.
[0208] 1 H NMR (300 MHz, CDCl 3 ) δ 8.18 (s, 1H), 7.92 (s, 1H), 7.90-7.83 (m, 2H), 7.54-7.40 (m, 5H), 7.31-7.24 (m, 2H)
Compound 5: 3-(2-Chlorophenyl)-7-phenylthieno[3,2-d]pyrimidin-4(3H)-one
[0209] In the same manner as the synthesis of Compound 1, methyl 3-amino-4-phenylthiophene-2-carboxylate (100 mg, 0.43 mmol), triethyl orthoformate (1.0 ml), 2-chlorophenyl (102.1 mg, 0.8 mmol), and acetic acid (0.06 ml) were used to give 19.2 mg (0.057 mmol, 13.2% yield) of the title compound.
[0210] 1 H NMR (300 MHz, CDCl 3 ) δ 8.04 (s, 1H), 7.91 (s, 1H), 7.87-7.83 (m, 2H), 7.64-7.62 (m, 1H), 7.53-7.41 (m, 6H)
Compound 6: 3-(3-Chlorophenyl)-7-phenylthieno[3,2-d]pyrimidin-4(3H)-one
[0211] In the same manner as the synthesis of Compound 1, methyl 3-amino-4-phenylthiophene-2-carboxylate (50 mg, 0.21 mmol), triethyl orthoformate (0.47 ml), 3-chlorophenyl (50.9 mg, 0.21 mmol), and acetic acid (0.06 ml) were used to give 16 mg (0.047 mmol, 22.5% yield) of the title compound.
[0212] 1 H NMR (300 MHz, CDCl 3 ) δ 8.13 (s, 1H), 7.89 (s, 1H), 7.85-7.81 (m, 2H), 7.54-7.45 (m, 5H), 7.42-7.30 (m, 2H)
Compound 7: 3-(4-Chlorophenyl)-7-phenylthieno[3,2-d]pyrimidin-4(3H)-one
[0213] In the same manner as the synthesis of Compound 1, methyl 3-amino-4-phenylthiophene-2-carboxylate (60 mg, 0.26 mmol), triethyl orthoformate (0.5 ml), 4-chloroaniline (61 mg, 0.48 mmol), and acetic acid (0.06 ml) were used to give 31.6 mg (0.093 mmol, 36% yield) of the title compound.
[0214] 1 H NMR (300 MHz, CDCl 3 ) δ 8.19 (s, 1H), 7.93 (s, 1H), 7.86 (d, J=1.4 Hz, 2H), 7.58-7.50 (m, 4H), 7.46-7.40 (m, 3H)
Compound 8: 3-(3-Bromophenyl)-7-phenylthieno[3,2-d]pyrimidin-4(3H)-one
[0215] In the same manner as the synthesis of Compound 1, methyl 3-amino-4-phenylthiophene-2-carboxylate (200 mg, 0.86 mmol), triethyl orthoformate (2 ml), 3-bromoaniline (280 mg, 1.63 mmol), and acetic acid (0.2 ml) were used to give 40 mg (0.10 mmol, 12% yield) of the title compound.
[0216] 1 H NMR (400 MHz, CDCl 3 ) δ 8.19 (s, 1H), 7.94 (s, 1H), 7.88-7.86 (m, 2H), 7.70-7.68 (m, 2H), 7.56-7.42 (m, 5H)
Compound 9: 3-(4-Bromophenyl)-7-phenylthieno[3,2-d]pyrimidin-4(3H)-one
[0217] In the same manner as the synthesis of Compound 1, methyl 3-amino-4-phenylthiophene-2-carboxylate (200 mg, 0.86 mmol), triethyl orthoformate (2 ml), 4-bromoaniline (280 mg, 1.63 mmol), and acetic acid (0.2 ml) were used to give 13 mg (0.034 mmol, 4% yield) of the title compound.
[0218] 1 H NMR (400 MHz, CDCl 3 ) δ 7.18 (s, 1H), 7.93 (s, 1H), 7.87-7.85 (m, 2H), 7.74-7.70 (m, 2H), 7.55-7.51 (m, 2H), 7.46-7.42 (m, 1H), 7.38-7.35 (m, 2H)
Compound 10: 3-(2-Methoxyphenyl)-7-phenylthieno[3,2-d]pyrimidin-4(3H)-one
[0219] In the same manner as the synthesis of Compound 1, methyl 3-amino-4-phenylthiophene-2-carboxylate (200 mg, 0.86 mmol), triethyl orthoformate (2 ml), o-anisidine (201 mg, 1.63 mmol), and acetic acid (0.2 ml) were used to give 204 mg (0.61 mmol, 71% yield) of the title compound.
[0220] 1 H NMR (400 MHz, CDCl 3 ) δ 8.09 (s, 1H), 7.91-7.88 (m, 3H), 7.54-7.38 (m, 5H), 7.14 (t, J=8.2 Hz, 2H), 3.85 (s, 3H)
Compound 11: 3-(3-Methoxyphenyl)-7-phenylthieno[3,2-d]pyrimidin-4(3H)-one
[0221] In the same manner as the synthesis of Compound 1, methyl 3-amino-4-phenylthiophene-2-carboxylate (70 mg, 0.30 mmol), triethyl orthoformate (0.57 ml), m-anisidine (0.063 ml, 0.56 mmol), and acetic acid (0.07 ml) were used to give 83 mg (0.25 mmol, 83% yield) of the title compound.
[0222] 1 H NMR (300 MHz, CDCl 3 ) δ 8.22 (s, 1H), 7.93-7.81 (m, 3H), 7.55-7.41 (m, 4H), 7.12-7.04 (m, 3H), 3.88 (s, 3H)
Compound 12: 3-(4-Methoxyphenyl)-7-phenylthieno[3,2-d]pyrimidin-4(3H)-one
[0223] In the same manner as the synthesis of Compound 1, methyl 3-amino-4-phenylthiophene-2-carboxylate (58 mg, 0.25 mmol), triethyl orthoformate (0.5 ml), p-anisidine (58 mg, 0.47 mmol), and acetic acid (0.06 ml) were used to give 26 mg (0.078 mmol, 31% yield) of the title compound.
[0224] 1 H NMR (300 MHz, CDCl 3 ) δ 8.20 (s, 1H), 7.90-7.85 (m, 3H), 7.54-7.45 (m, 2H), 7.45-7.36 (m, 3H), 7.06 (d, J=6.8 Hz, 2H), 3.89 (s, 3H)
Compound 13: 3-(3,4-Dimethoxyphenyl)-7-phenylthieno[3,2-d]pyrimidin-4(3H)-one
[0225] In the same manner as the synthesis of Compound 1, methyl 3-amino-4-phenylthiophene-2-carboxylate (52 mg, 0.22 mmol), triethyl orthoformate (0.45 ml), 3,4-dimethoxyaniline (62.8 mg, 0.41 mmol), and acetic acid (0.06 ml) were used to give 48 mg (0.13 mmol, 59% yield) of the title compound.
[0226] 1 H NMR (300 MHz, CDCl 3 ) δ 8.22 (s, 1H), 7.90-7.86 (m, 3H), 7.54-7.40 (m, 3H), 7.03-6.94 (m, 3H), 3.97 (s, 3H), 3.93 (s, 3H)
Compound 14: 3-(3,5-Dimethoxyphenyl)-7-phenylthieno[3,2-d]pyrimidin-4(3H)-one
[0227] In the same manner as the synthesis of Compound 1, methyl 3-amino-4-phenylthiophene-2-carboxylate (72.3 mg, 0.31 mmol), triethyl orthoformate (0.62 ml), 3,5-dimethoxyaniline (88.8 mg, 0.58 mmol), and acetic acid (0.07 ml) were used to give 75.7 mg (0.21 mmol, 68% yield) of the title compound.
[0228] 1 H NMR (300 MHz, CDCl 3 ) δ 8.24 (s, 1H), 7.91-7.86 (m, 3H), 7.55-7.41 (m, 3H), 6.61 (s, 3H), 3.85 (s, 6H)
Compound 15: 3-(4-Hydroxyphenyl)-7-phenylthieno[3,2-d]pyrimidin-4(3H)-one
[0229] In the same manner as the synthesis of Compound 1, methyl 3-amino-4-phenylthiophene-2-carboxylate (500 mg, 2.14 mmol), triethyl orthoformate (5 ml), 4-aminophenol (444 mg, 4.07 mmol), and acetic acid (0.5 ml) were used to give 283 mg (0.88 mmol, 41% yield) of the title compound.
[0230] 1 H NMR (300 MHz, DMSO) δ 9.89 (brs, 1H), 8.47 (s, 1H), 8.44 (s, 1H), 7.98 (d, J=7.2 Hz, 2H), 7.52-7.32 (m, 5H), 6.94-6.89 (m, 2H)]
Compound 16: 7-Phenyl-3-(o-tolyl)thieno[3,2-d]pyrimidin-4(3H)-one
[0231] In the same manner as the synthesis of Compound 1, methyl 3-amino-4-phenylthiophene-2-carboxylate (200 mg, 0.86 mmol), triethyl orthoformate (2 ml), o-toluidine (175 mg, 1.63 mmol), and acetic acid (0.2 ml) were used to give 62 mg (0.19 mmol, 23% yield) of the title compound.
[0232] 1 H NMR (400 MHz, CDCl 3 ) δ 8.11 (s, 1H), 7.94 (s, 1H), 7.91-7.89 (m, 2H), 7.55-7.39 (m, 6H), 7.30 (d, J=7.6 Hz, 1H), 2.26 (s, 3H)
Compound 17: 7-Phenyl-3-(m-tolyl)thieno[3,2-d]pyrimidin-4(3H)-one
[0233] In the same manner as the synthesis of Compound 1, methyl 3-amino-4-phenylthiophene-2-carboxylate (200 mg, 0.86 mmol), triethyl orthoformate (2 ml), m-toluidine (175 mg, 1.63 mmol), and acetic acid (0.2 ml) were used to give 40 mg (0.13 mmol, 15% yield) of the title compound.
[0234] 1 H NMR (400 MHz, CDCl 3 ) δ 8.21 (s, 1H), 7.91 (s, 1H), 7.88 (d, J=7.6 Hz, 2H), 7.54-7.25 (m, 7H), 2.48 (s, 3H)
Compound 18: 7-Phenyl-3-p-tolylthieno[3,2-d]pyrimidin-4(3H)-one
[0235] In the same manner as the synthesis of Compound 1, methyl 3-amino-4-phenylthiophene-2-carboxylate (80 mg, 0.34 mmol), triethyl orthoformate (0.65 ml), p-toluidine (67.5 mg, 0.63 mmol), and acetic acid (0.08 ml) were used to give 73.8 mg (0.23 mmol, 68% yield) of the title compound.
[0236] 1 H NMR (300 MHz, CDCl 3 ) δ 8.21 (s, 1H), 7.91-7.88 (m, 3H), 7.55-7.34 (m, 7H), 2.48 (s, 3H)
Compound 19: 3-(4-Ethylphenyl)-7-phenylthieno[3,2-d]pyrimidin-4(3H)-one
[0237] In the same manner as the synthesis of Compound 1, methyl 3-amino-4-phenylthiophene-2-carboxylate (50 mg, 0.21 mmol), triethyl orthoformate (0.42 ml), 4-ethylaniline (0.05 ml, 0.39 mmol), and acetic acid (0.05 ml) were used to give 59.5 mg (0.18 mmol, 60% yield) of the title compound.
[0238] 1 H NMR (300 MHz, CDCl 3 ) δ 8.23 (s, 1H), 7.92-7.87 (m, 3H), 7.55-7.37 (m, 7H), 2.78 (q, J=7.8 Hz, 2H), 1.34 (t, J=7.8 Hz, 3H)
Compound 20: 3-(2,6-Dimethylphenyl)-7-phenylthieno[3,2-d]pyrimidin-4(3H)-one
[0239] In the same manner as the synthesis of Compound 1, methyl 3-amino-4-phenylthiophene-2-carboxylate (43 mg, 0.18 mmol), triethyl orthoformate (0.34 ml), 2,6-dimethylaniline (0.04 ml, 0.33 mmol), and acetic acid (0.042 ml) were used to give 34.8 mg (0.10 mmol, 56% yield) of the title compound.
[0240] 1 H NMR (300 MHz, CDCl 3 ) δ 8.00 (s, 1H), 7.96 (s, 1H), 7.94-7.90 (m, 2H), 7.58-7.19 (m, 6H), 2.20 (s, 6H)
Compound 21: 3-(2,5-Dimethylphenyl)-7-phenylthieno[3,2-d]pyrimidin-4(3H)-one
[0241] In the same manner as the synthesis of Compound 1, methyl 3-amino-4-phenylthiophene-2-carboxylate (45.6 mg, 0.20 mmol), triethyl orthoformate (0.40 ml), 2,5-dimethylaniline (44.8 mg, 0.37 mmol), and acetic acid (0.05 ml) were used to give 28.8 mg (0.087 mmol, 44% yield) of the title compound.
[0242] 1 H NMR (300 MHz, CDCl 3 ) δ 8.11 (s, 1H), 7.95-7.87 (m, 3H), 7.57-7.26 (m, 5H), 7.12 (s, 1H), 2.34 (s, 3H), 2.21 (s, 3H)
Compound 22: 3-(3,4-Dimethylphenyl)-7-phenylthieno[3,2-d]pyrimidin-4(3H)-one
[0243] In the same manner as the synthesis of Compound 1, methyl 3-amino-4-phenylthiophene-2-carboxylate (70 mg, 0.30 mmol), triethyl orthoformate (0.57 ml), 3,4-dimethylaniline (67.8 mg, 0.56 mmol), and acetic acid (0.07 ml) were used to give 49.2 mg (0.15 mmol, 50% yield) of the title compound.
[0244] 1 H NMR (300 MHz, CDCl 3 ) δ 8.21 (s, 1H), 7.92-7.88 (m, 3H), 7.56-7.18 (m, 6H), 2.38 (s, 6H)
Compound 23: 3-(4-Oxo-7-phenylthieno[3,2-d]pyrimidin-3(4H)-yl)benzonitrile
[0245] In the same manner as the synthesis of Compound 1, methyl 3-amino-4-phenylthiophene-2-carboxylate (100 mg, 0.43 mmol), triethyl orthoformate (1 ml), 3-aminobenzonitrile (96 mg, 0.81 mmol), and acetic acid (0.1 ml) were used to give 20 mg (0.061 mmol, 14% yield) of the title compound.
[0246] 1 H NMR (400 MHz, CDCl 3 ) δ 8.58 (s, 1H), 8.54 (s, 1H), 8.19 (t, J=1.6 Hz, 1H), 8.05 (d, J=6.0 Hz, 1H), 8.00 (d, J=7.2 Hz, 3H), 7.82 (t, J=8.0 Hz, 1H), 7.52 (t, J=7.6 Hz, 2H), 7.43 (t, J=7.4 Hz, 1H)
Compound 24: 4-(4-Oxo-7-phenylthieno[3,2-d]pyrimidin-3(4H)-yl)benzonitrile
[0247] In the same manner as the synthesis of Compound 1, methyl 3-amino-4-phenylthiophene-2-carboxylate (100 mg, 0.43 mmol), triethyl orthoformate (1 ml), 4-aminobenzonitrile (96 mg, 0.81 mmol), and acetic acid (0.1 ml) were used to give 38 mg (0.12 mmol, 27% yield) of the title compound.
[0248] 1 H NMR (400 MHz, CDCl 3 ) δ 8.56 (s, 1H), 8.53 (s, 1H), 8.11 (d, J=7.6 Hz, 2H), 7.99 (d, J=8.0 Hz, 2H), 7.85 (d, J=7.6 Hz, 2H), 7.52 (t, J=8.4 Hz, 2H), 7.45-7.41 (m, 1H)
Compound 25: 7-Phenyl-3-(3-trifluoromethyl)phenyl)thieno[3,2-d]pyrimidin-4(3H)-one
[0249] In the same manner as the synthesis of Compound 1, methyl 3-amino-4-phenylthiophene-2-carboxylate (200 mg, 0.86 mmol), triethyl orthoformate (2 ml), 3-trifluoromethylaniline (263 mg, 1.63 mmol), and acetic acid (0.2 ml) were used to give 12 mg (0.032 mmol, 4% yield) of the title compound.
[0250] 1 H NMR (400 MHz, CDCl 3 ) δ 8.21 (s, 1H), 7.95 (s, 1H), 7.87 (d, J=6.8 Hz, 2H), 7.83-7.69 (m, 4H), 7.53 (t, J=7.4 Hz, 2H), 7.45 (t, J=7.4 Hz, 1H)
Compound 26: 7-Phenyl-3-(4-(trifluoromethyl)phenyl)thieno[3,2-d]pyrimidin-4(3H)-one
[0251] In the same manner as the synthesis of Compound 1, methyl 3-amino-4-phenylthiophene-2-carboxylate (50 mg, 0.21 mmol), triethyl orthoformate (0.40 ml), p-trifluoromethaneaniline (0.05 ml, 0.39 mmol), and acetic acid (0.06 ml) were used to give 12.2 mg (0.033 mmol, 16% yield) of the title compound.
[0252] 1 H NMR (300 MHz, CDCl 3 ) δ 8.22 (s, 1H), 7.97 (s, 1H), 7.90-7.86 (m, 4H), 7.65 (d, J=8.4 Hz, 2H), 7.54 (t, J=7.8 Hz, 2H), 7.48-7.30 (m, 1H)
Compound 27: 7-Phenyl-3-(4-trifluoro methoxy)phenyl)thieno[3,2-d]pyrimidin-4(3H)-one
[0253] In the same manner as the synthesis of Compound 1, methyl 3-amino-4-phenylthiophene-2-carboxylate (200 mg, 0.86 mmol), triethyl orthoformate (2 ml), 4-trifluoromethoxyaniline (289 mg, 1.63 mmol), and acetic acid (0.2 ml) were used to give 70 mg (0.18 mmol, 21% yield) of the title compound.
[0254] 1 H NMR (400 MHz, CDCl 3 ) δ 8.27 (s, 1H), 7.92 (s, 1H), 7.87-7.85 (m, 2H), 7.54-7.50 (m, 4H), 7.46-7.42 (m, 3H)
Compound 28: 3-(4-Nitrophenyl)-7-phenylthieno[3,2-d]pyrimidin-4(3H)-one
[0255] In the same manner as the synthesis of Compound 1, methyl 3-amino-4-phenylthiophene-2-carboxylate (200 mg, 0.86 mmol), triethyl orthoformate (2 ml), 4-nitroaniline (225 mg, 1.63 mmol), and acetic acid (0.2 ml) were used to give 31 mg (0.089 mmol, 10% yield) of the title compound.
[0256] 1 H NMR (400 MHz, CDCl 3 ) δ 8.46 (d, J=8.8 Hz, 1H), 8.22 (s, 1H), 7.97 (s, 1H), 7.86 (d, J=7.6 Hz, 2H), 7.72 (d, J=8.4 Hz, 2H), 7.54 (t, J=7.4 Hz, 2H), 7.47-7.45 (m, 1H)
Compound 29: 7-Phenyl-3-(3-vinylphenyl)thieno[3,2-d]-pyrimidin-4(3H)-one
[0257] In the same manner as the synthesis of Compound 1, methyl 3-amino-4-phenylthiophene-2-carboxylate (50 mg, 0.21 mmol), triethyl orthoformate (0.47 ml), 4-vinylaniline (47.5 mg, 0.39 mmol), and acetic acid (0.06 ml) were used to give 8 mg (0.024 mmol, 11.5% yield) of the title compound.
[0258] 1 H NMR (300 MHz, CDCl 3 ) δ 8.22 (s, 1H), 7.9 (s, 1H), 7.86-7.83 (m, 2H), 7.61-7.48 (m, 5H), 7.44-7.38 (m, 1H), 7.36-7.31 (m, 1H), 6.76 (dd, J=23.6, 14.4 Hz, 1H), 5.82 (d, J=23.6 Hz, 1H), 5.37 (d, J=14.4 Hz, 1H)
Compound 30: 7-Phenyl-3-(4-vinylphenyl)thieno[3,2-d]pyrimidin-4(3H)-one
[0259] In the same manner as the synthesis of Compound 1, methyl 3-amino-4-phenylthiophene-2-carboxylate (100 mg, 0.43 mmol), triethyl orthoformate (1 ml), 4-aminostyrene (97 mg, 0.81 mmol), and acetic acid (0.1 ml) were used to give 10 mg (0.030 mmol, 7% yield) of the title compound.
[0260] 1 H NMR (400 MHz, CDCl 3 ) δ 8.53 (s, 1H), 8.52 (s, 1H), 8.01 (d, J=8.4 Hz, 2H), 7.69 (d, J=8.4 Hz, 2H), 7.58-7.40 (m, 5H), 6.89-6.82 (m, 1H), 5.98 (d, J=17.6 Hz, 1H), 5.40 (d, J=10.8 Hz, 1H)
Compound 31: 3-(4-Fluorophenyl)-7-(2-fluorophenyl)thieno[3,2-d]pyrimidin-4(3H)-one
[0261] In the same manner as the synthesis of Compound 1, methyl 3-amino-4-(2-fluorophenyl)thiophene-2-carboxylate (88 mg, 0.35 mmol), triethyl orthoformate (0.77 ml), 4-fluoroaniline (63 ml, 0.46 mmol), and acetic acid (0.09 ml) were used to give 32 mg (0.095 mmol, 27% yield) of the title compound.
[0262] 1 H NMR (300 MHz, CDCl 3 ) δ 8.2 (s, 1H), 8.07 (d, J=1.5 Hz, 1H), 7.6 (td, J=7.6, 1.7 Hz, 1H), 7.49-7.40 (m, 3H), 7.35-7.23 (m, 4H)
Compound 32: 3-(4-Chlorophenyl)-7-(2-fluorophenyl)thieno[3,2-d]pyrimidin-4(3H)-one
[0263] In the same manner as the synthesis of Compound 1, methyl 3-amino-4-(2-fluorophenyl)thiophene-2-carboxylate (100 mg, 40 mmol), triethyl orthoformate (2.0 ml), 4-chloroaniline (94.43 mg, 0.74 mmol), and acetic acid (0.1 ml) were used to give 38 mg (0.11 mmol, 27% yield) of the title compound.
[0264] 1 H NMR (300 MHz, CDCl 3 ) δ 8.15 (s, 1H), 8.03 (s, 1H), 7.85-7.84 (m, 1H), 7.58 (d, J=8.4 Hz, 2H), 7.44 (d, J=11.4 Hz, 2H), 7.40-7.26 (m, 3H)
Compound 33: 7-(2-Fluorophenyl)-3-(4-methoxyphenyl)thieno[3,2-d]pyrimidin-4(3H)-one
[0265] In the same manner as the synthesis of Compound 1, methyl 3-amino-4-(2-fluorophenyl)thiophene-2-carboxylate (100 mg, 0.40 mmol), triethyl orthoformate (2.0 ml), p-anisidine (91.17 mg, 0.74 mmol), and acetic acid (0.1 ml) were used to give 22 mg (0.062 mmol, 16% yield) of the title compound.
[0266] 1 H NMR (300 MHz, CDCl 3 ) δ 8.20 (s, 1H), 8.05 (s, 1H), 8.04-7.89 (m, 1H), 7.40-7.28 (m, 5H), 7.10-7.07 (m, 2H), 3.91 (s, 3H)
Compound 34: 7-(2-Fluorophenyl)-3-(4-hydroxyphenyl)thieno[3,2-d]pyrimidin-4(3H)-one
[0267] In the same manner as the synthesis of Compound 1, methyl 3-amino-4-(2-fluorophenyl)thiophene-2-carboxylate (500 mg, 1.99 mmol), triethyl orthoformate (5 ml), 4-aminophenol (412 mg, 3.78 mmol), and acetic acid (0.5 ml) were used to give 328 mg (0.97 mmol, 49% yield) of the title compound.
[0268] 1 H NMR (300 MHz, DMSO) δ 9.90 (s, 1H), 8.40 (s, 1H), 7.81 (td, J=7.7 Hz, J=1.5 Hz, 1H), 7.52-7.44 (m, 1H), 7.38-7.30 (m, 4H), 6.93-6.90 (m, 1H)
Compound 35: 7-(2-Fluorophenyl)-3-(3-hydroxyphenyl)thieno[3,2-d]pyrimidin-4(3H)-one
[0269] In the same manner as the synthesis of Compound 1, methyl 3-amino-4-(2-fluorophenyl)thiophene-2-carboxylate (80 mg, 0.3 mmol), triethyl orthoformate (0.72 ml), 3-aminophenol (64.6 mg, 0.59 mmol), and acetic acid (0.09 ml) were used to give 41.5 mg (0.12 mmol, 38.3% yield) of the title compound.
[0270] 1 H NMR (300 MHz, DMSO) δ 9.96 (s, 1H), 8.42 (s, 2H), 7.83-7.78 (m, 1H), 7.51-7.45 (m, 1H), 7.39-7.31 (m, 3H), 6.95-6.91 (m, 3H)
Compound 36: 7-(2-Fluorophenyl)-3-(m-tolyl)thieno[3,2-d]pyrimidin-4(3H)-one
[0271] In the same manner as the synthesis of Compound 1, methyl 3-amino-4-(2-fluorophenyl)thiophene-2-carboxylate (80 mg, 0.3 mmol), triethyl orthoformate (0.79 ml), m-toluidine (63.8 mg, 0.59 mmol), and acetic acid (0.09 ml) were used to give 70 mg (0.21 mmol, 65.0% yield) of the title compound.
[0272] 1 H NMR (400 MHz, DMSO) δ 8.45-8.43 (m, 2H), 7.85-7.80 (m, 1H), 7.53-7.46 (m, 2H), 7.40-7.33 (m, 5H), 2.41 (s, 3H)
Compound 37: 3-(3-Chlorophenyl)-7-(2-fluorophenyl)thieno[3,2-d]pyrimidin-4(3H)-one
[0273] In the same manner as the synthesis of Compound 1, methyl 3-amino-4-(2-fluorophenyl)thiophene-2-carboxylate (80 mg, 0.3 mmol), triethyl orthoformate (0.79 ml), 3-chloroaniline (75.5 mg, 0.59 mmol), and acetic acid (0.09 ml) were used to give 84 mg (0.24 mmol, 73.6% yield) of the title compound.
[0274] 1 H NMR (400 MHz, DMSO) δ 8.49 (s, 1H), 8.45 (s, 1H), 7.83-7.78 (m, 2H), 7.64-7.52 (m, 3H), 7.50-7.48 (m, 1H), 7.42-7.34 (m, 2H)
Compound 38: 7-(2-Fluorophenyl)-3-(3-vinylphenyl)thieno[3,2-d]pyrimidin-4(3H)-one
[0275] In the same manner as the synthesis of Compound 1, methyl 3-amino-4-(2-fluorophenyl)thiophene-2-carboxylate (80 mg, 0.3 mmol), triethyl orthoformate (0.79 ml), 3-vinylaniline (70.6 mg, 0.59 mmol), and acetic acid (0.09 ml) were used to give 64 mg (0.18 mmol, 57.4% yield) of the title compound.
[0276] 1 H NMR (400 MHz, DMSO) δ 8.49 (s, 1H), 8.44 (s, 1H), 8.44-7.80 (m, 1H), 7.72 (s, 1H), 7.64 (d, J=7.6 Hz), 7.59-7.34 (m, 3H), 7.40-7.34 (m, 2H), 6.83 (dd, J=17.6, 10.8 Hz, 1H), 5.97 (d, J=17.6 Hz, 1H), 5.39 (d, J=10.8 Hz, 1H)
Compound 39: 3-(7-(2-Fluorophenyl)-4-oxothieno[3,2-d]pyrimidin-3(4H)-yl)benzonitrile
[0277] In the same manner as the synthesis of Compound 1, methyl 3-amino-4-(2-fluorophenyl)thiophene-2-carboxylate (80 mg, 0.3 mmol), triethyl orthoformate (0.79 ml), 3-aminobenzonitrile (70 mg, 0.59 mmol), and acetic acid (0.09 ml) were used to give 20 mg (0.06 mmol, 18.0% yield) of the title compound.
[0278] 1 H NMR (400 MHz, CDCl 3 ) δ 8.13 (s, 1H), 8.06-8.05 (m, 1H), 7.85-7.80 (m, 3H), 7.73-7.70 (m, 2H), 7.42-7.38 (m, 1H), 7.31-7.27 (m, 1H), 7.25-7.23 (m, 1H)
Compound 40: 3-(4-Chlorophenyl)-7-(3-fluorophenyl)thieno[3,2-d]pyrimidin-4(3H)-one
[0279] In the same manner as the synthesis of Compound 1, methyl 3-amino-4-(2-fluorophenyl)thiophene-2-carboxylate (50 mg, 0.2 mmol), triethyl orthoformate (0.45 ml), 4-chloroaniline (47.2 mg, 0.37 mmol), and acetic acid (0.05 ml) were used to give 52.1 mg (0.15 mmol, 73.0% yield) of the title compound.
[0280] 1 H NMR (400 MHz, DMSO) δ 8.65 (s, 1H), 8.56 (s, 1H), 7.96-7.88 (m, 2H), 7.69-7.63 (m, 4H), 7.59-7.53 (m, 1H), 7.29-7.24 (m, 1H)
Compound 41: 7-(3-Fluorophenyl)-3-(4-methoxyphenyl)thieno[3,2-d]pyrimidin-4(3H)-one
[0281] In the same manner as the synthesis of Compound 1, methyl 3-amino-4-(3-fluorophenyl)thiophene-2-carboxylate (56.2 mg, 0.22 mmol), triethyl orthoformate (0.42 ml), p-anisidine (50.5 mg, 0.41 mmol), and acetic acid (0.05 ml) were used to give 30.3 mg (0.086 mmol, 39% yield) of the title compound.
[0282] 1 H NMR (300 MHz, CDCl 3 ) δ 8.22 (s, 1H), 7.95 (s, 1H), 7.68-7.10 (m, 8H), 3.84 (s, 3H)
Compound 42: 3-(4-Chlorophenyl)-7-(4-fluorophenyl)thieno[3,2-d]pyrimidin-4(3H)-one
[0283] In the same manner as the synthesis of Compound 1, methyl 3-amino-4-(4-fluorophenyl)thiophene-2-carboxylate (80 mg, 0.32 mmol), triethyl orthoformate (2 ml), 4-chloroaniline (74.45 mg, 0.59 mmol), and acetic acid (0.08 ml) were used to give 46 mg (0.13 mmol, 40% yield) of the title compound.
[0284] 1 H NMR (300 MHz, CDCl 3 ) δ 8.52 (s, 1H), 8.45 (s, 1H), 8.08-8.03 (m, 2H), 7.66-7.61 (m, 4H), 7.61-7.32 (m, 2H)
Compound 43: 7-(4-Fluorophenyl)-3-(4-methoxyphenyl)thieno[3,2-d]pyrimidin-4(3H)-one
[0285] In the same manner as the synthesis of Compound 1, methyl 3-amino-4-(4-fluorophenyl)thiophene-2-carboxylate (80 mg, 0.32 mmol), triethyl orthoformate (2 ml), p-anisidine (72.9 mg, 0.59 mmol), and acetic acid (0.08 ml) were used to give 57 mg (0.16 mmol, 51% yield) of the title compound.
[0286] 1 H NMR (300 MHz, CDCl 3 ) δ 8.5 (s, 1H), 8.48 (s, 1H), 8.08-8.04 (m, 2H), 7.48 (d, J=8.70, 2H), 7.35 (dd, J=8.70, 9.00 Hz, 2H), 7.13 (d, J=2.1 Hz, 2H), 3.84 (s, 3H)
Compound 44: 7-(2-Chlorophenyl)-3-(4-chlorophenyl)thieno[3,2-d]pyrimidin-4(3H)-one
[0287] In the same manner as the synthesis of Compound 1, methyl 3-amino-4-(2-chlorophenyl)thiophene-2-carboxylate (100 mg, 0.373 mmol), triethyl orthoformate (2 ml), 4-chloroaniline (88.5 mg, 0.70 mmol), and acetic acid (0.1 ml) were used to give 31.3 mg (0.084 mmol, 23% yield) of the title compound.
[0288] 1 H NMR (300 MHz, CDCl 3 ) δ 8.15 (s, 1H), 7.97 (s, 1H), 7.58-7.44 (m, 4H), 7.44-7.40 (m, 4H)
Compound 45: 7-(2-Chlorophenyl)-3-(4-methoxyphenyl)thieno[3,2-d]pyrimidin-4(3H)-one
[0289] In the same manner as the synthesis of Compound 1, methyl 3-amino-4-(2-chlorophenyl)thiophene-2-carboxylate (100 mg, 0.373 mmol), triethyl orthoformate (2 ml), p-anisidine (85.56 mg, 0.70 mmol), and acetic acid (0.1 ml) were used to give 48.7 mg (0.13 mmol, 35% yield) of the title compound.
[0290] 1 H NMR (300 MHz, CDCl 3 ) δ 8.18 (s, 1H), 7.96 (s, 1H), 7.65-7.54 (m, 2H), 7.45-7.36 (m, 4H), 7.11-7.07 (m, 2H), 3.91 (s, 3H)
Compound 46: 7-(3-Chlorophenyl)-3-(4-chlorophenyl)thieno[3,2-d]pyrimidin-4(3H)-one
[0291] In the same manner as the synthesis of Compound 1, methyl 3-amino-4-(2-methoxyphenyl)thiophene-2-carboxylate (80 mg, 0.3 mmol), triethyl orthoformate (0.66 ml), 4-chloroaniline (71.2 mg, 0.56 mmol), and acetic acid (0.09 ml) were used to give 78.3 mg (0.21 mmol, 70.8% yield) of the title compound.
[0292] 1 H NMR (400 MHz, CDCl 3 ) δ 8.17 (s, 1H), 7.94 (s, 1H), 7.89-7.88 (m, 1H), 7.75-7.72 (m, 1H), 7.56-7.54 (m, 2H), 7.41-7.39 (m, 4H)
Compound 47: 7-(3-Chlorophenyl)-3-(4-methoxyphenyl)thieno[3,2-d]pyrimidin-4(3H)-one
[0293] In the same manner as the synthesis of Compound 1, methyl 3-amino-4-(3-chlorophenyl)thiophene-2-carboxylate (80 mg, 0.3 mmol), triethyl orthoformate (0.66 ml), p-anisidine (68.5 mg, 0.56 mmol), and acetic acid (0.09 ml) were used to give 84 mg (0.23 mmol, 76% yield) of the title compound.
[0294] 1 H NMR (400 MHz, CDCl 3 ) δ 8.19 (s, 1H), 7.92 (s, 1H), 7.90-7.89 (m, 1H), 7.76-7.36 (m, 1H), 7.44-7.33 (m, 4H), 7.08-7.04 (m, 2H), 3.88 (s, 3H)
Compound 48: 3,7-Bis(4-chlorophenyl)thieno[3,2-d]pyrimidin-4(3H)-one
[0295] In the same manner as the synthesis of Compound 1, methyl 3-amino-4-(4-chlorophenyl)thiophene-2-carboxylate (100 mg, 0.373 mmol), triethyl orthoformate (2 ml), 4-chloroaniline (88.5 mg, 0.70 mmol), and acetic acid (0.1 ml) were used to give 15 mg (0.04 mmol, 11% yield) of the title compound.
[0296] 1 H NMR (300 MHz, CDCl 3 ) δ 8.15 (s, 1H), 7.90 (s, 1H), 7.81-7.79 (m, 2H), 7.54 (d, J=6.3 Hz, 2H), 7.46 (d, J=6.3 Hz, 2H), 7.39 (d, J=6.9 Hz, 2H)
Compound 49: 7-(4-Chlorophenyl)-3-(4-methoxyphenyl)thieno[3,2-d]pyrimidin-4(3H)-one
[0297] In the same manner as the synthesis of Compound 1, methyl 3-amino-4-(4-chlorophenyl)thiophene-2-carboxylate (100 mg, 0.373 mmol), triethyl orthoformate (2 ml), p-anisidine (85.56 mg, 0.70 mmol), and acetic acid (0.1 ml) were used to give 97 mg (0.26 mmol, 70% yield) of the title compound.
[0298] 1 H NMR (300 MHz, CDCl 3 ) δ 8.22 (s, 1H), 7.93 (s, 1H), 7.87-7.83 (m, 2H), 7.52-7.48 (m, 2H), 7.41-7.36 (m, 2H), 7.12-7.07 (m, 2H), 3.92 (s, 3H)
Compound 50: 7-(2-Bromophenyl)-3-(4-chlorophenyl)thieno[3,2-d]pyrimidin-4(3H)-one
[0299] In the same manner as the synthesis of Compound 1, methyl 3-amino-4-(2-bromophenyl)thiophene-2-carboxylate (150 mg, 0.48 mmol), triethyl orthoformate (0.64 ml), 4-chloroaniline (75 mg, 0.59 mmol), and acetic acid (0.08 ml) were used to give 148.2 mg (0.35 mmol, 73% yield) of the title compound.
[0300] 1 H NMR (300 MHz, CDCl 3 ) δ 8.13 (s, 1H), 7.93 (s, 1H), 7.45 (d, J=8.1 Hz, 1H), 7.24-7.04 (m, 7H)
Compound 51: 7-(2-Bromophenyl)-3-(4-methoxyphenyl)thieno[3,2-d]pyrimidin-4(3H)-one
[0301] In the same manner as the synthesis of Compound 1, methyl 3-amino-4-(2-bromophenyl)thiophene-2-carboxylate (1.4 g, 4.48 mmol), triethyl orthoformate (12 ml), p-anisidine (930 mg, 8.52 mmol), and acetic acid (1.2 ml) were used to give 422 mg (1.02 mmol, 23% yield) of the title compound.
[0302] 1 H NMR (300 MHz, DMSO) δ 8.37 (s, 1H), 7.33 (s, 1H), 7.79 (d, J=5.8 Hz, 1H), 7.53-7.46 (m, 4H), 7.42-7.38 (m, 1H), 7.13-7.09 (m, 3H), 3.84 (s, 3H)
Compound 52: 7-(2-Iodophenyl)-3-(4-methoxyphenyl)thieno[3,2-d]pyrimidin-4(3H)-one
[0303] In the same manner as the synthesis of Compound 1, methyl 3-amino-4-(2-iodophenyl)thiophene-2-carboxylate (700 mg, 1.95 mmol), triethyl orthoformate (3 ml), p-anisidine (231 mg, 2.12 mmol), and acetic acid (0.3 ml) were used to give 460 mg (1.00 mmol, 51% yield) of the title compound.
[0304] 1 H NMR (400 MHz, CDCl 3 ) δ 8.37 (s, 1H), 8.28 (s, 1H), 8.02 (dd, J=8.0, 1.2 Hz, 1H), 7.54-7.46 (m, 3H), 7.42 (dd, J=7.6, 1.6 Hz, 1H), 7.21 (td, J=7.6, 1.6 Hz, 1H), 7.13-7.093 (m, 2H)
Compound 53: 3-(4-Methoxyphenyl)-7-(2-(trimethylstannyl)phenyl)thieno[3,2-d]pyrimidin-4(3H)-one
[0305] 7-(2-Iodophenyl)-3-(4-methoxyphenyl)thieno[3,2-d]pyrimidin-4(3H)-one (300 mg, 0.65 mmol), hexamethylditin (427 mg, 1.30 mmol), Pd(PPh 3 ) 4 (150 mg, 0.13 mmol), and Ag 2 O (302 mg, 1.30 mmol) were dissolved in dry toluene (4 ml) in a reaction vessel. The oxygen content of the mixture was maximized using argon gas and an aspirator. Thereafter, the mixture was stirred at 100° C. for 16 hr. After completion of the reaction, the reaction mixture was cooled to room temperature and purified by silica gel column chromatography (EtOAc:Hex=1:3) to give 200 mg (0.40 mmol, 62% yield) of the title compound.
[0306] 1 H NMR (400 MHz, CDCl 3 ) δ 8.38 (s, 1H), 8.13 (s, 1H), 7.61-7.59 (m, 1H), 7.48-7.38 (m, 5H), 7.13-7.11 (m, 2H), 3.85 (s, 3H), 0.00 (quint, J=27.6 Hz, 9H)
Compound 54: 3-(4-Chlorophenyl)-7-(o-tolyl)thieno[3,2-d]pyrimidin-4(3H)-one
[0307] In the same manner as the synthesis of Compound 1, methyl 3-amino-4-(o-tolyl)thiophene-2-carboxylate (80 mg, 0.32 mmol), triethyl orthoformate (0.7 ml), 4-chloroaniline (76.8 mg, 0.6 mmol), and acetic acid (0.1 ml) were used to give 33.5 mg (0.09 mmol, 28.4% yield) of the title compound.
[0308] 1 H NMR (400 MHz, CDCl 3 ) δ 8.09 (s, 1H), 7.73 (s, 1H), 7.54-7.52 (m, 2H), 7.40-7.38 (m, 2H), 7.35-7.31 (m, 4H), 2.28 (s, 3H)
Compound 55: 3-(4-Methoxyphenyl)-7-(o-tolyl)thieno[3,2-d]pyrimidin-4(3H)-one
[0309] In the same manner as the synthesis of Compound 1, methyl 3-amino-4-(o-tolyl)thiophene-2-carboxylate (100 mg, 0.4 mmol), triethyl orthoformate (0.88 ml), p-anisidine (92.6 mg, 0.75 mmol), and acetic acid (0.13 ml) were used to give 83.2 mg (0.24 mmol, 60% yield) of the title compound.
[0310] 1 H NMR (400 MHz, CDCl 3 ) δ 8.11 (s, 1H), 7.70 (s, 1H), 7.36-7.30 (m, 6H), 7.04 (d, J=2 Hz, 2H), 3.87 (s, 3H), 2.28 (s, 3H)
Compound 56: 3-(4-Chlorophenyl)-7-(m-tolyl)thieno[3,2-d]pyrimidin-4(3H)-one
[0311] In the same manner as the synthesis of Compound 1, methyl 3-amino-4-(m-tolyl)thiophene-2-carboxylate (80 mg, 0.32 mmol), triethyl orthoformate (0.7 ml), 4-chloroaniline (76.8 mg, 0.6 mmol), and acetic acid (0.1 ml) were used to give 85.1 mg (0.23 mmol, 72.1% yield) of the title compound.
[0312] 1 H NMR (300 MHz, CDCl 3 ) δ 8.15 (s, 1H), 7.88 (s, 1H), 7.63-7.61 (m, 2H), 7.55-7.51 (m, 2H), 7.41-7.35 (m, 3H), 2.44 (s, 3H)
Compound 57: 3-(4-Methoxyphenyl)-7-(m-tolyl)thieno[3,2-d]pyrimidin-4(3H)-one
[0313] In the same manner as the synthesis of Compound 1, methyl 3-amino-4-(m-tolyl)thiophene-2-carboxylate (80 mg, 0.32 mmol), triethyl orthoformate (0.7 ml), p-anisidine (74.1 mg, 0.6 mmol), and acetic acid (0.1 ml) were used to give 36.5 mg (0.11 mmol, 32.7% yield) of the title compound.
[0314] 1 H NMR (300 MHz, CDCl 3 ) δ 8.17 (s, 1H), 7.86 (s, 1H), 7.63-7.62 (m, 2H), 7.37-7.33 (m, 3H), 7.22-7.20 (m, 1H), 7.06-7.03 (m, 2H), 3.87 (s, 3H), 2.44 (s, 3H)
Compound 58: 3-(4-Chlorophenyl)-7-(p-tolyl)thieno[3,2-d]pyrimidin-4(3H)-one
[0315] In the same manner as the synthesis of Compound 1, methyl 3-amino-4-(p-tolyl)thiophene-2-carboxylate (100 mg, 0.40 mmol), triethyl orthoformate (1 ml), 4-chloroaniline (94.4 mg, 0.74 mmol), and acetic acid (0.1 ml) were used to give 48 mg (0.14 mmol, 35% yield) of the title compound.
[0316] 1 H NMR (300 MHz, CDCl 3 ) δ 8.19 (s, 1H), 7.90 (s, 1H), 7.78 (d, J=8.1 Hz, 2H), 7.59-7.56 (m, 2H), 7.46-7.42 (m, 2H), 7.35-7.30 (m, 2H), 2.46 (s, 3H)
Compound 59: 3-(4-Methoxyphenyl)-7-(p-tolyl)thieno[3,2-d]pyrimidin-4(3H)-one
[0317] In the same manner as the synthesis of Compound 1, methyl 3-amino-4-(p-tolyl)thiophene-2-carboxylate (100 mg, 0.40 mmol), triethyl orthoformate (1 ml), p-anisidine (91.63 mg, 0.74 mmol), and acetic acid (0.1 ml) were used to give 98.3 mg (0.28 mmol, 70% yield) of the title compound.
[0318] 1 H NMR (300 MHz, CDCl 3 ) δ 8.21 (s, 1H), 7.88 (s, 1H), 7.78-7.75 (m, 2H), 7.41-7.33 (m, 4H), 7.11-7.08 (m, 2H), 3.92 (s, 3H), 2.45 (s, 3H)
Compound 60: 3-(4-Chlorophenyl)-7-(2-methoxyphenyl)thieno[3,2-d]pyrimidin-4(3H)-one
[0319] In the same manner as the synthesis of Compound 1, methyl 3-amino-4-(2-methoxyphenyl)thiophene-2-carboxylate (50 mg, 0.21 mmol), triethyl orthoformate (0.41 ml), 4-chloroaniline (45.05 mg, 0.35 mmol), and acetic acid (0.05 ml) were used to give 49.4 mg (0.13 mmol, 70.5% yield) of the title compound.
[0320] 1 H NMR (300 MHz, CDCl 3 ) δ 8.12 (s, 1H), 8.01 (s, 1H), 7.65-7.62 (m, 1H), 7.55-7.51 (m, 2H), 7.43-7.37 (m, 3H), 7.12-7.04 (m, 2H), 3.85 (s, 1H)
Compound 61: 7-(2-Methoxyphenyl)-3-(4-methoxyphenyl)thieno[3,2-d]pyrimidin-4(3H)-one
[0321] In the same manner as the synthesis of Compound 1, methyl 3-amino-4-(2-methoxyphenyl)thiophene-2-carboxylate (40 mg, 0.15 mmol), triethyl orthoformate (0.33 ml), p-anisidine (34.8 mg, 0.28 mmol), and acetic acid (0.04 ml) were used to give 31 mg (0.09 mmol, 56.7% yield) of the title compound.
[0322] 1 H NMR (400 MHz, CDCl 3 ) δ 8.14 (s, 1H), 7.99 (s, 1H), 7.65 (dd, J=7.6, 1.6 Hz, 1H) 7.41-7.33 (m, 3H), 7.11-7.03 (m, 4H), 3.87 (s, 3H), 3.85 (s, 3H)
Compound 62: 3-(4-Chlorophenyl)-7-(3-methoxyphenyl)thieno[3,2-d]pyrimidin-4(3H)-one
[0323] In the same manner as the synthesis of Compound 1, methyl 3-amino-4-(3-methoxyphenyl)thiophene-2-carboxylate (80 mg, 0.3 mmol), triethyl orthoformate (0.66 ml), 4-chloroaniline (72.1 mg, 0.57 mmol), and acetic acid (0.08 ml) were used to give 13.2 mg (0.04 mmol, 11.9% yield) of the title compound.
[0324] 1 H NMR (400 MHz, CDCl 3 ) δ 8.16 (s, 1H), 7.92 (s, 1H), 7.54 (dd, J=6.8, 2 Hz, 2H), 7.43-7.39 (m, 3H), 6.96-6.94 (m, 1H), 3.88 (s, 3H)
Compound 63: 7-(3-Methoxyphenyl)-3-(4-methoxyphenyl)thieno[3,2-d]pyrimidin-4(3H)-one
[0325] In the same manner as the synthesis of Compound 1, methyl 3-amino-4-(3-methoxyphenyl)thiophene-2-carboxylate (80 mg, 0.3 mmol), triethyl orthoformate (0.66 ml), p-anisidine (70.2 mg, 0.57 mmol), and acetic acid (0.08 ml) were used to give 56 mg (0.15 mmol, 51.2% yield) of the title compound.
[0326] 1 H NMR (400 MHz, CDCl 3 ) δ 8.18 (s, 1H), 7.89 (s, 1H), 7.44-7.40 (m, 3H), 7.36-7.34 (m, 2H), 7.06-7.04 (m, 2H), 6.98-6.93 (m, 1H), 3.88 (s, 6H)
Compound 64: 3-(4-Chlorophenyl)-7-(4-methoxyphenyl)thieno[3,2-d]pyrimidin-4(3H)-one
[0327] In the same manner as the synthesis of Compound 1, methyl 3-amino-4-(4-methoxyphenyl)thiophene-2-carboxylate (80 mg, 0.3 mmol), triethyl orthoformate (0.66 ml), 4-chloroaniline (71.2 mg, 0.56 mmol), and acetic acid (0.08 ml) were used to give 96.2 mg (0.26 mmol, 86.9% yield) of the title compound.
[0328] 1 H NMR (400 MHz, CDCl 3 ) δ 8.15 (s, 1H), 7.82 (s, 1H), 7.77 (d, J=8.8 Hz, 2H), 7.54 (d, J=8.8 Hz, 2H), 7.39 (d, J=8.8 Hz, 2H), 7.02 (d, J=8.8 Hz, 2H), 3.86 (s, 3H)
Compound 65: 3,7-Bis(4-methoxyphenyl)thieno[3,2-d]pyrimidin-4(3H)-one
[0329] In the same manner as the synthesis of Compound 1, methyl 3-amino-4-(4-methoxyphenyl)thiophene-2-carboxylate (80 mg, 0.3 mmol), triethyl orthoformate (0.66 ml), p-anisidine (70.2 mg, 0.57 mmol), and acetic acid (0.08 ml) were used to give 95.7 mg (0.26 mmol, 87.5% yield) of the title compound.
[0330] 1 H NMR (400 MHz, CDCl 3 ) δ 8.47 (s, 1H), 8.39 (s, 1H), 7.97 (d, J=8.8 Hz, 2H), 7.5 (d, J=8.8 Hz, 2H), 7.13 (d, J=8.8 Hz, 2H), 7.07 (d, J=8.8 Hz, 2H), 3.85 (s, 3H), 3.83 (s, 3H)
Compound 66: 3-(4-Chlorophenyl)-7-(3,4-dimethoxyphenyl)thieno[3,2-d]pyrimidin-4(3H)-one
[0331] In the same manner as the synthesis of Compound 1, methyl 3-amino-4-(3,4-dimethoxyphenyl)thiophene-2-carboxylate (30 mg, 0.13 mmol), triethyl orthoformate (0.31 ml), 4-chloroaniline (29.7 mg, 0.23 mmol), and acetic acid (0.04 ml) were used to give 14.5 mg (0.04 mmol, 28% yield) of the title compound.
[0332] 1 H NMR (400 MHz, CDCl 3 ) δ 8.16 (s, 1H), 7.85 (s, 1H), 7.55-7.53 (m, 2H), 7.47 (d, J=8 Hz, 4H), 7.00 (d, J=8 Hz, 2H), 3.95 (d, J=8 Hz, 6H)
Compound 67: 7-(3,4-Dimethoxyphenyl)-3-(4-methoxyphenyl)thieno[3,2-d]pyrimidin-4(3H)-one
[0333] In the same manner as the synthesis of Compound 1, methyl 3-amino-4-(3,4-dimethoxyphenyl)thiophene-2-carboxylate (80 mg, 0.27 mmol), triethyl orthoformate (0.6 ml), 4-chloroaniline (62.5 mg, 0.51 mmol), and acetic acid (0.09 ml) were used to give 14.5 mg (0.04 mmol, 28% yield) of the title compound.
[0334] 1 H NMR (400 MHz, CDCl 3 ) δ 8.18 (s, 1H), 7.82 (s, 1H), 7.43-7.39 (m, 2H), 7.35 (dd, J=6.8, 2 Hz, 2H), 7.05 (dd, J=6.8, 2 Hz, 2H), 6.99 (d, J=8 Hz, 1H), 3.97 (d, J=9.6 Hz, 6H), 3.88 (s, 3H)
Compound 68: 7-(Benzo[d][1,3]dioxol-5-yl)-3-(4-chlorophenyl)thieno[3,2-d]pyrimidin-4(3H)-one
[0335] In the same manner as the synthesis of Compound 1, methyl 3-amino-4-(benzo[d][1,3]dioxol-5-yl)thiophene-2-carboxylate (60 mg, 0.21 mmol), triethyl orthoformate (0.48 ml), 4-chloroaniline (51.0 mg, 0.4 mmol), and acetic acid (0.06 ml) were used to give 47.3 mg (0.17 mmol, 79.5% yield) of the title compound.
[0336] 1 H NMR (300 MHz, CDCl 3 ) δ 8.14 (s, 1H), 8.13 (s, 1H), 7.55-7.52 (m, 2H), 7.41-7.35 (m, 3H), 7.03 (d, J=10.4 Hz, 1H), 6.93 (d, J=10.8 Hz, 1H), 6.02 (s, 2H)
Compound 69: 7-(Benzo[d][1,3]dioxol-5-yl)-3-(4-methoxyphenyl)thieno[3,2-d]pyrimidin-4(3H)-one
[0337] In the same manner as the synthesis of Compound 1, methyl 3-amino-4-(benzo[d][1,3]dioxol-5-yl)thiophene-2-carboxylate (60 mg, 0.21 mmol), triethyl orthoformate (0.46 ml), p-anisidine (49.6 mg, 0.4 mmol), and acetic acid (0.06 ml) were used to give 52.4 mg (0.14 mmol, 65.2% yield) of the title compound.
[0338] 1 H NMR (400 MHz, DMSO) δ 8.47 (s, 1H), 8.42 (s, 1H), 7.60-7.56 (m, 2H), 7.30 (dd, J=146.6, 8.86 Hz, 4H), 7.05 (d, J=8.08 Hz, 1H), 6.09 (s, 2H), 3.84 (s, 3H)
Compound 70: 3-(4-Chlorophenyl)-7-(naphthalen-1-yl)thieno[3,2-d]pyrimidin-4(3H)-one
[0339] In the same manner as the synthesis of Compound 1, methyl 3-amino-4-(naphthalen-1-yl)thiophene-2-carboxylate (43.8 mg, 0.15 mmol), triethyl orthoformate (0.32 ml), 4-chloroaniline (44.3 mg, 0.4 mmol), and acetic acid (0.04 ml) were used to give 27 mg (0.07 mmol, 46.3% yield) of the title compound.
[0340] 1 H NMR (300 MHz, CDCl 3 ) δ 8.05 (s, 1H), 7.95-7.91 (m, 3H), 7.74 (d, J=12 Hz, 1H), 7.61-7.38 (m, 8H)
Compound 71: 3-(4-Methoxyphenyl)-7-(naphthalen-1-yl)thieno[3,2-d]pyrimidin-4(3H)-one
[0341] In the same manner as the synthesis of Compound 1, methyl 3-amino-4-(naphthalen-1-yl)thiophene-2-carboxylate (60 mg, 0.21 mmol), triethyl orthoformate (0.46 ml), p-anisidine (48.5 mg, 0.39 mmol), and acetic acid (0.06 ml) were used to give 42.8 mg (0.12 mmol, 58.5% yield) of the title compound.
[0342] 1 H NMR (300 MHz, CDCl 3 ) δ 8.01 (s, 1H), 7.96-7.92 (m, 2H), 7.89 (s, 1H), 7.76 (d, J=8 Hz, 1H) 7.62-7.37 (m, 4H), 7.35-7.33 (m, 2H), 7.07-7.02 (m, 2H), 3.87 (s, 3H)
Compound 72: 3-(4-Chlorophenyl)-7-(naphthalen-2-yl)thieno[3,2-d]pyrimidin-4(3H)-one
[0343] In the same manner as the synthesis of Compound 1, methyl 3-amino-4-(naphthalen-2-yl)thiophene-2-carboxylate (43.8 mg, 0.15 mmol), triethyl orthoformate (0.32 ml), 4-chloroaniline (36.7 mg, 0.28 mmol), and acetic acid (0.04 ml) were used to give 100 mg (0.26 mmol, 92% yield) of the title compound.
[0344] 1 H NMR (300 MHz, CDCl 3 ) δ 8.37 (s, 1H), 8.13 (s, 1H), 7.96-7.85 (m, 5H), 7.52-7.48 (m, 4H), 7.38-7.35 (m, 2H)
Compound 73: 3-(4-Methoxyphenyl)-7-(naphthalen-2-yl)thieno[3,2-d]pyrimidin-4(3H)-one
[0345] In the same manner as the synthesis of Compound 1, methyl 3-amino-4-(naphthalen-2-yl)thiophene-2-carboxylate (80 mg, 0.28 mmol), triethyl orthoformate (0.62 ml), p-anisidine (64.7 mg, 0.53 mmol), and acetic acid (0.08 ml) were used to give 36.5 mg (0.1 mmol, 33.9% yield) of the title compound.
[0346] 1 H NMR (400 MHz, CDCl 3 ) δ 8.40 (s, 1H), 8.23 (s, 1H), 8.01 (s, 1H), 7.95-7.87 (m, 4H), 7.53-7.51 (m, 3H), 7.37 (d, J=8.8 Hz, 2H), 7.01 (d, J=8.8 Hz, 2H), 3.89 (s, 3H)
Compound 74: 3-(4-Methoxyphenyl)-2-methyl-7-phenylthieno[3,2-d]pyrimidin-4(3H)-one
[0347] 3-Amino-N-(4-methoxyphenyl)-4-phenylthiophene-2-carboxamide (57 mg, 0.18 mmol), triethyl orthoacetate (1 ml), and acetic acid (0.1 ml) were placed in a pressure bottle. The mixture was heated with stiffing at 160° C. for 18 hr. After the completion of the reaction was confirmed by TLC, the reaction mixture was cooled to room temperature and solidified with diethyl ether and EtOAc to give 13 mg (0.037 mmol, 21% yield) of the title compound.
[0348] 1 H NMR (300 MHz, DMSO) δ 8.43 (s, 1H), 8.01 (d, J=7.5 Hz, 2H), 7.52-7.37 (m, 5H), 7.11 (d, J=8.7 Hz, 2H) 3.84 (s, 3H), 2.19 (s, 3H)
Compound 75: 3-(4-Chlorophenyl)-7-phenylthieno[3,2-d]pyrimidin-2,4(1H,3H)-dione
[0349] Methyl 3-amino-4-phenylthiophene-2-carboxylate (400 mg, 1.71 mmol), triethylamine (0.04 ml, 0.43 mmol), and 4-chlorophenyl isocyanate (0.39 ml, 3.16 mmol) were dissolved in 1,4-dioxane (10 ml) in a reaction vessel. The mixture was heated with stirring at 90° C. for 3 days. After the completion of the reaction was confirmed by TLC, the reaction mixture was cooled to room temperature and filtered. The filtered solid was dissolved in a 10% sodium hydroxide/methanol (3 ml/12 ml) solution and refluxed with stirring at 100° C. overnight. After completion of the reaction, the reaction solution was cooled to room temperature, acidified with 3 N hydrochloric acid, and filtered to give 548 mg (1.54 mmol, 90% yield) of the title compound as a solid.
[0350] 1 H NMR (300 MHz, CDCl 3 ) δ 7.74 (s, 1H), 7.65 (s, 1H), 7.45-7.61 (m, 7H), 7.27-7.30 (m, 2H)
[0000]
Compound 76: 3-(4-Chlorophenyl)-2-(dimethylamino)-7-phenylthieno[3,2-d]pyrimidin-4(3H)-one
[0351] 3-(4-Chlorophenyl)-7-phenylthieno[3,2-d]pyrimidin-2,4(1H,3H)-dione (100 mg, 0.3 mmol), N,N-diethylaniline (0.014 ml, 0.09 mmol), and phosphoryl chloride (0.34 ml, 3.6 mmol) were placed in a reaction vessel. The mixture was heated with stirring at 130° C. overnight. After the completion of the reaction was confirmed by TLC, the reaction mixture was cooled to room temperature and separated with NaHCO 3 and dichloromethane. The extracted organic layer was washed with brine, dried over anhydrous MgSO 4 , and filtered. The filtrate was distilled under reduced pressure. The concentrate was purified by silica gel column chromatography (EtOAc:Hex=1:5) to give 2-chloro-3-(4-chlorophenyl)-7-phenyl-2,3-dihydrothieno[3,2-d]pyrimidin-4(1H)-one (22.7 mg, 0.06 mmol, 20% yield).
[0352] The thus synthesized compound 2-chloro-3-(4-chlorophenyl)-7-phenyl-2,3-dihydrothieno[3,2-d]pyrimidin-4(1H)-one (22.7 mg, 0.06 mmol) was mixed with a solution of N,N-dimethylamine (3 ml) and diisopropylethylamine (0.01 ml, 0.06 mmol) in THF. The mixture was heated with stirring at 65° C. overnight. After the completion of the reaction was confirmed by TLC, the reaction mixture was cooled to room temperature and separated with water and dichloromethane. The extracted organic layer was washed with brine, dried over anhydrous MgSO 4 , and filtered. The filtrate was distilled under reduced pressure. The concentrate was purified by silica gel column chromatography (EtOAc:Hex=1:5) to give 14.1 mg (0.037 mmol, 62% yield) of the title compound.
[0353] 1 H NMR (300 MHz, CDCl 3 ) δ 8.00-7.97 (m, 2H), 7.84 (s, 1H), 7.52-7.30 (m, 8H), 2.69 (s, 6H)
Compound 77: 3-Butyl-7-phenylthieno[3,2-d]pyrimidin-4(3H)-one
[0354] In the same manner as the synthesis of Compound 1, methyl 3-amino-4-phenylthiophene-2-carboxylate (100 mg, 0.43 mmol), triethyl orthoformate (1.0 ml), n-butylamine (0.097 ml, 0.99 mmol), and acetic acid (0.1 ml) were used to give 92 mg (0.32 mmol, 75.2% yield) of the title compound.
[0355] 1 H NMR (400 MHz, CDCl 3 ) δ 8.10 (s, 1H), 7.82-7.79 (m, 3H), 7.49-7.56 (m, 2H), 7.40-7.36 (m, 1H), 4.07 (t, J=7.3 Hz, 2H), 1.84-1.76 (m, 2H), 1.42 (sextet, J=7.5 Hz, 2H), 0.97 (t, J=7.4 Hz, 3H)
Compound 78: 3-Allyl-7-phenylthieno[3,2-d]pyrimidin-4(3H)-one
[0356] In the same manner as the synthesis of Compound 1, methyl 3-amino-4-phenylthiophene-2-carboxylate (100 mg, 0.43 mmol), triethyl orthoformate (1.0 ml), allylamine hydrochloride (92.6 mg, 0.99 mmol), and acetic acid (0.1 ml) were used to give 66.4 mg (0.25 mmol, 57.5% yield) of the title compound.
[0357] 1 H NMR (300 MHz, CDCl 3 ) δ 8.11 (s, 1H), 7.84-7.79 (m, 3H), 7.50-7.44 (m, 2H), 7.41-7.36 (m, 1H), 6.08-5.95 (m, 1H), 5.34-5.24 (m, 2H), 4.72-4.67 (m, 2H)
Compound 79: 3-Cyclobutyl-7-phenylthieno[3,2-d]pyrimidin-4(3H)-one
[0358] In the same manner as the synthesis of Compound 1, methyl 3-amino-4-phenylthiophene-2-carboxylate (100 mg, 0.43 mmol), triethyl orthoformate (1.0 ml), cyclobutylamine (0.084 ml, 0.99 mmol), and acetic acid (0.1 ml) were used to give 83.9 mg (0.30 mmol, 69.1% yield) of the title compound.
[0359] 1 H NMR (400 MHz, CDCl 3 ) δ 8.27 (s, 1H), 7.82-7.79 (m, 3H), 7.49-7.45 (m, 2H), 7.40-7.36 (m, 1H), 5.17-5.09 (m, 1H), 2.63-2.56 (m, 2H), 2.44-2.32 (m, 2H), 1.99-1.91 (m, 2H)
Compound 80: 3-Cyclopentyl-7-phenylthieno[3,2-d]pyrimidin-4(3H)-one
[0360] In the same manner as the synthesis of Compound 1, methyl 3-amino-4-phenylthiophene-2-carboxylate (100 mg, 0.43 mmol), triethyl orthoformate (1.0 ml), cyclopentylamine (0.080 ml, 0.81 mmol), and acetic acid (0.1 ml) were used to give 108.3 mg (0.37 mmol, 85% yield) of the title compound.
[0361] 1 H NMR (400 MHz, CDCl 3 ) δ 8.21 (s, 1H), 7.82-7.79 (m, 3H), 7.49-7.45 (m, 2H), 7.40-7.36 (m, 1H), 5.30-5.23 (m, 1H), 2.31-2.22 (m, 2H), 1.99-1.75 (m, 6H), 1.57-1.54 (m, 2H)
Compound 81: 3-Cyclohexyl-7-phenylthieno[3,2-d]pyrimidin-4(3H)-one
[0362] In the same manner as the synthesis of Compound 1, methyl 3-amino-4-phenylthiophene-2-carboxylate (100 mg, 0.43 mmol), triethyl orthoformate (1.0 ml), cyclohexylamine (0.113 ml, 0.99 mmol), and acetic acid (0.1 ml) were used to give 109.7 mg (0.35 mmol, 82.2% yield) of the title compound.
[0363] 1 H NMR (400 MHz, CDCl 3 ) δ 8.20 (s, 1H), 7.82-7.79 (m, 3H), 7.49-7.44 (m, 2H), 7.40-7.36 (m, 1H), 4.91-4.84 (m, 1H), 2.05 (d, J=12.0 Hz, 2H), 1.95 (d, J=13.2 Hz, 2H), 1.81-1.78 (m, 1H), 1.68-1.48 (m, 4H), 1.32-1.21 (m, 1H)
Compound 82: 3-Cyclooctyl-7-phenylthieno[3,2-d]pyrimidin-4(3H)-one
[0364] In the same manner as the synthesis of Compound 1, methyl 3-amino-4-phenylthiophene-2-carboxylate (100 mg, 0.43 mmol), triethyl orthoformate (1.0 ml), cyclooctylamine (0.113 ml, 0.81 mmol), and acetic acid (0.1 ml) were used to give 82.9 mg (0.24 mmol, 57% yield) of the title compound.
[0365] 1 H NMR (400 MHz, CDCl 3 ) δ 8.19 (s, 1H), 7.82-7.79 (m, 3H), 7.49-7.44 (m, 2H), 7.40-7.36 (m, 1H), 5.17-5.10 (m, 1H), 2.04-1.94 (m, 4H), 1.87-1.83 (m, 2H), 1.74-1.60 (m, 8H)
Compound 83: 3-(Cyclopropylmethyl)-7-phenylthieno[3,2-d]pyrimidin-4(3H)-one
[0366] In the same manner as the synthesis of Compound 1, methyl 3-amino-4-phenylthiophene-2-carboxylate (100 mg, 0.43 mmol), triethyl orthoformate (1.0 ml), cyclopropanemethylamine (0.086 ml, 0.99 mmol), and acetic acid (0.1 ml) were used to give 76 mg (0.27 mmol, 62.6% yield) of the title compound.
[0367] 1 H NMR (400 MHz, CDCl 3 ) δ 8.19 (s, 1H), 7.83-7.79 (m, 3H), 7.49-7.45 (m, 2H), 7.40-7.36 (m, 1H), 3.93 (d, J=7.2 Hz, 2H), 1.37-1.25 (m, 1H), 0.71-0.59 (m, 2H), 0.50-0.39 (m, 2H)
Compound 84: 3-(Cyclohexylmethyl)-7-phenylthieno[3,2-d]pyrimidin-4(3H)-one
[0368] In the same manner as the synthesis of Compound 1, methyl 3-amino-4-phenylthiophene-2-carboxylate (100 mg, 0.43 mmol), triethyl orthoformate (1.0 ml), cyclohexanemethylamine (0.129 ml, 0.99 mmol), and acetic acid (0.1 ml) were used to give 102.3 mg (0.32 mmol, 73.3% yield) of the title compound.
[0369] 1 H NMR (400 MHz, CDCl 3 ) δ 8.04 (s, 1H), 7.82-7.79 (m, 3H), 7.49-7.45 (m, 2H), 7.40-7.36 (m, 1H), 3.77 (d, J=7.3 Hz, 2H), 1.95-1.84 (m, 1H), 1.74-1.67 (m, 5H), 1.29-1.12 (m, 3H), 1.07-0.98 (m, 2H)
Compound 85: 3-((1R,4R)-4-methylcyclohexyl)-7-phenylthieno[3,2-d]pyrimidin-4(3H)-one
[0370] In the same manner as the synthesis of Compound 1, methyl 3-amino-4-phenylthiophene-2-carboxylate (76 mg, 0.33 mmol), triethyl orthoformate (1.0 ml), trans-4-methylcyclohexylamine (0.1 ml, 0.76 mmol), and acetic acid (0.1 ml) were used to give 53.9 mg (0.17 mmol, 50.3% yield) of the title compound.
[0371] 1 H NMR (400 MHz, CDCl 3 ) δ 8.20 (s, 1H), 7.84-7.79 (m, 3H), 7.49-7.45 (m, 2H), 7.40-7.36 (m, 1H), 4.90-4.82 (m, 1H), 2.05-2.01 (m, 2H), 1.92-1.88 (m, 2H), 1.75-1.64 (m, 2H), 1.55-1.44 (m, 1H), 1.31-1.21 (m, 2H), 0.98 (d, J=6.5 Hz, 3H)
Compound 86: 7-Phenyl-3-(tetrahydro-2H-pyran-4-yl)thieno[3,2-d]pyrimidin-4(3H)-one
[0372] In the same manner as the synthesis of Compound 1, methyl 3-amino-4-phenylthiophene-2-carboxylate (100 mg, 0.43 mmol), triethyl orthoformate (1.0 ml), 4-aminotetrahydropyrane (0.102 ml, 0.99 mmol), and acetic acid (0.1 ml) were used to give 76.7 mg (0.25 mmol, 57.1% yield) of the title compound.
[0373] 1 H NMR (400 MHz, CDCl 3 ) δ 8.22 (s, 1H), 7.85 (s, 1H), 7.82-7.79 (m, 2H), 7.50-7.46 (m, 2H), 7.41-7.37 (m, 1H), 5.21-5.13 (m, 1H), 4.18-4.14 (m, 2H), 3.63 (td, J=11.4, 2.7 Hz, 2H), 2.08-1.96 (m, 4H)
Compound 87: (R)-7-phenyl-3-(1,2,3,4-tetrahydronaphthalen-1-yl)thieno[3,2-d]pyrimidin-4(3H)-one
[0374] In the same manner as the synthesis of Compound 1, methyl 3-amino-4-phenylthiophene-2-carboxylate (100 mg, 0.43 mmol), triethyl orthoformate (1.0 ml), (R)-1,2,3,4-tetrahydronaphthalen-1-amine (0.141 ml, 0.99 mmol), and acetic acid (0.1 ml) were used to give 73.3 mg (0.20 mmol, 47.6% yield) of the title compound.
[0375] 1 H NMR (400 MHz, CDCl 3 ) δ 7.86 (s, 1H), 7.81-7.77 (m, 3H), 7.46-7.41 (m, 2H), 7.37-7.33 (m, 1H), 7.24-7.20 (m, 2H), 7.17-7.13 (m, 1H), 6.99-6.97 (m, 1H), 6.29 (t, J=6.0 Hz, 1H), 3.01-2.84 (m, 2H), 2.37-2.28 (m, 1H), 2.13-2.05 (m, 1H), 1.98-1.85 (m, 2H)
Compound 88: (S)-7-phenyl-3-(1,2,3,4-tetrahydro naphthalen-1-yl)thieno[3,2-d]pyrimidin-4(3H)-one
[0376] In the same manner as the synthesis of Compound 1, methyl 3-amino-4-phenylthiophene-2-carboxylate (100 mg, 0.43 mmol), triethyl orthoformate (1.0 ml), (S)-1,2,3,4-tetrahydronaphthalen-1-amine (0.141 ml, 0.99 mmol), and acetic acid (0.1 ml) were used to give 82.1 mg (0.23 mmol, 53.3% yield) of the title compound.
[0377] 1 H NMR (400 MHz, CDCl 3 ) δ 7.87 (s, 1H), 7.81-7.77 (m, 3H), 7.46-7.41 (m, 2H), 7.37-7.33 (m, 1H), 7.26-7.20 (m, 2H), 7.17-7.13 (m, 1H), 6.98-6.97 (m, 1H), 6.29 (t, J=6.0 Hz, 1H), 3.01-2.84 (m, 2H), 2.36-2.28 (m, 1H), 2.13-2.04 (m, 1H), 1.97-1.85 (m, 2H)
Compound 89: (S)-7-phenyl-3-((tetrahydrofuran-2-yl)methyl)thieno[3,2-d]pyrimidin-4(3H)-one
[0378] In the same manner as the synthesis of Compound 1, methyl 3-amino-4-phenylthiophene-2-carboxylate (100 mg, 0.43 mmol), triethyl orthoformate (1.0 ml), (S)-(tetrahydrofuran-2-yl)methanamine (0.102 ml, 0.99 mmol), and acetic acid (0.1 ml) were used to give 90.1 mg (0.29 mmol, 67.1% yield) of the title compound.
[0379] 1 H NMR (400 MHz, CDCl 3 ) δ 8.25 (s, 1H), 7.83-7.80 (m, 3H), 7.49-7.46 (m, 2H), 7.40-7.36 (m, 1H), 4.42 (dd, J=10.3, 2.8 Hz, 1H), 4.27-4.21 (m, 1H), 3.96-3.73 (m, 3H), 2.17-2.07 (m, 1H), 1.97-1.83 (m, 2H), 1.67-1.58 (m, 1H)
Compound 90: (R)-7-phenyl-3-((tetrahydrofuran-2-yl)methyl)thieno[3,2-d]pyrimidin-4(3H)-one
[0380] In the same manner as the synthesis of Compound 1, methyl 3-amino-4-phenylthiophene-2-carboxylate (100 mg, 0.43 mmol), triethyl orthoformate (1.0 ml), (R)-(tetrahydrofuran-2-yl)methanamine (0.102 ml, 0.99 mmol), and acetic acid (0.1 ml) were used to give 97.3 mg (0.31 mmol, 72.4% yield) of the title compound.
[0381] 1 H NMR (400 MHz, CDCl 3 ) δ 8.25 (s, 1H), 7.83-7.80 (m, 3H), 7.49-7.45 (m, 2H), 7.40-7.36 (m, 1H), 4.42 (dd, J=10.4, 2.8 Hz, 1H), 4.27-4.21 (m, 1H), 3.96-3.73 (m, 3H), 2.17-2.07 (m, 1H), 1.97-1.82 (m, 2H), 1.67-1.58 (m, 1H)
Compound 91: 3-(1-Methylpiperidin-4-yl)-7-phenylthieno[3,2-d]pyrimidin-4(3H)-one
[0382] In the same manner as the synthesis of Compound 1, methyl 3-amino-4-phenylthiophene-2-carboxylate (100 mg, 0.43 mmol), triethyl orthoformate (1.0 ml), 1-methylpiperidin-4-amine (0.124 ml, 0.99 mmol), and acetic acid (0.1 ml) were used to give 47.3 mg (0.15 mmol, 33.8% yield) of the title compound.
[0383] 1 H NMR (400 MHz, CDCl 3 ) δ 8.24 (s, 1H), 7.83-7.78 (m, 3H), 7.49-7.45 (m, 2H), 7.40-7.36 (m, 1H), 4.98-4.90 (m, 1H), 3.03 (d, J=12.2 Hz, 2H), 2.36 (s, 3H), 2.27-2.20 (m, 2H), 2.03-1.98 (m, 4H)
Compound 92: 3-Isobutyl-7-phenylthieno[3,2-d]pyrimidin-4(3H)-one
[0384] In the same manner as the synthesis of Compound 1, methyl 3-amino-4-phenylthiophene-2-carboxylate (100 mg, 0.43 mmol), triethyl orthoformate (1.0 ml), isobutylamine (0.099 ml, 0.99 mmol), and acetic acid (0.1 ml) were used to give 69.7 mg (0.25 mmol, 57% yield) of the title compound.
[0385] 1 H NMR (400 MHz, CDCl 3 ) δ 8.06 (s, 1H), 7.83-7.80 (m, 3H), 7.50-7.46 (m, 2H), 7.41-7.36 (m, 1H), 3.87 (d, J=7.3 Hz, 2H), 2.31-2.17 (m, 1H), 1.00 (d, J=6.7 Hz, 6H)
Compound 93: 3-Neopentyl-7-phenylthieno[3,2-d]pyrimidin-4(3H)-one
[0386] In the same manner as the synthesis of Compound 1, methyl 3-amino-4-phenylthiophene-2-carboxylate (100 mg, 0.43 mmol), triethyl orthoformate (1.0 ml), neopentylamine (0.117 ml, 0.99 mmol), and acetic acid (0.1 ml) were used to give 45.8 mg (0.15 mmol, 35.7% yield) of the title compound.
[0387] 1 H NMR (400 MHz, CDCl 3 ) δ 8.09 (s, 1H), 7.83-7.80 (m, 3H), 7.50-7.45 (m, 2H), 7.40-7.36 (m, 1H), 3.94 (s, 2H), 1.04 (s, 9H)
Compound 94: 3-(2-Methylcyclohexyl)-7-phenylthieno[3,2-d]pyrimidin-4(3H)-one
[0388] In the same manner as the synthesis of Compound 1, methyl 3-amino-4-phenylthiophene-2-carboxylate (100 mg, 0.43 mmol), triethyl orthoformate (1.0 ml), 2-methylcyclohexanamine (0.120 ml, 0.90 mmol), and acetic acid (0.1 ml) were used to give 65.9 mg (0.20 mmol, 47.2% yield) of the title compound.
[0389] 1 H NMR (400 MHz, CDCl 3 ) δ 8.14 (m, 1H), 7.83-7.81 (m, 3H), 7.49-7.45 (m, 2H), 7.40-7.36 (m, 1H), 5.00 (dt, J=13.2, 3.8 Hz, 0.4H), 4.67 (brs, 0.6H), 2.49-1.23 (m, 9H), 0.88 (d, J=7.2 Hz, 1H), 0.83 (d, J=6.4 Hz, 2H)
Compound 95: 3-(3-Methylcyclohexyl)-7-phenylthieno[3,2-d]pyrimidin-4(3H)-one
[0390] In the same manner as the synthesis of Compound 1, methyl 3-amino-4-phenylthiophene-2-carboxylate (100 mg, 0.43 mmol), triethyl orthoformate (1.0 ml), 3-methylcyclohexanamine (0.120 ml, 0.90 mmol), and acetic acid (0.1 ml) were used to give 98.4 mg (0.30 mmol, 70.5% yield) of the title compound.
[0391] 1 H NMR (400 MHz, CDCl 3 ) δ 8.23 (s, 0.3H), 8.20 (s, 0.7H), 7.83-7.80 (m, 3H), 7.49-7.46 (m, 2H), 7.41-7.35 (m, 1H), 5.19-5.11 (m, 0.3H), 4.95-4.87 (m, 0.7H), 2.28-1.50 (m, 8H), 1.34-1.16 (m, 1H), 1.02-0.92 (m, 3H)
Compound 96: 3-(4-Ethylcyclohexyl)-7-phenylthieno[3,2-d]pyrimidin-4(3H)-one
[0392] In the same manner as the synthesis of Compound 1, methyl 3-amino-4-phenylthiophene-2-carboxylate (100 mg, 0.43 mmol), triethyl orthoformate (1.0 ml), 4-ethylcyclohexanamine (0.133 ml, 0.90 mmol), and acetic acid (0.1 ml) were used to give 6.8 mg (0.02 mmol, 4.7% yield) of the title compound.
[0393] 1 H NMR (400 MHz, CDCl 3 ) δ 8.22 (s, 0.6H), 8.19 (s, 0.4H), 7.82-7.79 (m, 3H), 7.48-7.44 (m, 2H), 7.39-7.35 (m, 1H), 4.90-4.79 (m, 1H), 2.07-1.62 (m, 8H), 1.51-1.43 (m, 1H), 1.33-1.16 (m, 2H), 0.95-0.90 (m, 3H)
Compound 97: (1R,4R)-4-(4-oxo-7-phenylthieno[3,2-d]pyrimidin-3(4H)-yl)cyclohexyl acetate
[0394] In the same manner as the synthesis of Compound 1, methyl 3-amino-4-phenylthiophene-2-carboxylate (100 mg, 0.43 mmol), triethyl orthoformate (1.0 ml), (1r,4r)-4-aminocyclohexyl acetate hydrochloride (174 mg, 0.90 mmol), and acetic acid (0.1 ml) were used to give 73.4 mg (0.20 mmol, 46.3% yield) of the title compound.
[0395] 1 H NMR (400 MHz, CDCl 3 ) δ 8.16 (s, 1H), 7.84-7.79 (m, 3H), 7.49-7.45 (m, 2H), 7.40-7.37 (m, 1H), 4.95-4.89 (m, 1H), 4.84-4.76 (m, 1H), 2.21-2.07 (m, 7H), 1.91-1.62 (m, 4H)
Compound 98: 3-Butyl-7-(2-fluorophenyl)thieno[3,2-d]pyrimidin-4(3H)-one
[0396] In the same manner as the synthesis of Compound 1, methyl 3-amino-4-(2-fluorophenyl)thiophene-2-carboxylate (100 mg, 0.40 mmol), triethyl orthoformate (1.0 ml), n-butylamine (0.076 ml, 0.76 mmol), and acetic acid (0.1 ml) were used to give 113.2 mg (0.37 mmol, 93.6% yield) of the title compound.
[0397] 1 H NMR (400 MHz, CDCl 3 ) δ 8.09 (s, 1H), 7.96 (d, J=1.6 Hz, 1H), 7.83 (td, J=7.6, 1.8 Hz, 1H), 7.40-7.35 (m, 1H), 7.28-7.18 (m, 2H), 4.07 (t, J=7.3 Hz, 2H), 1.84-1.77 (m, 2H), 1.51-1.37 (m, 2H), 0.98 (t, J=7.4 Hz, 3H)
Compound 99: 3-Allyl-7-(2-fluorophenyl)thieno[3,2-d]pyrimidin-4(3H)-one
[0398] In the same manner as the synthesis of Compound 1, methyl 3-amino-4-(2-fluorophenyl)thiophene-2-carboxylate (100 mg, 0.40 mmol), triethyl orthoformate (1.0 ml), allylamine (86 mg, 0.92 mmol), and acetic acid (0.1 ml) were used to give 11.7 mg (0.04 mmol, 10.2% yield) of the title compound.
[0399] 1 H NMR (400 MHz, CDCl 3 ) δ 8.09 (s, 1H), 7.97 (d, J=1.6 Hz, 1H), 7.83 (td, J=7.6, 1.8 Hz, 1H), 7.40-7.35 (m, 1H), 7.28-7.17 (m, 2H), 6.06-5.97 (m, 1H), 5.34-5.26 (m, 2H), 4.71-4.69 (m, 2H)
Compound 100: 3-Cyclobutyl-7-(2-fluorophenyl)thieno[3,2-d]pyrimidin-4(3H)-one
[0400] In the same manner as the synthesis of Compound 1, methyl 3-amino-4-(2-fluorophenyl)thiophene-2-carboxylate (100 mg, 0.40 mmol), triethyl orthoformate (1.0 ml), cyclobutylamine (0.065 ml, 0.76 mmol), and acetic acid (0.1 ml) were used to give 110.2 mg (0.37 mmol, 91.7% yield) of the title compound.
[0401] 1 H NMR (400 MHz, CDCl 3 ) δ 8.26 (s, 1H), 7.95 (d, J=1.6 Hz, 1H), 7.83 (td, J=7.6, 1.8 Hz, 1H), 7.40-7.35 (m, 1H), 7.28-7.18 (m, 2H), 5.17-5.08 (m, 1H), 2.64-2.56 (m, 2H), 2.43-2.32 (m, 2H), 1.99-1.91 (m, 2H)
Compound 101: 3-Cyclopentyl-7-(2-fluorophenyl)thieno[3,2-d]pyrimidin-4(3H)-one
[0402] In the same manner as the synthesis of Compound 1, methyl 3-amino-4-(2-fluorophenyl)thiophene-2-carboxylate (100 mg, 0.40 mmol), triethyl orthoformate (1.0 ml), cyclopentylamine (0.09 ml, 0.92 mmol), and acetic acid (0.1 ml) were used to give 75 mg (0.24 mmol, 59.7% yield) of the title compound.
[0403] 1 H NMR (400 MHz, CDCl 3 ) δ 8.20 (s, 1H), 7.95 (d, J=1.6 Hz, 1H), 7.82 (td, J=7.6, 1.8 Hz, 1H), 7.40-7.34 (m, 1H), 7.28-7.17 (m, 2H), 5.30-5.22 (m, 1H), 2.30-2.22 (m, 2H), 1.98-1.75 (m, 6H)
Compound 102: 3-Cyclohexyl-7-(2-fluorophenyl)thieno[3,2-d]pyrimidin-4(3H)-one
[0404] In the same manner as the synthesis of Compound 1, methyl 3-amino-4-(2-fluorophenyl)thiophene-2-carboxylate (100 mg, 0.40 mmol), triethyl orthoformate (1.0 ml), cyclohexylamine (0.128 ml, 0.92 mmol), and acetic acid (0.1 ml) were used to give 76 mg (0.23 mmol, 57.9% yield) of the title compound.
[0405] 1 H NMR (400 MHz, CDCl 3 ) δ 8.19 (s, 1H), 7.95 (d, J=1.6 Hz, 1H), 7.83 (td, J=7.6, 1.8 Hz, 1H), 7.40-7.34 (m, 1H), 7.28-7.17 (m, 2H), 4.91-4.84 (m, 1H), 2.06-2.03 (m, 2H), 1.96-1.93 (m, 2H), 1.80 (d, J=13.5 Hz, 1H), 1.67-1.48 (m, 4H), 1.32-1.19 (m, 1H)
Compound 103: 3-Cyclooctyl-7-(2-fluorophenyl)thieno[3,2-d]pyrimidin-4(3H)-one
[0406] In the same manner as the synthesis of Compound 1, methyl 3-amino-4-(2-fluorophenyl)thiophene-2-carboxylate (100 mg, 0.40 mmol), triethyl orthoformate (1.0 ml), cyclooctylamine (0.128 ml, 0.92 mmol), and acetic acid (0.1 ml) were used to give 90.4 mg (0.25 mmol, 63.4% yield) of the title compound.
[0407] 1 H NMR (400 MHz, CDCl 3 ) δ 8.18 (s, 1H), 7.95 (d, J=1.6 Hz, 1H), 7.83 (td, J=7.6, 1.8 Hz, 1H), 7.41-7.34 (m, 1H), 7.28-7.17 (m, 2H), 5.17-5.10 (m, 1H), 2.05-1.60 (m, 14H)
Compound 104: 3-(Cyclopropylmethyl)-7-(2-fluorophenyl)thieno[3,2-d]pyrimidin-4(3H)-one
[0408] In the same manner as the synthesis of Compound 1, methyl 3-amino-4-(2-fluorophenyl)thiophene-2-carboxylate (100 mg, 0.40 mmol), triethyl orthoformate (1.0 ml), cyclopropanemethylamine (0.066 ml, 0.76 mmol), and acetic acid (0.1 ml) were used to give 57.1 mg (0.17 mmol, 43% yield) of the title compound.
[0409] 1 H NMR (400 MHz, CDCl 3 ) δ 8.17 (s, 1H), 7.94 (d, J=1.4 Hz, 1H), 7.82 (td, J=7.6, 1.8 Hz, 1H), 7.38-7.32 (m, 1H), 7.26-7.16 (m, 2H), 3.91 (d, J=7.2 Hz, 2H), 1.34-1.22 (m, 1H), 0.69-0.57 (m, 2H), 0.48-0.37 (m, 2H)
Compound 105: 3-(Cyclohexanemethyl)-7-(2-fluorophenyl)thieno[3,2-d]pyrimidin-4(3H)-one
[0410] In the same manner as the synthesis of Compound 1, methyl 3-amino-4-(2-fluorophenyl)thiophene-2-carboxylate (100 mg, 0.40 mmol), triethyl orthoformate (1.0 ml), cyclohexanemethylamine (0.099 ml, 0.76 mmol), and acetic acid (0.1 ml) were used to give 102.1 mg (0.31 mmol, 78.7% yield) of the title compound.
[0411] 1 H NMR (400 MHz, CDCl 3 ) δ 8.04 (s, 1H), 7.96 (d, J=1.6 Hz, 1H), 7.84 (td, J=7.6, 1.8 Hz, 1H), 7.40-7.34 (m, 1H), 7.28-7.17 (m, 2H), 3.88 (d, J=7.2 Hz, 2H), 1.95-1.84 (m, 1H), 1.74-1.64 (m, 6H), 1.28-0.98 (m, 6H)
Compound 106: 7-(2-Fluorophenyl)-3-((1R,4R)-4-methylcyclohexyl)thieno[3,2-d]pyrimidin-4(3H)-one
[0412] In the same manner as the synthesis of Compound 1, methyl 3-amino-4-(2-fluorophenyl)thiophene-2-carboxylate (100 mg, 0.40 mmol), triethyl orthoformate (1.0 ml), trans-4-methylcyclohexylamine (0.1 ml, 0.76 mmol), and acetic acid (0.1 ml) were used to give 87.1 mg (0.25 mmol, 63.6% yield) of the title compound.
[0413] 1 H NMR (400 MHz, CDCl 3 ) δ 8.18 (s, 1H), 7.94 (d, J=1.6 Hz, 1H), 7.83 (td, J=7.6, 1.8 Hz, 1H), 7.39-7.33 (m, 1H), 7.27-7.16 (m, 2H), 4.89-4.81 (m, 1H), 2.05-2.01 (m, 2H), 1.91-1.87 (m, 2H), 1.73-1.63 (m, 2H), 1.55-1.43 (m, 1H), 1.30-1.20 (m, 2H), 0.97 (d, J=6.5 Hz, 3H)
Compound 107: 3-Cycloheptyl-7-phenylthieno[3,2-d]pyrimidin-4(3H)-one
[0414] In the same manner as the synthesis of Compound 1, methyl 3-amino-4-phenylthiophene-2-carboxylate (80 mg, 0.34 mmol), triethyl orthoformate (0.65 ml), cycloheptylamine (0.08 ml, 0.63 mmol), and acetic acid (0.08 ml) were used to give 103 mg (0.32 mmol, 93% yield) of the title compound.
[0415] 1 H NMR (300 MHz, CDCl 3 ) δ 8.22 (s, 1H), 7.86-7.83 (m, 3H), 7.51-7.36 (m, 2H), 7.38-7.25 (m, 1H), 5.06-4.97 (m, 1H), 2.11-1.65 (m, 12H)
Compound 108: 3-Cycloheptyl-7-(2-fluorophenyl)thieno[3,2-d]pyrimidin-4(3H)-one
[0416] In the same manner as the synthesis of Compound 1, methyl 3-amino-4-(2-fluorophenyl)thiophene-2-carboxylate (70 mg, 0.28 mmol), triethyl orthoformate (2 ml), cycloheptylamine (0.066 ml, 0.52 mmol), and acetic acid (0.1 ml) were used to give 45 mg (0.13 mmol, 47% yield) of the title compound.
[0417] 1 H NMR (300 MHz, CDCl 3 ) δ 8.22 (s, 1H), 7.98 (s, 1H), 7.84-7.98 (m, 1H), 7.38-7.41 (m, 1H), 7.19-7.31 (m, 2H), 5.03 (m, 1H), 1.66-2.13 (m, 12H)
Compound 109: 3-(2,3-Dihydro-1H-inden-2-yl)-7-phenylthieno[3,2-d]pyrimidin-4(3H)-one
[0418] In the same manner as the synthesis of Compound 1, methyl 3-amino-4-phenylthiophene-2-carboxylate (55.8 mg, 0.24 mmol), triethyl orthoformate (0.53 ml), 2-aminoindene (59.25 mg, 0.45 mmol), and acetic acid (0.06 ml) were used to give 48 mg (0.14 mmol, 58% yield) of the title compound.
[0419] 1 H NMR (300 MHz, CDCl 3 ) δ 8.02 (s, 1H), 7.80 (s, 1H), 7.75-7.72 (m, 2H), 7.43 (t, J=10 Hz, 2H), 7.37-7.22 (m, 5H), 5.90-5.82 (m, 1H) 3.67 (d, J=10.4 Hz, 1H), 3.60 (d, J=10.4 Hz, 1H), 3.18 (dd, J=22.8, 4.4 Hz, 2H)
Compound 110: 3-(4-Isopropylcyclohexyl)-7-phenylthieno[3,2-d]pyrimidin-4(3H)-one
[0420] In the same manner as the synthesis of Compound 1, methyl 3-amino-4-phenylthiophene-2-carboxylate (100 mg, 0.43 mmol), triethyl orthoformate (1 ml), 4-isopropylcyclohexylamine (0.148 ml, 0.90 mmol), and acetic acid (0.1 ml) were used to give 88.5 mg (0.25 mmol, 58.4% yield) of the title compound.
[0421] 1 H NMR (400 MHz, CDCl 3 ) δ 8.22 (s, 0.5H), 8.18 (s, 0.5H), 7.81-7.77 (m, 3H), 7.47-7.43 (m, 2H), 7.38-7.34 (m, 1H), 4.88-4.79 (m, 1H), 2.08-1.12 (m, 10H) 0.93 (d, J=6.6 Hz, 3H), 0.89 (d, J=6.8 Hz, 3H)
Compound 111: 7-Phenyl-3-(4-propylcyclohexyl)thieno[3,2-d]pyrimidin-4(3H)-one
[0422] In the same manner as the synthesis of Compound 1, methyl 3-amino-4-phenylthiophene-2-carboxylate (100 mg, 0.43 mmol), triethyl orthoformate (1 ml), 4-propylcyclohexylamine (0.148 ml, 0.90 mmol), and acetic acid (0.1 ml) were used to give 105.7 mg (0.30 mmol, 69.7% yield) of the title compound.
[0423] 1 H NMR (400 MHz, CDCl 3 ) δ 8.22 (s, 0.5H), 8.18 (s, 0.5H), 7.80-7.78 (m, 3H), 7.49-7.43 (m, 2H), 7.38-7.34 (m, 1H), 4.88-4.78 (m, 1H), 2.05-1.60 (m, 7H) 1.43-1.14 (m, 6H), 0.94-0.87 (m, 3H)
Compound 112: 3-(4-(Tert-butyl)cyclohexyl)-7-phenylthieno[3,2-d]pyrimidin-4(3H)-one
[0424] In the same manner as the synthesis of Compound 1, methyl 3-amino-4-phenylthiophene-2-carboxylate (100 mg, 0.43 mmol), triethyl orthoformate (1 ml), 4-t-butylcyclohexylamine (0.161 ml, 0.90 mmol), and acetic acid (0.1 ml) were used to give 103.1 mg (0.28 mmol, 65.4% yield) of the title compound.
[0425] 1 H NMR (400 MHz, CDCl 3 ) δ 8.51 (s, 0.5H), 8.20 (s, 0.5H), 7.82-7.80 (m, 3H), 7.50-7.45 (m, 2H), 7.41-7.36 (m, 1H), 5.05-5.01 (m, 0.5H), 4.88-4.80 (m, 0.5H), 2.22-1.94 (m, 4H) 1.80-1.60 (m, 2H), 1.41-1.10 (m, 3H), 0.90 (d, J=10 Hz, 9H)
Compound 113: (1r,4r)-4-(7-(2-fluorophenyl)-4-oxothieno[3,2-d]pyrimidin-3(4H)-yl)cyclohexyl acetate
[0426] In the same manner as the synthesis of Compound 1, methyl 3-amino-4-(2-fluorophenyl)thiophene-2-carboxylate (100 mg, 0.40 mmol), triethyl orthoformate (1 ml), (1r,4r)-4-aminocyclohexyl acetate hydrochloride (147 mg, 0.76 mmol), and acetic acid (0.1 ml) were used to give 83.6 mg (0.22 mmol, 56.7% yield) of the title compound.
[0427] 1 H NMR (400 MHz, CDCl 3 ) δ 8.14 (s, 1H), 7.95 (brd, J=1.3 Hz, 1H), 7.81 (td, J=1.7, 7.6 Hz, 1H), 7.39-7.33 (m, 1H), 7.27-7.16 (m, 2H), 4.94-4.86 (m, 1H), 4.82-4.74 (m, 1H), 2.20-2.06 (m, 7H) 1.86-1.76 (m, 2H), 1.71-1.61 (m, 2H)
Compound 114: 7-(2-Fluorophenyl)-3-isobutylthieno[3,2-d]pyrimidin-4(3H)-one
[0428] In the same manner as the synthesis of Compound 1, methyl 3-amino-4-(2-fluorophenyl)thiophene-2-carboxylate (100 mg, 0.40 mmol), triethyl orthoformate (1 ml), isobutylamine (0.076 ml, 0.76 mmol), and acetic acid (0.1 ml) were used to give 101 mg (0.33 mmol, 83.5% yield) of the title compound.
[0429] 1 H NMR (400 MHz, CDCl 3 ) δ 8.05 (s, 1H), 7.96 (brd, J=1.6 Hz, 1H), 7.85 (td, J=1.8, 7.6 Hz, 1H), 7.40-7.34 (m, 1H), 7.28-7.17 (m, 2H), 3.87 (d, J=7.4 Hz, 2H), 2.30-2.16 (m, 1H), 0.99 (d, J=6.7 Hz, 6H)
Compound 115: 7-(2-Fluorophenyl)-3-neopentylthieno[3,2-d]pyrimidin-4(3H)-one
[0430] In the same manner as the synthesis of Compound 1, methyl 3-amino-4-(2-fluorophenyl)thiophene-2-carboxylate (100 mg, 0.40 mmol), triethyl orthoformate (1 ml), neopentylamine (0.090 ml, 0.76 mmol), and acetic acid (0.1 ml) were used to give 96.5 mg (0.31 mmol, 76.3% yield) of the title compound.
[0431] 1 H NMR (400 MHz, CDCl 3 ) δ 8.08 (s, 1H), 7.97 (brd, J=1.7 Hz, 1H), 7.86 (td, J=1.8, 7.6 Hz, 1H), 7.40-7.34 (m, 1H), 7.29-7.18 (m, 2H), 3.94 (s, 2H), 1.04 (s, 9H)
Compound 116: 3-Cyclooctyl-7-(o-tolyl)thieno[3,2-d]pyrimidin-4(3H)-one
[0432] In the same manner as the synthesis of Compound 1, methyl 3-amino-4-(o-tolyl)thiophene-2-carboxylate (100 mg, 0.40 mmol), triethyl orthoformate (1 ml), cyclooctylamine (0.107 ml, 0.77 mmol), and acetic acid (0.1 ml) were used to give 85.4 mg (0.24 mmol, 60.6% yield) of the title compound.
[0433] 1 H NMR (300 MHz, CDCl 3 ) δ 8.11 (s, 1H), 7.63 (brd, J=0.8 Hz, 1H), 7.30-7.23 (m, 4H), 5.16-5.07 (m, 1H), 2.24 (s, 3H), 2.04-1.59 (m, 14H)
Compound 117: 3-Cycloheptyl-7-(o-tolyl)thieno[3,2-d]pyrimidin-4(3H)-one
[0434] In the same manner as the synthesis of Compound 1, methyl 3-amino-4-(o-tolyl)thiophene-2-carboxylate (100 mg, 0.40 mmol), triethyl orthoformate (1 ml), cycloheptylamine (0.098 ml, 0.77 mmol), and acetic acid (0.1 ml) were used to give 44 mg (0.13 mmol, 32.5% yield) of the title compound.
[0435] 1 H NMR (400 MHz, CDCl 3 ) δ 8.12 (s, 1H), 7.63 (s, 1H), 7.34-7.24 (m, 4H), 5.01-4.96 (m, 1H), 2.24 (s, 3H), 2.11-2.06 (m, 2H), 1.90-1.59 (m, 10H)
Formulation Examples
[0436] The novel compounds of Formula 1 according to the present invention can be formulated into various dosage forms depending on the intended purpose. Some methods for preparing dosage forms containing the compounds of Formula 1 as active ingredients are exemplified below, but the present invention is not limited thereto.
Formulation Example 1
Tablets (Direct Compression)
[0437] 5.0 mg of each of the active ingredients was sieved, mixed with 14.1 mg of lactose, 0.8 mg of Crospovidone USNF and 0.1 mg of magnesium stearate, and compressed into tablets.
Formulation Example 2
Tablets (Wet Granulation)
[0438] 5.0 mg of each of the active ingredients was sieved and mixed with 16.0 mg of lactose and 4.0 mg of starch. To the mixture was added an appropriate amount of a solution of 0.3 mg of Polysolvate 80 in pure water, followed by atomization. After drying, the atomized mixture was sieved and mixed with 2.7 mg of colloidal silicon dioxide and 2.0 mg of magnesium stearate. The finely divided powder was compressed into tablets.
Formulation Example 3
Powders and Capsules
[0439] 5.0 mg of each of the active ingredients was sieved and mixed with 14.8 g of lactose, 10.0 mg of polyvinyl pyrrolidone and 0.2 mg of magnesium stearate. The mixture was filled in a hard No. 5 gelatin capsule using a suitable device.
Formulation Example 4
Injectable Preparations
[0440] 100 mg of each of the active ingredients, 180 mg of mannitol, 26 mg of Na 2 HPO 4 .12H 2 O and 2974 mg of distilled water were mixed to prepare an injectable preparation.
[0441] The IC 50 values (nM) of the novel compounds of Formula 1 according to the present invention against mGluR1 were measured by the method described in the following experimental example.
Experimental Example 1
mGluR1 Activity Screening Method Using FDSS6000
[0442] Cells of Chem3 Cell Line (HTS145C:Millipore) in which mGluR1 was stably expressed were adjusted to a density of 2×10 6 /ml. 50 μl of the cells were plated in each well of a 96-well plate, and stabilized at 5% CO 2 and 37° C. for 1 hr. The cells were allowed to react with an HBSS buffer containing a Ca 2+ fluorescent dye (FLIPR Calcium 5 assay kit: Molecular Devices) under the conditions of 5% CO 2 and 37° C. for 30 min. As a result of the reaction, the cells were labeled with the fluorescent dye. Separately from the 96-well plate containing the fluorescently labeled cells, another 96-well plate was prepared that contained L-Glutamate (final concentration=30 μM) activating mGluR1 and a blocking drug to be screened. Most cell-based HTS systems have liquid application systems necessary for drug injection but no liquid inhalation systems. For this reason, 25 μl of each of the blocking drug and L-Glutamate was prepared at a 6-fold higher concentration in an HBSS buffer and diluted 6-fold in the final volume (150 μl) of the cell plate before measurement. Specifically, after drug pretreatment for 75 sec following recording the reference value at 20 sec, a change in intracellular calcium concentration caused by L-glutamate administration was measured using FDSS6000. The inhibitory effect of the test substance was expressed as a percent (%) relative to the area of the 480 nm/520 nm ratio in a control group untreated with the test substance. 10 μM PCTC20001 was always used as the control drug.
[0443] For detailed imaging of calcium, the cells were selectively exposed to an excitation wavelength (480 nm) from four xenon light sources mounted in FDSS6000 through a computer-controlled filter wheel. Data were recorded at 1.23-sec intervals. Emitter fluorescence light entering through a 520 nm long-pass filter was allowed to pass through a cooled CCD camera mounted in the system. An average 480 nm/520 nm ratio was obtained in each well of the 96-well plate using a digital fluorescence analyzer. All imaging data were collected and analyzed with the help of a dedicated program for FDSS6000 (Hamamatsu Photonics).
[0444] Measurement of IC 50 Values Against mGluR1
[0445] The IC 50 values (nM) of the novel compounds of Formula 1 according to the present invention against mGluR1 are shown in Table 1.
[0000]
TABLE 1
Test compound
IC 50 (nM)
Compound 2
407
Compound 6
58
Compound 7
66
Compound 18
112
Compound 29
74
Compound 32
30
Compound 58
80
Compound 59
661
Compound 68
447
Compound 69
1,987
Compound 74
564 | Disclosed are thienopyrimidinone derivatives as antagonists that act on metabotropic glutamate receptor subtype 1. The thienopyrimidinone derivatives show pharmacological activity against metabotropic glutamate receptor-related diseases, including pain, such as neuropathic pain and migraine, psychiatric diseases, such as anxiety disorder and schizophrenia, urinary incontinence, and neurodegenerative diseases, such as Parkinson's disease and Alzheimer's disease. Also disclosed are methods for preparing the thienopyrimidinone derivatives, and pharmaceutical compositions containing the thienopyrimidinone derivatives as active ingredients. | 0 |
[0001] This application claims the benefit of U.S. patent application Ser. No. 60/210,252, filed Jun. 8, 2000, which is hereby incorporated by reference in its entirety.
FIELD OF THE INVENTION
[0002] The present invention relates to the use of aldehyde donors, such as 1,3-bis(hydroxymethyl)-5,5-dimethylhydantoin, to stabilize peroxides in aqueous solutions and in particular circulating water slurries in papermaking applications.
BACKGROUND OF THE INVENTION
[0003] The bleaching of wood fibers frequently involves the use of peroxides, such as hydrogen peroxide. Hydrogen peroxide, however, is readily decomposed by catalase, an enzyme often found in recycled water (i.e. water from processing recycled paper). Most aerobic bacteria synthesize peroxide-degrading enzymes (e.g. catalase and peroxidase) as a defense against free-radical-producing peroxides that are formed during cell respiration. In a mill white water environment, temperatures and the availability of nutrients encourage bacterial growth. The presence of hydrogen peroxide stimulates bacteria to generate catalase to destroy it, sometimes enough to hamper or disable a hydrogen peroxide treatment stage. As a result, peroxide stability is limited and bleaching effectiveness is reduced. The conditions of recycled paper processing, deinking and bleaching are especially conducive to enzyme peroxide degradation.
[0004] Some of the methods employed to stabilize hydrogen peroxide include biocide treatments (e.g. peracetic acid treatment), use of high hydrogen peroxide dosages and steep bleaching.
[0005] U.S. Pat. No. 5,728,263 describes the use of dialdehydes and acetals thereof, such as glutaraldehyde, to inhibit the decomposition of peroxide in the treatment of recycled and other fiber pulps. Hydrogen peroxide stability is enhanced by the addition of glutaraldehyde. Glutaraldehyde, however, has a poor safety profile and high concentrations of it are required to inhibit peroxide decomposition.
[0006] U.S. Pat. No. 5,885,412 describes the use of certain hydroxyl amines and alkyl derivatives, including hydroxylammonium sulfate, ascorbic acid and formic acid, that suppress or inhibit hydrogen peroxide degradation by enzymes, such as peroxidases and catalases, during bleaching of cellulose fibers and do not affect microorganisms.
[0007] Great Britain Patent Publication No. 2,269,191 describes the use of an organic peracid that has a disinfectant effect on catalase producing microorganisms at neutral or acidic pH.
[0008] U.S. Pat. No. 4,908,456 teaches the use of methylolated hydantoin, especially 1,3-dimethylol-5,5-dimethylhydantoin (DMDMH) as an antimicrobial agent.
[0009] U.S. Pat. No. 5,405,862 teaches the preparation of low free formaldehyde DMDMH compositions which are used in biocidal effective amounts in any medium in which microbial growth is to be retarded.
[0010] There is a need for a method of stabilizing hydrogen peroxide in the presence of catalase and other peroxide degenerating enzymes that is not hazardous.
SUMMARY OF THE INVENTION
[0011] The present invention is a method of stabilizing hydrogen peroxide in an aqueous solution, such as a circulating water slurry, comprising a peroxide, such as hydrogen peroxide. The aqueous solution may include organic matter. The method comprises adding an aldehyde donor, such as a methylolhydantoin, to the solution (or slurry). The inventors have discovered that aldehyde donors significantly reduce the decomposition of hydrogen peroxide by catalase and other peroxide decomposing enzymes, which are often present in recycled paper. As a result, less hydrogen peroxide needs to be added to a solution to effectively bleach organic matter in the solution. Furthermore, aldehyde donors are safe to handle and cost effective.
[0012] Another embodiment is a method of bleaching recycled papers in a circulating water slurry comprising organic matter. The method comprises adding hydrogen peroxide and an aldehyde donor to the slurry.
[0013] Yet another embodiment is a method of inhibiting catalase and/or other peroxide decomposing enzymes in an aqueous solution, such as a circulating water slurry, comprising adding an aldehyde donor to the aqueous solution.
[0014] Yet another embodiment is a method of stabilizing a peroxide in an aqueous solution comprising maintaining a peroxide stabilizing effective amount of at least one aldehyde donor in the aqueous solution.
[0015] Yet another embodiment is a method of inhibiting catalase and/or other peroxide decomposing enzymes in an aqueous solution, such as a circulating water slurry, comprising maintaining a peroxide decomposing enzyme inhibiting effective amount of at least one aldehyde donor in the aqueous solution.
DETAILED DESCRIPTION OF THE INVENTION
[0016] In any identified embodiments, the term “about” means within 50%, preferably within 25%, and more preferably within 10% of a given value or range. Alternatively, the term “about” means within an acceptable standard error of the mean, when considered by one of ordinary skill in the art.
[0017] The present invention provides a method of stabilizing a peroxide, such as hydrogen peroxide, in an aqueous solution comprising the peroxide. The method comprises adding to or maintaining an aldehyde donor in the aqueous solution. Generally, the peroxide is added to the solution in the form of a bleaching solution.
[0018] The aqueous solution can be (i) a circulating water slurry comprising organic matter or (ii) a slurry dilution water. Generally, a slurry dilution water contains little (<0.2% by weight), if any, organic matter. Slurry dilution waters are frequently added to dilute or form solutions containing organic matter, especially pulp. Furthermore, slurry dilution water is frequently recovered from circulating water slurries containing organic matter by methods known in the art.
[0019] The term “aldehyde donor” as used herein is defined as any material which is not an aldehyde but upon aqueous dilution liberates a compound which gives positive reactions with aldehyde identifying reagents, i.e. a compound which can identify aldehyde groups. Generally, the liberated compound has the formula
[0020] where R is any functional group. In other words, the term “aldehyde donor” includes any compound which is not an aldehyde but when hydrolyzed forms an aldehyde or a compound which gives positive reactions with aldehyde identifying reagents. Examples of aldehyde identifying reagents include, but are not limited to, Benedicts solution, Tollens reagent, and acetyl acetone.
[0021] Suitable aldehyde donors include, but are not limited to, imidazolidinyl urea, Quaternium-15, diazolidinyl urea, bromonitropropanediol, methenamine, 5-bromo-5-nitro-1,3-dioxane, sodium hydroxymethylglycinate, 3,5-dimethyl-1,3,5,2H-tetrahydrothiadiazine-2-thione, hexahydro-1,3,5-tris(2-hydroxyethyl)triazine, hexahydo-1,3,5-triethyl-s-triazine, polymethoxy bicyclic oxazolidine, tetrakis (hydroxymethyl) phosphonium sulfate, methylolhydantoins, and any combination of any of the foregoing.
[0022] Preferred aldehyde donors include, but are not limited to, methylolhydantoins, such as monomethyloldimethylhydantoins (MMDMHs), dimethyloldimethylhydantoins (DMDMHs), and any combination of any of the foregoing. Examples of methylolhydantoins include, but are not limited to, 1-hydroxymethyl-5,5-dimethylhydantoin (a MMDMH), 3-hydroxymethyl-5,5-dimethylhydantoin (a MMDMH), and 1,3-bis(hydroxymethyl)-5,5-dimethylhydantoin (DMDMH) mixtures (which are available as aqueous solutions under the tradenames Dantogard® and Glydant® from Lonza Inc. of Fair Lawn, N.J.). Other preferred aldehyde donors include, but are not limited to, low free formaldehyde compositions of dimethyloldimethylhydantoin, such as those described in U.S. Pat. No. 5,405,862, which is hereby incorporated by reference. Preferably, the aldehyde donor has a free formaldehyde concentration of less than 0.2% based on 100% total weight of aldehyde donor. Low free formaldehyde compositions reduce workplace exposure risk to formaldehyde. Generally, the weight ratio of methylolhydantoins to peroxide ranges from about 10:1 to about 1:1000.
[0023] According to a preferred embodiment, the aldehyde donor is a mixture of 1-hydroxymethyl-5,5-dimethylhydantoin, 3-hydroxymethyl-5,5-dimethylhydantoin, and 1,3-bis(hydroxymethyl)-5,5-dimethylhydantoin. Preferably, the mixture has a free formaldehyde concentration of less than 0.2% by weight, based on 100% total weight of the mixture. An example of a preferred mixture is a 65-70% aqueous solution of MMDMH, DMDMH, and 5,5-dimethylhydantoin (DMH) available under the tradename Dantogard® 2000 from Lonza, Inc of Fair Lawn, N.J.
[0024] The aldehyde donor significantly reduces the decomposition rate of hydrogen peroxide by catalase and other peroxide decomposing enzymes. The amount of the aldehyde donor added to the solution is typically sufficient to maintain a peroxide stabilizing effective concentration (i.e. a concentration sufficient to prevent decomposition of the peroxide) and/or a peroxide decomposing enzyme inhibiting effective concentration in the solution (such as a catalase inhibiting concentration). According to a preferred embodiment, the concentration of aldehyde donor maintained in the slurry is less than a microbicidally effective amount. Preferably, the concentration of aldehyde donor maintained in the solution ranges from about 1 to about 1,000 ppm, more preferably from about 30 to about 200 ppm, and most preferably from about 60 to about 120 ppm. According to one embodiment, the concentration of aldehyde donor maintained in the solution ranges from about 1 to about 5000 ppm, from about 100 to about 1000 ppm, from about 250 to about 500 ppm, from about 250 to about 750 ppm, from about 50 to about 500 ppm, from about 50 to about 750 ppm, from about 100 to about 200 ppm, or from about 200 to about 400 ppm.
[0025] Although many of the aldehyde donors identified above are also known biocides, their concentration in the solution can be less than that necessary to have a significant biocidal effect, i.e. they generally provide less than a 2 log reduction in the microorganism population in short contact time applications (e.g. 3 hours or less). The term “log reduction in the microorganism population” refers to the difference between the logarithm (base 10) of the microorganism count of an untreated substrate after a given contact time, such as 3 hours or less, and the logarithm of the microorganism count of an identical substrate treated with an aldehyde donor after the same contact time. According to one embodiment, the aldehyde donor causes a log reduction in microorganism population of less than 0.5 or 1.
[0026] A biocidal concentration of one or more biocides may also be added to or maintained in the solution. Suitable biocides include, but are not limited to, those described in Great Britain Patent Publication No. 2,269,191, which is hereby incorporated by reference. Other suitable biocides include, but are not limited to, thiocarbamates, such as sodium dimethyl dithiocarbamate; glutaraldehyde; dibromo nitrile propionamide (DBNPA); bromnitropropanediol; tetrakis (hydroxymethyl) phosphonium sulfate; bromonitrostyrene (BNS); benzisothiazolones; methylene bis(thiocyanate); 2-mercaptobenzothiazole (MBT); isothiazolines, including 5-chloro-2-methl-4-isothiazolin-3-one (CMI), 2-methyl-4-isothiazolin-3-one (MI), octyl-4-isothiazolin-3 -one, and mixtures thereof; bistrichloromethylsulfone (BTCMS); quaterary ammonium compounds, such as alkyldimethylbenzyl ammonium chlorides and dialkydimethyl ammonium chlorides; 2-bromo-4-hydroxyacetophenone (BHAP); and 5-oxo-3,4-dichloro-1,2-dithiol; and any combination of any of the foregoing.
[0027] Peracetic acid may be added to the solution to kill or inhibit the growth of microorganisms and/or to bleach any organic matter in the solution. Therefore, a microbicidally effective amount and/or a bleaching effective amount of peracetic acid may be added to or maintained in the solution.
[0028] The aldehyde donor may be added directly to the solution (e.g. slurry or slurry dilution water) or bleaching solution as a solid or liquid. Preferably, the aldehyde donor is added to the solution as a liquid. For example, the aldehyde donor may be added as an aqueous mixture. The concentration of aldehyde donor in such an aqueous mixture typically ranges from about 5 to about 95% by weight and preferably from about 20 to about 75% by weight, based upon 100% weight of total mixture. The aldehyde donor may be added before, simultaneously with, or after the hydrogen peroxide is added to the aqueous solution, or alternatively to the peroxide bleaching solution itself.
[0029] The hydrogen peroxide may be added alone or as a mixture with one or more biocides to the solution (or slurry) or peroxide bleaching solution. For example, a mixture of hydrogen peroxide and peracetic acid may be added to the solution (or slurry) or peroxide bleaching solution.
[0030] According to one embodiment, a blend of one or more aldehyde donors, CMI, and MI is added to the solution (or slurry). The blend may optionally contain isothiazoline stabilizers as known in the art. A preferred blend includes CMI, MI, and at least one of MMDMH and DMDMH. According to another embodiment, a blend of one or more aldehyde donors and a benzisothiazolinone is added to the solution (or slurry). A preferred blend includes benzisothiazolinone and at least one of MMDMH and DMDMH. Such aldehyde donor blends are described in U.S. Pat. Nos. 6,121,302 and 6,114,366, which are incorporated herein by reference.
[0031] The concentration of hydrogen peroxide added to or maintained in the solution is typically a bleaching effective concentration in the solution. The concentration of hydrogen peroxide maintained in the solution preferably ranges from about 1 to about 50,000 ppm, more preferably ranges from about 10 to about 10,000 ppm, and most preferably ranges from about 100 to about 1,000 ppm.
[0032] The solution may be, for example, a pulp slurry, a papermaking slurry, a mineral slurry or white water. White water is generally separated liquid that is re-circulated to a preceding stage of a papermaking process, especially to the first disintegration stage, where paper, water and chemicals are mixed.
[0033] Generally, a mineral slurry comprises of from about 50 to about 80% by weight of mineral matter, such as, but not limited to, calcium carbonate or clay. The mineral slurry may also contain an organic dispersing agent. Preferred organic dispersing agents include, but are not limited to, polyacrylates.
[0034] Typical pulp slurries in paper applications contain from about 0.2 to about 18% by weight of organic matter, based upon 100% total weight of slurry. The organic matter is typically comprised of wood fiber (or pulp) and adjuvants, such as sizing and starch. Generally, the organic matter comprises from about 90 to about 99% by weight of wood fiber (or pulp), based upon 100% total weight of organic matter. According to a preferred embodiment, the wood fiber is at least partially derived from recycled paper.
[0035] The pulp slurry may also contain other adjuvants known in the art. Examples of such adjuvants include, but are not limited to, slimicides; sodium hydroxide (or other caustic); peroxide stabilizers, such as sodium silicate, magnesium sulfate, and polyphosphates; chelating agents, such as EDTA; fatty acids; and combinations thereof.
[0036] Generally, the pH of the solution ranges from about 7 to about 13 and preferably from about 8 to about 11. In another embodiment, the pH of the solution ranges from about 4 to about 13, preferably from about 7 to about 12, and more preferably from about 8 to about 11.
[0037] The following examples are intended to describe the present invention without limitation.
EXAMPLE 1
[0038] Process waters from a papermaking facility which uses recycled fibers were collected during a bleaching stage and allowed to stand for 2 hours to achieve total depletion of the hydrogen peroxide in the process waters.
[0039] Into five separate Pyrex beakers were placed 400 ml of the process water. One was retained as a control. 150 and 300 ppm of an aqueous solution containing 40% by weight of 1,3-bis(hydroxymethyl)-5,5-dimethylhydantoin (DMDMH) (Dantogard®) were added to two beakers for a total concentration of 60 ppm and 120 ppm of DMDMH, respectively. On an equivalent aldehyde basis, this corresponds to 0.65 mEq/l and 1.30 mEq/l, respectively. 150 and 300 ppm of an aqueous solution containing 55% by weight of glutaraldehyde were added to the remaining two beakers for a total concentration of 83 ppm and 166 ppm of glutaraldehyde, respectively. On an equivalent aldehyde basis, this corresponds to 1.66 mEq/l and 3.32 mEq/l, respectively. The samples were placed in a controlled water bath at 45° C. and stirred with a magnetic stirrer set on slow agitation.
[0040] To all the test samples, a sufficient volume of a 1% (by weight) hydrogen peroxide (H 2 O 2 ) aqueous solution was added to achieve a concentration of 20-25 ppm of hydrogen peroxide in the samples. At regular time intervals, over a 45 minute period, aliquots were removed and analyzed for peroxide residual (i.e. the concentration of hydrogen peroxide) using a thiosulfate titration kit (HACH Test Kit, Model HYP-1, available from Hach Company of Loveland, Colo.). The results, shown in Table 1, correlate to the amount of peroxide present at the specific time interval, expressed as ppm of hydrogen peroxide.
TABLE 1 H 2 O 2 Stabilization by DMDMH and Glutaraldehyde (expressed as ppm H 2 O 2 ) Time DMDMH DMDMH Glutaraldehyde Glutaraldehyde (min) Control (60 ppm) (120 ppm) (83 ppm) (166 ppm) 0 25 25 26 25 26 10 22 24 24 24 24 15 21 23 23 22 21 20 19 22 20 20 19 30 15 18 18 16 17 40 13 16 17 14 15 45 10 15 16 12 13
[0041] The results show that DMDMH provides superior peroxide stabilization compared to glutaraldehyde. On a ppm product basis, the DMDMH surpassed the performance of the glutaraldehyde. See Table 1. DMDMH surpasses the performance of glutaraldehyde when added at 38% lower concentrations. When considered on a molar aldehyde basis, it is demonstrated that DMDMH surpasses the performance of glutaraldehyde when added at a concentration 73% lower in aldehyde equivalents.
EXAMPLE 2
[0042] DMDMH hydrogen peroxide stabilization was demonstrated in a sample of white water obtained from a paperboard mill using recycled paper (50% mix, 15% corrugated, 15% news, and 20% other) as follows. The white water sample was diluted with 10 parts of sterilized tap water for every part of white water. Into three separate Pyrex® beakers, 100 ml of the diluted white water was added. One beaker was retained as a control. 250 and 500 ppm of an aqueous solution containing 40% by weight of DMDMH, available as Dantogard® from Lonza Inc., (i.e. 100 ppm of DMDMH and 200 ppm of DMDMH) were added to the remaining two beakers, respectively. The solutions were tested at 37° C. and a pH of 7.8. Hydrogen peroxide was added to the white water in quantities sufficient to achieve a concentration of 300 ppm H 2 O 2 . Aliquots were taken at the indicated times and analyzed for residual peroxide with a thiosulfate titration kit (Hach Test Kit, Model HYP-1). The results are shown in Table 2 as ppm H 2 O 2
TABLE 2 Peroxide Residual (ppm H 2 O 2 ) Dantogard ® Dantogard ® Time (minutes) Control 250 ppm 500 ppm 0 300 300 300 10 136 160 180 20 70 94 127 30 42 68 97
[0043] Dantogard® provided significant hydrogen peroxide stabilization as shown in Table 2. After 30 minutes elapsed time, hydrogen peroxide residuals in the sample treated with 500 ppm Dantogard® were more than twice that in the untreated control.
EXAMPLE 3
[0044] The biocidal efficacy of Dantogard® at 250 and 500 ppm (i.e. 100 and 200 ppm of DMDMH) was determined as follows. 50 ml of the undiluted white water sample of Example 2 was treated with 250 and 500 ppm Dantogard®. The test water temperature was 37° C. and the pH was ˜7.0.
[0045] Microorganism counts were performed after 3 hours contact time using the tryptone glucose extract agar pour plate methodology described in the American Society for Testing and Materials (ASTM) E 1839-96, “Standard Test Method for Efficacy of Slimicides for the Paper Industry—Bacterial and Fungal Slime”.
[0046] The microorganism count values were then converted to their corresponding log value. The log microbial population reduction values were calculated by subtracting the log of the microorganism count for the respective Dantogard® sample from the log of the microorganism count for the control. The results are shown in Table 3.
[0047] Microorganism count reductions of only 0.06 and 0.23 log were observed for Dantogard® concentrations of 250 and 500 ppm, respectively.
TABLE 3 Log microbial Biocidal efficacious White Water Microorganism population according to ASTM Sample Count (cfu/ml) reduction E-1839-96 criteria* Untreated Control 1.3 × 10 8 — — 250 ppm 1.2 × 10 8 0.06 No Dantogard ® 500 ppm 7.9 × 10 7 0.23 No Dantogard ®
EXAMPLE 4
[0048] Hydrogen peroxide stabilization was demonstrated in another white water sample as follows.
[0049] Into three separate beakers were placed 100 ml of a white water sample obtained from a tissue and towel mill using recycled newsprint as a pulp feed stock. The recycled feed stock had been subject to deinking and peroxide bleaching in the tissue and towel mill. One beaker was retained as a control. 250 and 500 ppm of Dantogard® were added to the other two beakers, respectively.
[0050] The test temperature was 32° C. and the pH was 7.6. 30 ppm of hydrogen peroxide was added to the samples. Aliquots were taken at the indicated times and analyzed for residual peroxide using a thiosulfate titration kit (Hach Test Kit, Model HYP-1). The results are shown in Table 4 below.
TABLE 4 Peroxide Residual (ppm H 2 O 2 ) Time (minutes) Control 250 ppm Dantogard ® 500 ppm Dantogard ® 0 30 30 30 20 14 21 22 40 8 15 16
[0051] Dantogard® provided significant hydrogen peroxide stabilization as shown in Table 4. After 40 minutes elapsed time, the concentration of hydrogen peroxide in the sample with 500 ppm Dantogard® was twice that of the untreated control.
EXAMPLE 5
[0052] The Dantogard® concentrations found to provide hydrogen peroxide stabilization in Example 4 (250-500 ppm) were again found to be below the concentrations required to provide significant biocidal efficacy according to ASTM E 1839-96.
[0053] 50 ml of an undiluted white water sample of Example 4 was treated with Dantogard® at concentrations of 250 and 500 ppm (100 and 200 ppm DMDMH). The test water temperature was 32° C., and the pH was 7.6.
[0054] Microorganism counts were performed after 3 hours contact time using the tryptone glucose extract agar pour plate methodology as described in ASTM E 1839-96.
[0055] The microorganism count values were then converted to their corresponding log value. The log microbial population reduction values were calculated by subtracting the log of the microorganism count for the Dantogard® sample from the log of the microorganism count for the control. The results are shown in Table 5.
TABLE 5 Microorganism Log Microbial Biocidal efficacious Count Population by ASTM E Agent (cfu/ml) Reduction 1839-96 criteria* Control time zero 8.0 × 10 6 — — Control 1.1 × 10 7 0 — Dantogard ® 5.1 × 10 6 0.37 No 250 ppm Dantogard ® 1.9 × 10 6 0.80 No 500 ppm
EXAMPLE 6
[0056] Direct inhibition of catalase by DMDMH solutions was demonstrated by monitoring catalase promoted hydrogen peroxide decomposition in sterile media.
[0057] Hydrogen peroxide solutions containing 470 ppm active peroxide in sterile Butterfield's phosphate buffer (pH=7.0) were treated with 1.2 units of catalase ( A. niger available from Sigma Aldrich of St. Louis, Mo. (C-3515)) alone or with 263 or 526 ppm of Dantogard® 2000, available from Lonza Inc. of Fair Lawn, N.J., or 526 ppm of an aqueous 49% glutaraldehyde solution. Dantogard® 2000 is a 65% aqueous mixture of DMDMH, MMDMH and DMH having a minimal free formaldehyde concentration. The peroxide decomposition rate was monitored during the decrease in peroxide concentration from 390 to 350 ppm by ultraviolet absorbance at 240 nm. The temperature was 23° C. The results are shown Table 6.
TABLE 6 Peroxide Decomposition Normalized Sample Rate (ppm/sec) Decomposition Rate Control 0.230 1.00 263 ppm 0.143 0.62 Dantogard ® 2000 526 ppm 0.073 0.32 Dantogard ® 2000 526 ppm 0.230 1.0 glutaraldehyde (49%)
EXAMPLE 7
[0058] Direct inhibition of catalase by DMDMH solutions was demonstrated by monitoring catalase promoted hydrogen peroxide decomposition in a pH 9.2 borate buffer.
[0059] Hydrogen peroxide solutions containing 450 ppm active peroxide in a 0.57% borax buffer (pH=9.2) were treated with 1.2 units catalase ( A. niger derived Sigma Aldrich C-3515) in the presence and absence of Dantogard® (Lonza Inc. of Fairlawn, N.J.). The peroxide decomposition rate was monitored during the decrease in peroxide concentration from 390 to 350 ppm by ultraviolet absorbance at 240 nm. The temperature was 23° C. The results are shown Table 7.
TABLE 7 Peroxide Decomposition Rates Rate Normalized Product (ppm/sec) Decomposition Rate Control 0.106 1.00 Dantogard 500 ppm 0.051 0.48
[0060] All patents, publications, applications, and test methods mentioned above are hereby incorporated by reference. Many variations of the present matter will suggest themselves to those skilled in the art in light of the above detailed description. All such obvious variations are within the patented scope of the appended claims. | The present invention is a method of stabilizing hydrogen peroxide in an aqueous solution, such as a circulating water slurry, comprising a peroxide, such as hydrogen peroxide. The aqueous solution may include organic matter. The method comprises adding an aldehyde donor, such as a methylolhydantoin, to the solution (or slurry). The inventors have discovered that aldehyde donors significantly reduce the decomposition of hydrogen peroxide by catalase and other peroxide decomposing enzymes, which are often present in recycled paper. As a result, less hydrogen peroxide needs to be added to a solution to effectively bleach organic matter in the solution. Furthermore, aldehyde donors are safe to handle and cost effective. Another embodiment is a method of bleaching recycled papers in a circulating water slurry comprising organic matter. The method comprises adding hydrogen peroxide and an aldehyde donor to the slurry. Yet another embodiment is a method of inhibiting catalase and/or other peroxide decomposing enzymes in an aqueous solution, such as a circulating water slurry, comprising adding an aldehyde donor to the aqueous solution. | 3 |
BACKGROUND OF THE INVENTION
The present invention relates to a vehicle suspension system and in particular to a vehicle suspension impact energy absorption arrangement and integrated rear impact collision safety arrangement.
BRIEF SUMMARY OF THE INVENTION
A vehicle impact energy absorption arrangement comprises a vehicle frame, a slider suspension arrangement coupled with the vehicle frame, and an impact force absorbing arrangement. The slider suspension arrangement comprises at least one trailing arm member having a first end and a second end, a support bracket coupled to the vehicle frame and pivotably supporting the first end of the first trailing arm, and a spring member positioned between the second end of the trailing arm and the vehicle frame. The impact force absorbing arrangement comprises a mounting member coupled to the vehicle frame, a first pivot member pivotably coupled to the mounting member, a second pivot member pivotably mounted to the mounting member, at least one elastically deformable biasing member positioned between the first pivot member and the mounting member and between the second pivot member and the mounting member, wherein the first pivot member is configured to pivot and elastically deform the at least one biasing member when impacted by the slider suspension arrangement, and wherein the second pivot member is configured to pivot and elastically deform the at least one biasing member when the second pivot member receives a forwardly directed force.
Another aspect of the present invention is to provide a vehicle impact energy absorbing arrangement that includes a vehicle frame, a slider suspension arrangement coupled to the vehicle frame, and an impact force absorbing arrangement. The slider suspension arrangement comprises at least one trailing arm member having a first end and a second end, a support bracket coupled to the vehicle frame and pivotably supporting the first end of the at least one trailing arm, and a spring member positioned between the second end of the trailing arm and the vehicle frame. The impact force absorbing arrangement comprises a mounting member coupled to the vehicle frame, a first pivot member pivotably coupled to the mounting member and at least one elastically deformable biasing member positioned between the first pivot member and the mounting member, wherein the first pivot member is configured to pivot and elastically deform the at least one biasing member when impacted by the slider suspension arrangement.
Yet another aspect of the present invention is to provide a vehicle impact energy absorbing arrangement that includes a vehicle frame, a slider suspension arrangement coupled to the vehicle frame, and an impact force absorbing arrangement. The slider suspension arrangement includes at least one trailing arm having a first end and a second end, a support bracket coupled to the vehicle frame and pivotably supporting the first end of the at least one trailing arm, and a spring member positioned between the second end of the trailing arm and the vehicle frame. The impact force absorbing arrangement includes a mounting member coupled to the vehicle frame, a first pivot member pivotably coupled to the mounting member, and at least one elastically deformable biasing member positioned between the first pivot member and the mounting member, wherein the first pivot member is configured to pivot and elastically deform the at least one biasing member when impacted by the slider suspension arrangement.
Still yet another aspect of the present invention is to provide a vehicle impact force absorbing arrangement for use on a vehicle that includes a slider suspension arrangement, the vehicle impact force absorbing arrangement including a mounting member coupled to the vehicle frame, a first pivot member pivotably coupled to the mounting member, a second pivot member pivotably coupled to the mounting member, at least one elastically deformable biasing member positioned between the first pivot member and the mounting member and between the second pivot member and the mounting member, wherein the first pivot member is configured to pivot and elastically deform the at least one biasing member when impacted by the slider suspension arrangement, and wherein the second pivot member is configured to pivot and elastically deform the at least one biasing member when the second pivot member receives a forwardly directed force.
The principle objects of the present invention are to provide a durable, impact force absorbing arrangement that can be easily and quickly assembled, may be retrofit onto existing trailer assemblies, is economical to manufacture, capable of a long operating life, reduces damage typically associated with excessive force being applied by an operator to a slider suspension assembly, increases the safety of passengers in a vehicle that collides with the rear of a trailer assembly while simultaneously reducing the damage to the trailer typically associated with rear collisions, and is particularly well adapted for the proposed use.
These and other advantages of the invention will be further understood and appreciated by those skilled in the art by reference to the following written specification, claims, and appended drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partial side elevational view of a vehicle impact energy absorption arrangement mounted to an associated vehicle;
FIG. 2 is a perspective view of a vehicle slider suspension arrangement;
FIG. 3 is a partial side elevational view of the vehicle impact energy absorption arrangement, wherein a slider suspension arrangement has impacted the impact force absorbing arrangement;
FIG. 4 is a partial side elevational view of the vehicle impact energy absorption arrangement, wherein the impact force absorbing arrangement has been impacted by a secondary vehicle; and
FIG. 5 is a partial side elevational view of an alternative embodiment of the vehicle impact energy absorption arrangement.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
For purposes of description herein, the terms “upper,” “lower,” “right,” “left,” “rear,” “front,” “vertical,” “horizontal,” and derivatives thereof shall relate to the invention as oriented in FIG. 1 . However, it is to be understood that the invention may assume various alternative orientations and step sequences, except where expressly specified to the contrary. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in the following specification are exemplary embodiments of the inventive concepts defined in the appended claims. Hence, specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be considered as limiting, unless the claims expressly state otherwise.
The reference numeral 10 ( FIG. 1 ) generally designates a vehicle impact energy absorption arrangement embodying the present invention. In the illustrated example, the vehicle impact energy absorption arrangement includes a vehicle frame assembly 12 , a slider suspension arrangement 14 coupled to the vehicle frame assembly 12 , and an impact force absorbing arrangement 16 .
The vehicle frame assembly 12 includes a pair of longitudinally-extending frame members, of which frame member 18 is illustrated in FIG. 1 . The frame assembly 12 also includes a plurality of cross-wise extending frame members (not shown).
The vehicle slider suspension arrangement 14 ( FIG. 2 ) comprises a plurality of support brackets 20 pivotably supporting corresponding trailing arms 22 , and spring members in the form of pneumatic springs 24 . Each trailing arm 22 includes a first end 26 pivotably coupled to a support bracket 30 , and a second end 28 configured such that the pneumatic spring 24 is operably positioned between the second end 28 of the trailing arm 22 and a slider rail 30 of the slider suspension arrangement 14 as well as the frame member 18 of the vehicle frame assembly 12 . An axle member 32 extends between pairings of the trailing arms 22 located on opposite sides of the associated vehicle. The slider suspension arrangement 14 is longitudinally adjustable in the directions 34 with respect to the vehicle frame assembly 12 .
In the illustrated example, the impact force absorbing arrangement 16 includes a mounting member 40 coupled to the vehicle frame assembly 12 , a first pivot arrangement 42 pivotably coupled to the mounting member for pivoting about a pivot axis 44 , and a second pivot arrangement 46 pivotably coupled to the mounting member 40 for pivoting about a pivot axis 48 , and a biasing member 50 operably positioned between the first and second pivot arrangements 42 , 46 and the mounting member 40 . In the illustrated example, the first pivot arrangement 42 includes a pivot arm 52 having a downwardly-extending portion 54 and a rearwardly-extending portion 56 . The biasing member 50 is positioned between the rearwardly-extending portion 56 of the biasing member 50 and the mounting member 40 . The second pivot arrangement 46 includes a downwardly-extending portion 58 and a forwardly-extending portion 60 . The biasing member 50 is operably positioned between the forwardly-extending portion 60 of the second pivot arrangement 46 and the mounting member 40 . The biasing member 50 may comprise a pneumatic spring, a hydraulic damper, a rubber bushing, and the like.
In operation, and as best illustrated in FIG. 3 , the impact force absorption arrangement 16 is adapted to absorb the impact between the slider suspension arrangement 14 and the impact force absorbing arrangement 16 , thereby reducing the forces exerted by the slider suspension arrangement 14 on the vehicle frame assembly 12 . Specifically, excessive forces generated on the overall system during position adjustment of the slider suspension arrangement 14 with respect to the vehicle frame assembly 12 may result in damage to the slider suspension arrangement 14 , the vehicle frame assembly 12 , or both. In the illustrated example, the slider suspension arrangement 14 is moved rearwardly in a direction 64 until the slider suspension arrangement 14 impacts a bumper member 66 positioned on a forward side of the downwardly-extending portion 54 of the first pivot arrangement 42 . Impact of the slider suspension arrangement 14 with the bumper member 66 causes the first pivot arrangement 42 to pivot about the pivot axis 48 in a direction 68 , thereby causing the rearwardly-extending portion 56 of the first pivot arrangement 42 to compress the biasing member 50 in a direction 70 . The biasing member 50 absorbs the impact energy exerted by the slider suspension arrangement 14 and reduces or eliminates any damage to the slider suspension arrangement 14 and/or the vehicle frame assembly 12 .
As best illustrated in FIG. 4 , a rear impact collision of a secondary vehicle 72 with the downwardly-extending portion 58 of the second pivot arrangement 46 causes the second pivot arrangement 46 to rotate about the pivot axis 48 in a direction 80 , thereby causing the forwardly-extending portion 60 of the second pivot arrangement 46 to compress the biasing member 50 in a direction 82 . The biasing member 50 is adapted to absorb the energy exerted by the secondary vehicle 72 onto the second pivot arrangement 46 , thereby ensuring the safety of the passengers in the secondary vehicle 72 , and simultaneously reducing the damage to the vehicle frame assembly 12 or the remainder of the vehicle.
FIG. 5 illustrates an alternative embodiment of the vehicle impact energy absorption arrangement 10 a. Since the vehicle impact energy absorption arrangement 10 a is similar to the previously described vehicle energy absorption arrangement 10 , similar parts appearing in FIGS. 1-4 and FIG. 5 , respectively are represented by the same, corresponding reference numeral, except for the suffix “a” in the numerals of the latter. In the illustrated example, the vehicle impact energy absorption arrangement 10 a is configured to lower the reaction point of the arrangement to a position equal to or below a center of mass of the slider suspension arrangement 14 . Specifically, the suspension arrangement 14 includes a brace 90 that is configured to abut the bumper member 66 a during rearward movement of the slider suspension arrangement 14 a in the direction 64 a. A structural reinforcement member 92 structurally reinforces and attaches the bumper member 66 a to the downwardly-extending portion 54 a of the first pivot arrangement 42 a. The location and configuration of the brace 90 lowers the reaction point of the forces exerted on the slider suspension arrangement 14 during position adjustment of the suspension slider assembly arrangement with respect to the vehicle frame assembly, to a position below the slider suspension arrangement 14 , thus generating a moment that forces the slider suspension arrangement 14 in an upward direction as opposed to forcing the slider suspension arrangement away from the vehicle frame assembly 12 . The vehicle impact energy absorption arrangement 10 a is also configured to provide improved aerodynamic efficiencies. Specifically, the brace 90 may be configured to act as an aerodynamic shield or windbreak. Further, the configuration and positioning of the above-described components of the vehicle impact energy absorption arrangement 10 a may serve to reduce the wind drag associated with the overall assembly by forcing airflow completely or significantly below the vehicle impact energy absorption arrangement 10 a.
The present inventive vehicle impact energy absorption arrangement can be easily and quickly assembled, may be retrofit onto existing trailer assemblies, is economical to manufacture, capable of a long operating life, reduces damage typically associated with excessive force being applied by an operator to a slider suspension assembly, increases the safety of passengers in a vehicle that collides with the rear of a trailer assembly while simultaneously reducing the damage to the trailer typically associated with rear collisions, and is particularly well adapted for the proposed use.
In In the foregoing description, it will be readily appreciated by those skilled in the art that modifications may be made to the invention without departing from the concepts as disclosed herein. Such modifications are to be considered as included in the following claims, unless these claims by their language expressly state otherwise. | A vehicle impact energy absorption arrangement includes a vehicle frame, a slider suspension arrangement coupled to the vehicle frame and including an axle member, and a spring member biasing the axle member, and an impact force absorbing arrangement that includes a mounting member coupled to the vehicle frame, first and second pivot members each pivotably coupled to the mounting member, and an elastically deformable biasing member positioned between each of the pivot members and the mounting member, wherein each of the pivot members is configured to pivot and elastically deform the at least one biasing member when impacted. | 1 |
TECHNICAL FIELD
This invention pertains to the handling of continuous strips of asphaltic material, such as asphaltic material suitable for use as roofing membranes and roofing shingles. In one of its more specific aspects, this invention relates to the cooling of the asphaltic strip material in the production process.
BACKGROUND OF THE INVENTION
A common method for the manufacture of asphalt shingles is the production of a continuous strip of asphaltic shingle material followed by a shingle cutting operation which cuts the continuous strip into individual shingles. In the production of asphaltic strip material, either an organic felt or a glass fiber mat is passed through a saturator, containing liquid asphalt at a very hot temperature, to form a saturated asphaltic strip. Subsequently, the hot asphaltic strip is passed beneath a granule applicator which applies the protective surface granules to portions of the asphaltic strip material. In conventional shingle processes, the hot asphaltic strip material is next directed toward a cooling section where the asphaltic strip is held in the form of numerous loops. The cooling section of existing processes acts as an accumulator or temporary storage means for the asphaltic strip prior to shingle cutting and packaging. The asphaltic strip is maintained in the cooling section for a short period of time during which the asphaltic strip is cooled by the effects of the factory air acting on the loops. Some production processes provide for fans for blowing factory air through the loops, in a direction generally parallel to the lengths of material in the loops, and generally perpendicular to the machine direction of the shingle production machine. Some production processes use a water spray to wet the asphaltic strip prior to the blowing of air through the loops.
One of the problems associated with existing shingle production processes is that during the summer months, when factory air is at elevated temperatures and can be well over 100° F., the cooling section is insufficient to cool the asphaltic strip to the degree required for proper cutting and packaging of the shingles. This is especially true in relatively warm climates, such as the southern portion of the United States. The problem of inability to cool the shingle can also be bothersome in cool weather because outside cooling air applied to the asphaltic strip can evaporate and hold much less moisture than warm air can. If the asphaltic strip is too hot, the shingle cutting operation is adversely affected. Also the shingle packaging operation becomes less efficient when the shingles are too hot, and hot shingles become a greater fire hazard once they are packaged. Also, it is desirable to avoid packaging wet shingles. As new technology is applied to existing shingle production facilities, the speed with which the continuous asphaltic strip can be produced is increased. Thus, it has been found that in many cases the limiting factor in increasing the speed and the efficiency of a shingle production machine is the ability to cool and dry the asphaltic strip prior to cutting and packaging.
One of the attempts to solve the problem of cooling asphaltic strip material is disclosed in U.S. Pat. No. 2,365,352, to Moffitt. Moffitt describes a continuous asphaltic strip production process in which the cooling section contains a single water spray means for spraying water onto the loops of shingles as the loops are formed in the cooling section. Moffitt also provides for blowing cooling air through the loops, in a direction parallel to the strip material, while the loops are in the cooling section. Moffitt's solution to the asphaltic strip cooling problem is disadvantageous in that the air flow is not perpendicular or normal to the asphaltic strip material and is, therefore, relatively inefficient. The relatively inefficient nature of Moffitt's cooling system necessitates a rather lengthy cooling section in the machine direction. Also, in part due to the inefficiency of the air flow, Moffitt's system requires an enclosed cooling section, which greatly increases the capital expense of the apparatus.
A cooling system proposed for solving the above problem of cooling asphaltic strip material provides for the use of repeated applications of spraying an evaporative liquid such as water onto the asphaltic material, with each application of evaporated liquid being followed by air jets impinging onto the asphaltic strip material in a direction normal to the strip material to evaporate the liquid, thereby cooling and drying the strip material. This proposed cooling system for cooling strip material is highly dependent on temperature and humidity conditions of the air being impinged upon the strip material. The higher the relative humidity of the air used to evaporate the liquid, the greater the difficulty in obtaining substantially complete evaporation of the liquid. Also, colder air is able to hold less moisture than warm air, and thus, the temperature affects the evaporation of the liquid. There is a need for a method and apparatus for cooling asphaltic strip material in which the ability of the air jets impinging on the asphaltic strip material to evaporate the liquid on the strip material is taken into account.
SUMMARY OF THE INVENTION
According to this invention, there is provided a method for cooling a continuously moving strip of asphaltic material comprising subjecting the asphaltic material to a plurality of cooling cycles, each cooling cycle comprising spraying evaporative liquid onto the asphaltic material from a means for spraying and evaporating the evaporative liquid immediately downstream from the means for spraying by causing gases to impinge on the asphaltic material substantially normally to the asphaltic material, and further sensing the surface moisture of the asphaltic materials subsequent to one or more of the cooling cycles, and modifying the flow of evaporative liquid sprayed in one or more of the cooling cycles in response to the sensed surface moisture.
In a preferred embodiment of the invention, the surface moisture is sensed subsequent to all of the cooling cycles.
In a more preferred embodiment of the invention, the flow of the evaporative liquid is sequentially stopped or decreased in order beginning with the furthest downstream of the cycles toward the furthest upstream of the cycles, in response to the sensed surface moisture.
According to the this invention, there is also provided a method for cooling a continuously moving strip of asphaltic material comprising subjecting the asphaltic material to a plurality of cooling cycles, each cooling cycle comprising spraying evaporative liquid onto the asphaltic material from a means for spraying and evaporating the evaporative liquid immediately downstream from the means for spraying by causing gases to impinge on the asphaltic material substantially normally to the asphaltic material, and further sensing the temperature of the asphaltic material subsequent to one or more of the cooling cycles, and modifying the flow of evaporative liquid sprayed in one or more of the cooling cycles in response to the sensed temperature.
In a preferred embodiment of the invention, the flow of evaporative liquid is sequentially started or increased in the order beginning with the furthest upstream of the cycles toward the furthest downstream of the cycles, in response to the sensed temperature.
According to this invention, there is also provided apparatus for cooling a continuously moving strip of asphaltic material comprising means for directing the asphaltic material into a plurality of loops, and a plurality of cooling units, each of the cooling units being associated with one of the loops, and each cooling unit comprising spraying means positioned to spray evaporative liquid onto the apshaltic material in the loop and air delivery means positioned immediately downstream from the spraying means and adapted to cause gases to impinge on the asphaltic material substantially normally thereto to evaporate the evaporative liquid from the asphaltic material in the loop, and further including means for sensing the surface moisture of the asphaltic material downstream from one or more of the cooling units, and means for modifying the flow of evaporative liquid sprayed in one or more of the cooling units in response to the sensed surface moisture.
In a preferred embodiment of the invention, the means for sensing the surface moisture is positioned downstream from all of the cooling units.
According to this invention, there is also provided apparatus for cooling a continuously moving strip of asphaltic material comprising means for directing the asphaltic material into a plurality of loops, in a plurality of cooling units, each of the cooling units being associated with one of the loops, and each cooling unit comprising spraying means positioned to spray evaporative liquid onto the asphaltic material in the loop and air delivery means positioned immediately downstream from the spraying means and adapted to cause gases to impinge on the asphaltic material substantially normally thereto to evaporate the evaporative liquid from the asphaltic material in the loop, and further including means for sensing the temperature of the asphaltic material downstream from one or more of the cooling units, and means for modifying the flow of evaporative liquid sprayed in one or more of the cooling units in response to the sensed temperature.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic cross-sectional view in elevation of apparatus for producing asphaltic strip material according to the principles of this invention.
FIG. 2 is a schematic cross-sectional view in elevation of the cooling section of the production machine of FIG. 1.
FIG. 3 is a schematic vertical section on line 3--3 of FIG. 2.
FIG. 4 is a perspective view of an air delivery means according to the principles of the invention.
DESCRIPTION OF THE INVENTION
As shown in FIG. 1, base sheet 10, which can be an organic felt or a glass fiber mat, is passed through saturator 12 containing liquid asphalt to create continuous hot strip 13 of asphaltic material. The hot asphaltic strip can then be passed beneath granule applicator 14 which applies the surface coating granules to a portion of the asphaltic strip. Subsequently, the asphaltic strip is passed through cooling section 16 where it is cooled and dried. Within the cooling section, the asphaltic strip can be directed by upper pulleys 18 and lower pulleys 20 into a plurality of loops having lengths L and widths W. Preferably, the lengths are generally vertical. After passing through the cooling section, the cooled and dried asphaltic strip can be directed into temporary storage looper 22 which accumulates the asphaltic strip prior to its delivery to shingle cutter 24, and packaging operations, not shown.
As shown in FIG. 2, an initial means for applying water to the asphaltic strip as it enters the cooling section, such as nozzle 25, can be positioned at the entrance of the cooling section. The water from this nozzle flashes to steam during normal operation due to the high temperature of the asphaltic strip. Spraying means, such as nozzles 26a through 26h, are positioned upstream from various ones of the vertical lengths of the loops for spraying an evaporative liquid, such as water, onto the asphaltic material. As shown in FIG. 3, the spraying means can be comprised of a series of three nozzles positioned across the width of the continuous strip of asphaltic material. The nozzles are supplied from a source of evaporative liquid, not shown.
Positioned immediately downstream from each of the nozzles 26a through 26h are air delivery means 30a through 30h for evaporating the water on the strip material immediately downstream from each of the nozzles. As can be seen in FIGS. 2 and 3, associated with each loop is a cooling unit comprised of a set of nozzles for spraying water immediately followed by an air delivery means for evaporating the water. Thus, a series or plurality of cooling units carries out a plurality of cooling cycles on the strip material, each cycle having a water spraying step immediately followed by an evaporation step.
Each of the air delivery means is comprised of a plenum defined by orificed plates 32 which are generally parallel to the lengths of asphaltic material in the loops. Preferably, the orifices in the plates are round, and deliver arrays of column-like air jets, although any flow of gases providing evaporation of the liquid will be suitable for purposes of this invention. Also, the orifices of the orificed plates preferably extend along the entire height of the plenums so that the arrays are supplied from the plenums over substantially the entire height of the loops, as shown in FIGS. 3 and 4. Air passing from the plenums through the orificed plates causes an array of air jets to impinge on the asphaltic material substantially normally to the lengths of asphaltic material. The impingement of the air jets in a direction normal to the surface to be cooled facilitates the rapid and efficient cooling of the asphaltic strip. Preferably, the impinging air jets supply air at a rate within the range of from about 60 to about 70 cfm per square foot of plenum surface.
As shown in FIGS. 2 through 4, the air can be supplied to the plenums by plenum conduits 34. The plenum conduits can be adapted with any means suitable for controlling the flow of air therethrough, such as dampers, not shown, in order to balance the force of the arrays of air jets impinging on opposite sides of the lengths. For example, the length of asphaltic material downstream from spray nozzle 26b, which is positioned between plenums 30b and 30c, is subject to the force of the arrays of air jets impinging thereupon from those two plenums.
Positioned downstream from all the cooling units is moisture sensor 36. The moisture sensor can be any means suitable for measuring the amount of surface moisture on the asphaltic strip material traveling past the moisture sensor. A moisture sensor which would be sufficient for purposes of the invention would be a Quadri-Beam Moisture Analyzer, Model 475 manufactured by Moisture Systems Corporation, Hopkinton, Mass.
Also positioned downstream from the cooling units is temperature sensor 38, which can be any temperature sensing device suitable for measuring the temperature of the asphaltic strip material traveling past the temperature sensor. A device suitable for purposes of the invention would be a Williamson Model 4200 Infrared Temperature Sensing device. Although the moisture sensor and temperature sensor are shown as being positioned immediately downstream from the cooling section, either the moisture sensor or the temperature sensor, or both, can be positioned immediately upstream from the shingle cutter while continuing to operate under the principles of this invention. The moisture sensor and temperature sensor can be wired to a controller in order to provide control for the cooling taking place in the cooling section. The controller can be any means suitable, such as a microprocessor, for receiving data from the sensors and modifying the water flow from the spray nozzles.
As shown in FIG. 2, some of the cooling units can be provided with additional moisture sensors, such as moisture sensors 40, 42 and 44. Moisture sensor 40, for example, measures the surface moisture on the asphaltic strip material after the strip material has passed through the cooling unit comprised of spray nozzles 26a and plenums 30a and 30b. All of the moisture sensors are connected to the controller by means, not shown.
In operation, the controller can be programmed to control the operation of the spray nozzles in response to all of the moisture sensors. Preferably, the controller is programmed to sequentially stop or decrease the flow of evaporative liquid sprayed from the spray nozzles, in the order beginning with the furthest downstream of the cooling units toward furthest upstream of the cooling units, in response to the sensed surface moisture of the sensors. It is preferable that no new cooling cycle be initiated if the asphaltic strip material emerging from the previous cooling cycle has not been substantially dried. Thus, for example, if moisture sensor 36 indicates wet asphaltic material, then the controller would decrease or stop the flow of water from nozzles 26h. Also, if moisture sensor 44 indicates that the asphaltic strip material is wet, then spray nozzles 26e are either stopped or reduced in flow of evaporative liquid.
In the preferred embodiment of the invention, the sensing and slowing or stopping of the flow of liquid from various cooling units is done in a sequential order in the reverse machine direction. This can be done regardless of the number of moisture sensors, provided that there is one moisture sensor positioned downstream from all the controlled cooling units. For example, if moisture sensor 36 indicates that the asphaltic strip material is not substantially dry, then spray nozzles 26h can be stopped. If the moisture sensor still indicates a wet asphaltic strip, then spray nozzles 26f, 26 g and 26h are turned off. In the event that stopping the flow of evaporative liquid from spray nozzles 26f, 26g and 26h is insufficient to provide a dry shingle as measured by moisture sensor 36, then spray nozzles 26e are turned off. Thus, the nozzles are sequentially turned off or slowed down in the reverse machine direction until a condition of a dry shingle is sensed by the moisture sensor. Therefore, this invention encompasses both the control of the entire cooling section by one moisture sensor, such as moisture sensor 36, and the control of individual cooling units by moisture sensors positioned immediately downstream from those cooling units, such as moisture sensors 40, 42, and 44.
The positioning of additional temperature sensors, not shown, following individual cooling units can be effected in a manner similar to the placement of additional moisture sensors 40, 42 and 44. In operation, the nozzles of the cooling units can be sequentially turned on in the machine direction in response to a condition of sensed temperature above a predetermined temperature, in order to cool the asphaltic material prior to its being cut into shingles.
INDUSTRIAL APPLICABILITY
This invention will be found to be useful in the continuous production of asphaltic strip material for such uses as asphalt shingles. | A method and apparatus for cooling a continuously moving strip of asphaltic material includes directing the asphaltic material into a plurality of loops, spraying an evaporative liquid onto the asphaltic material, evaporating the evaporative liquid by causing an array of air jets to impinge on the asphaltic material subtantially normally to the asphaltic material, sensing the surface moisture of the asphaltic material subsequent to one or more of the loops, and modifying the flow of evaporative liquid sprayed in one or more of the loops in response to the sensed surface moisture. | 2 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to an axial piston machine with a rotating cylindrical drum, which has a multiplicity of cylindrical bores arranged concentrically to the axis of rotation with pistons capable of sliding longitudinally therein. The drum lies against a control surface adjacent the housing., in which case the pistons are in contact with a working surface that can be positioned diagonally to the axis of rotation and the cylindrical bores are provided with connecting openings to the control channels of the control surface, whereby the cylindrical drum is also supported in a longitudinally moveable manner. More particularly, the invention relates to such a machine wherein additional means is provided for controlling the pressing force of the cylindrical drum on the control surface, which is in working connection with the cylindrical drum.
2. Description of the Art
When such machines are used as pumps, especially as self-priming pumps, it is desirable that the pump have as high a suction rate as possible in order to minimize the filling losses caused by flow losses on the suction side and the resulting reduction in the delivery volume. The flow losses are a function of the flow velocity of the flow medium in the suction channel of the pump and the design of the latter. It is therefore necessary that the suction channel have as large a cross section as possible to keep the flow velocity and thus the pipe friction and flow losses low.
In the case of axial piston machines, there is a peculiarity that also leads to filling losses. This consists in the structurally induced gap between the housing control surface, which contains the orifices of the suction channel, designed as kidney-shaped control channels, and the rotating cylindrical drum lying against them. The gap is necessary so that a hydrostatic film of lubrication can form between the webs of the control surface and those of the cylindrical drum, which reduces the friction and facilitates disturbance-free and easy running of the machine. However, external leakage streams are caused by the gap, as well as inner leakage streams that flow directly from the high-pressure side to the low-pressure side of the control surface. The loss stream that results reduces the volumetric efficiency of the machine and thus the actual delivery volume. In order to achieve a satisfactory volumetric efficiency, the gap between the rotating cylindrical drum and the control surface must be kept as small as possible. This is achieved by a pressure spring which presses the cylindrical drum against the control surface and also by a connection which is produced between the cylindrical bores and the control channels through openings whose diameter is smaller than the diameter of the cylindrical bores. Through the latter measure, the cylindrical drum is pressed into the cylindrical bores against the control surface due to the fluid pressure, in which case the contact pressure is proportional to the loading of the machine. The leakage streams and/or filling losses of the axial piston machine are thus held at a low level.
The narrowed connection openings between the cylindrical bores and the control channels represent a constriction of the suction channel, which leads in the case of a certain desired delivery volume to a certain flow velocity in this region and thus to flow losses and, in accordance with the flow rate, to a restriction in the suction power of such a machine versus a machine lacking this structural means.
The geometric relationships on the suction side are thus essentially prescribed by the power and moment equilibrium between the hydrostatic release of the rotating cylindrical drum and limitation of the relief gap.
An axial piston machine of swash plate construction is disclosed in German patent DE-OS 22 50 510, in which an additional device situated around the outside diameter of the cylindrical drum induces an increase in the pressing force of the cylindrical drum on the control surface. A disadvantage in this device, however, is that it increases the structural volume of the axial piston machine substantially and leads to a complicated and expensive construction.
The present invention proposes to avoid those shortcomings and increase the suction ability of an axial piston machine in an economical manner.
SUMMARY OF THE INVENTION
According to the present invention, an axial piston machine with a cylindrical drum that lies against a control surface provided with control channels includes means for controlling the pressing force of the cylindrical drum on the control surface for increasing the suction ability. To increase the suction ability of the axial piston machine in an economical manner while retaining a small structural volume, the additional means is provided in a cavity between the inner surface of the cylindrical drum and the outer surface of the drive shaft. The additional means comprises at least one annular space that is formed by a hollow cylindrical inner surface of the cylindrical drum and two annular pistons capable of sliding longitudinally with respect to each other and arranged co-axially to the axis of rotation and is connected through connecting channels with the control channels and can be acted upon by high pressure, by which an additional pressing force can be exerted on the cylindrical drum.
The additional means can be thus obtained without the need for additional space and with simple means; it controls the pressing force of the cylindrical drum on the control surface, e.g., increasing it. An additional axial force is thus generated in the direction of the control surface. The additional contact pressure thus obtained can be used for an amplification of the kidney-shaped control channels in the control surface and the connection openings to the cylindrical bores, corresponding to the power and moment equilibrium. In some cases, the diameter of the connection openings can match the diameter of the cylindrical bores. A clear improvement in the suction capacity of the axial piston machine and an increase in the possible suction r.p.m. result in every case, which is advantageous, especially in machines that operate in an open cycle. An increase in the suction r.p.m. means that the machine can be capable of suction in an r.p.m. range that facilitates operation through a directly connected driving engine, so that reduction gearing, which was previously necessary, can be eliminated. This results in an increase in efficiency in such a unit.
The present invention can also be used for machines that operate in a closed cycle. The control channels can be enlarged and the webs between them can be broadened. The additional hydrostatic release of the cylindrical drum caused by a web broadening is then compensated by the axial force generated by the means.
It has proved advantageous if the additional means contains at least one piston surface that can be acted upon with operating pressure as a function of the delivery stream. The force of the cylindrical drum pressing on the control surface is controlled by the flow medium under the operating pressure that acts on the piston surface. The flow medium is drawn from the high-pressure control channels. The piston surface is thus loaded with flow medium under corresponding high pressure as a function of the load or the delivery stream of the machine.
The arrangement of the additional means can be used in machines whose cylindrical drum is supported in a longitudinally moveable manner on a drive shaft that passes through it centrally, as well as in machines that have no such central shaft.
In an advantageous embodiment of the invention, in which the additional means presses the cylindrical drum against the control surface and the cylindrical drum has a drive shaft passing through it centrally, the piston surface is formed between a hollow cylindrical inner surface of the cylindrical drum and two annular pistons that slide lengthwise with respect to each other and are arranged co-axially to the axis of rotation. The first annular piston has an axial support on the cylindrical drum and is capable of moving longitudinally with respect to the drive shaft and the second annular piston has an axial support on the drive shaft and is longitudinally moveable with respect to the cylindrical drum. The additional means can thus be constructed of only a few easily producable components and requires little space.
In another embodiment of the invention, the additional means has a direction of action away from the control surface. The cylinder block that is pressed by a pressure spring and, due to the pressure, into the cylindrical bores and the narrowings of the connection openings against the control surface thus undergoes a pressure-dependent release, which reduces the friction in the gap. Under certain conditions, i.e., if the axial force resulting from the relief pressure corresponds to the spring force, the force of the pressure spring is completely cancelled and the only force that still acts on the cylinder block is that resulting from the pressure in the cylindrical bores, and opposing it the hydrostatic release force in the gap. If the release pressure remains below a certain value, the full spring force acts on the cylindrical drum, by which higher r.p.m. are attainable, with no tipping of the cylindrical drum.
Hence, the additional means preferably comprises an annular piston arranged co-axially to the axis of rotation between a cylindrical outer surface of the drive shaft and a hollow cylindrical inner surface of the cylindrical drum. The piston is longitudinally moveable with respect to both the cylindrical drum and the drive shaft and with a cylindrical outer surface in connection with a hollow cylindrical inner surface of the cylindrical drum forms at least one annular space. In this case, the annular piston in the pressureless state of the axial piston machine has an initial end position, in which a pressure spring located between a hollow cylindrical inner surface of the annular piston and the cylindrical outer surface of the drive shaft has as large an axial extension as possible and the annular piston lies on a stop of the drive shaft. In the case of a given load of the axial piston machine, a second end position of the annular piston is provided, in which the pressure spring has as small an axial extension as possible and the annular piston lies on a stop of the cylindrical drum. When a certain pressure level is exceeded in the annular space, the annular piston moves into its second end position, so that the pressure spring no longer lies on the stop on the drive shaft and thus can no longer exert a pressing force on the cylindrical drum because the axial reaction force is no longer taken up by the drive shaft. Such a construction also has a low production cost. The pressure spring already present is supplemented only by an annular piston.
It is advantageous if at least one connecting channel located in the cylindrical drum is provided between the annular space and at least one of the control channels in the control surface. The connecting channel or channels can be readily introduced during production of the cylindrical drum. The drive shaft itself remains free of bore holes and grooves.
In axial piston machines with a device for adjusting the delivery volume and reversal of the direction of flow, e.g., a bilaterally pivotable axial piston pump of swash plate construction, according to another embodiment of the invention, at least one annular space and at least one connecting channel are assigned to each direction of flow. The additional means can be used in this case independently of the direction of flow, so that in each case the flow losses are reduced on both the suction and the pressure sides. It is desirable for this purpose if for the first direction of flow a multitude of connecting channels are spaced from each other concentrically to the axis of rotation on an initial graduated circle by an approximately identical angle, and for a second direction of flow a multitude of connecting channels are spaced by an approximately identical angle from each other concentrically to the axis of rotation on a second graduated circle. The annular space is thus loaded approximately uniformly with high pressure.
The invention will be understood and appreciated from a perusal of the specification taken with the following schematic representations showing one exemplary embodiment with several variants.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings:
FIG. 1 is an axial section on line 1--1 of FIG. 2 showing an embodiment of an axial piston machine according to the invention;
FIG. 2 is a section on line 2--2 of FIG. 1 showing a control surface of the axial piston machine shown in FIG. 1;
FIG. 3 is an axial section on line 3--3 of FIG. 4 showing a second embodiment of an axial piston machine according to the invention;
FIG. 4 is a section on line 4--4 of FIG. 3 showing a control surface of the axial piston machine shown in FIG. 3;
FIG. 5 is an axial section on line 5--5 of FIG. 6 showing a third embodiment of an axial piston machine according to the invention;
FIG. 6 is a section on line 6--6 of FIG. 5 showing a control surface of the axial piston machine shown in FIG. 5;
FIG. 7 is an axial section on line 7--7 of FIG. 8 showing a fourth embodiment of an axial piston machine according to the invention; and
FIG. 8 is a section on line 8--8 of FIG. 7 showing a control surface of the axial piston machine shown in FIG. 7.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The essential components of an axial piston machine according to the invention, in this example an axial piston machine of swash plate construction, are shown in the drawings wherein the housing and the working surface of the piston as well as some adjustment devices have not been shown.
A swash plate pump has a drive shaft 3 supported by bearings 1 and 2. The drive shaft 3 passes centrally through a cylindrical drum 4 and is connected with it in a rotationally contacting manner. The cylindrical drum 4 is longitudinally moveable within certain limits with respect to the drive shaft 3, which is achieved for example by a spline. The axial section shown in FIG. 1 is taken on section line 1--1 of FIG. 2. FIG. 2 in turn represents a section on line 2--2 of FIG. 1. The same drawing conventions apply for FIGS. 3-8.
An end of cylindrical drum 4 is located against control surface 5. The drum has a multitude of cylindrical bores 6 in which longitudinally moveable pistons 7 are located. The cylindrical bores 6 are arranged concentrically to the axis of rotation I of the drive shaft 3. The pistons 7 are connected with a working surface (not shown) that can be positioned obliquely to the axis of rotation. When the drive shaft 3 rotates, a piston stroke is induced in the conventional manner. The cylinder bores 6 are connected to control channels 9 and 10 of the control channel surface 5 by means of connecting openings 8 in certain rotational positions of the cylindrical drum 4. The connecting openings 8 are smaller in cross section than the cylindrical bores 6 so that the cylindrical drum 4 is pressed against the control surface 5 when a load-dependent pressure is present in the cylindrical bores 6. A hydrostatic relieving force, which acts in a known manner between the front face of the cylindrical drum 4 and the control surface 5, is directed against the axial force thus generated. In order to effect a certain pressing of the cylindrical drum 4 on the control surface 5 in the pressureless state of the swash plate pump and at a low pressure, a pressure spring 11 is provided, which is located in this embodiment inside the cylindrical drum 4 in an annular cavity 12 between a cylindrical outer surface 13 of the drive shaft 3 and a hollow cylindrical inner surface 14 of the cylindrical drum 4 co-axially to the axis of rotation I. The pressure spring 11 rests on the cylindrical drum 4 with its right end in the axial section via an annular piston 15 and a retaining ring 16. The annular piston 15 can also be made in several parts, as illustrated in the modification shown in the lower half of the axial section, namely of two parts 151 and 152, of which the latter forms a radial support flange 15a that projects inwardly toward the axis of rotation I. The annular piston 15 is moveable longitudinally with respect to both the inner wall 14 of the cylindrical drum 4 and the drive shaft 3, where the longitudinal movement with respect to the inner wall 14 of the cylindrical drum 4 is limited by the retaining ring 16 and makes contact with the hollow cylindrical inner surface 14 of the cylindrical drum 4 with its cylindrical outer surface. The annular cavity 12 in which the pressure spring 11 is located is situated between the cylindrical outer surface 13 of the drive shaft 3 and the inner surface of the annular piston 15.
The annular cavity 12 is closed off at one axial end by the support flange 15a and at the opposite axial end by a second annular piston 17, which forms an abutment for the pressure spring 11. The annular piston 17 is also axially moveable with respect to both the hollow cylindrical inner surface 14 of the cylindrical drum 4 and the drive shaft 3, in which case the axial movement relative to the drive shaft 3 is restricted by a collar 3a of the drive shaft 3. The pressure spring 11 is thus tensioned between the cylindrical drum 4 and the drive shaft 3.
The second annular piston 17 has a collar 17a oriented radially outwardly with respect to the axis of rotation I; its cylindrical outer surface lies on the hollow cylindrical inner surface 14 of the cylindrical drum 4. The first annular piston 15, together with the second annular piston 17 and the hollow cylindrical inner surface 14 of the cylindrical drum 4, form an annular space 18, which can be connected with at least one of the control channels 9 via a channel 19, which in this embodiment is essentially helical, and connection channels 20 in the cylindrical drum 4. The control channels 9 are under load-dependent high pressure when the pump is running. The connecting channels 20 are concentric to the axis of rotation I on a common graduated circle.
The number of connection channels 20 is basically arbitrary. However, the number and angular spacing are preferably chosen such that when the cylindrical drum 4 is rotating, at least one connecting channel 20 is always connected to a control channel 9. A connection to the control channel 10 of the control surface 5 is not provided in the embodiment shown in FIG. 1 because the swash plate pump is designed to have only one direction of throughflow.
The flow medium under high pressure passes from the control channels 9 through the connecting channels 20 and the channel 19 into the annular space 18, where it attempts to separate the annular pistons 15 and 17 from each other. A load-dependent additional pressing force is thus generated that presses the cylindrical drum 4 against the control surface 5. The additional means required for this consists, as described, only of the annular pistons 15 and 17, the channel 19 and the connecting channels 20.
The embodiment shown in FIGS. 3 and 4 differs from that shown in FIG. 1 in that the swash plate pump is designed for operation with different directions of flow, i.e., the swash plate can be swung from the zero position in two directions and back again. The additional means can thus operate bilaterally; two annular spaces 181 and 182 are provided to effect this mode of operation. The annular space 181 is connected to the connecting channels 20a and the annular space 182 to the connecting channels 20b. The connecting channels 20a are spaced by an approximately identical angular amount from each other on an initial inner graduated circle and are loaded with high pressure in an initial direction of flow. The connecting channels 20b are spaced by an approximately identical angular amount from each other on a second outer graduated circle. If the direction of flow changes, the connecting channels 20b are under high pressure. Independently of the direction of flow, one of the annular spaces 181 or 182 is thus always acted upon by high pressure in a load-dependent manner so that the additional means is active and presses the cylindrical drum 4 against the control surface 5.
"The embodiment shown in FIGS. 5 and 6 has a swash" plate pump with only one direction of flow. In this embodiment, only three connecting channels 20 arranged with a spacing of 120° on a graduated circle are required due to the configuration of the control channels 9 and 10 in the control surface 5 in order to achieve a uniform loading of the annular space 18 with high pressure.
A swash plate pump with two possible directions of flow is shown in FIGS. 7 and 8, in which the additional means relieves the cylindrical drum in operation. Instead of two annular pistons 15 and 17, a single stepped annular piston 251 is provided for this purpose; it works in conjunction with a stop 252. The annular piston 251 is moveable longitudinally with respect to both the cylindrical drum 4 and the drive shaft 3. In the rest position of the axial piston machine, the pressure spring 11 presses the annular piston 251 and the stop 252 apart into an initial end position, in which the annular piston 251 lies on the collar 3a of the drive shaft 3, the stop 252 lies on the retaining ring 16 on the cylindrical drum 4 and the pressure spring 11 has the greatest possible axial extension. The graduation of the annular piston 251 facilitates the development of two annular spaces 181 and 182, which can be loaded with high pressure depending on the direction of flow of the medium. Above a certain load or a certain pressure in one of the two annular spaces 181 or 182, the pressure spring 11 is compressed with the aid of the annular piston 251 and separated by the collar 3a until the annular piston 251 lies on the stop 252 in a second end position. The pressure spring 11 has its smallest possible axial extension in this position and cannot be further compressed. Although the pressure spring 11 is indeed tensioned, it still does not act on the cylindrical drum 4 to increase the pressing force on the control surface 5. The compressive force of the pressure spring Il is continuously reduced or increased between the two end positions by the load-dependent pressure rise in one of the two annular spaces 181 or 182.
Having described presently preferred embodiments of the invention, it is to be understood that the invention may be embodied within the scope of the appended claims. | An axial piston machine having a longitudinally movable rotary cylindrical drum with cylindrical bores arranged concentrically to the axis of rotation of the drum. A longitudinally sliding piston located in each bore and lying against a control surface in contact with the drum. The pistons have an end in contact with a control surface that can be positioned diagonally to the axis of rotation of the drum and said cylindrical bores are provided with openings connecting to control channels in the control surface. Additional piston surfaces are provided in a cavity formed in the cylindrical drum for controlling the pressing force of the cylindrical drum on the control surface. | 5 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. provisional application 61/558,299, filed Nov. 10, 2011, the entire contents of which are incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The invention relates to 2-amino-4H-naphtho[1,2-b]pyran-3-carbonitriles that are useful for treating ovarian cancer and other types of serosal cancers.
BACKGROUND OF THE INVENTION
[0003] Ovarian cancer ranks fifth in cancer deaths among women and causes more deaths than any other gynecologic malignancy. It is estimated that in the United States 22,430 new cases will be diagnosed each year with 15,280 deaths. Ovarian carcinoma remains enigmatic in at least two important respects. First, the histological region of origin for this cancer remains obscure and second, an identifiable premalignant lesion that is generally recognized by cancer pathologists is yet to be defined. The majority (80%) of patients present with advanced stage disease with cancer cells throughout the abdominal cavity, leading directly to the high mortality (5 year survival rates 15-45%). In contrast, the survival rate for early stage disease, with malignancy confined to the ovary, is about 95%.
[0004] The median overall survival for patients with advanced ovarian cancer has improved from approximately 1 year in 1975 to currently in excess of 3 years. For subsets of patients having optimally debulked disease and receiving treatment with taxane-and platinum-based combination chemotherapy, survival now exceeds 5 years. However the disease course is one of remission and relapse requiring intermittent re-treatment. The presence of cancer cells in effusions within the serosal (peritoneal, pleural, and pericardial) cavities is a clinical manifestation of advanced stage cancer and is associated with poor survival. Tumor cells in effusions most frequently originate from primary carcinomas of the ovary, breast, and lung, and from malignant mesothelioma, a native tumor of this anatomic site. Unlike the majority of solid tumors, particularly at the primary site, cancer cells in effusions are not amenable to surgical removal and failure in their eradication is one of the main causes of treatment failure.
[0005] PCT WO2011/057034 suggests that serosal ovarian cancer stem cells (also called catena cells), which possess a glycocalyx (pericellular coat), may be the most drug resistant structure in ovarian cancer. Presumably due to the impermeability of the glycocalyx, catena cells appear resistant to many chemotherapeutic agents. It is important to discover compounds that can penetrate the glycocalyx and exert toxicity against ovarian cancer stem cells. Eradicating cancer stem cells (CSCs) would be expected to increase the efficiency of therapy for ovarian or other serosal cancers, including metastatic serosal cancer.
SUMMARY OF THE INVENTION
[0006] The compounds of the invention are useful as anticancer agents, particularly in the treatment of ovarian and other serosal cancers.
[0007] In one aspect, the invention relates to a method for inhibiting the growth of an ovarian cancer cell or other cancer cell with a pericellular coat. The method comprises exposing the cell to a compound of formula I:
[0000]
[0000] wherein:
Y is CR 1 or N; Z is CR 5 or N; R 1 is chosen from H and (C 1 -C 8 )hydrocarbon; R 2 is chosen from H, halogen, —CF 3 , —NO 2 , —CN, —NHC(═O)(C 1 -C 8 )hydrocarbon and —NHSO 2 (C 1 -C 8 )hydrocarbon; R 3 is chosen from H and halogen; R 4 is chosen from H, halogen, —NO 2 , —CN, (C 1 -C 8 )hydrocarbon and —O—(C 1 -C 8 )hydrocarbon; and R 5 is chosen from H, halogen, —NO 2 , —CN, —NHC(═O)(C 1 -C 8 )hydrocarbon and —NHSO 2 (C 1 -C 8 )hydrocarbon.
[0015] In another aspect, the invention relates to a method for treating serosal cancer in a patient having serosal cancer, said method comprising administering to said patient a therapeutically effective amount of a compound of formula I.
[0016] In another aspect, the invention relates to a compound of formula:
[0000]
[0017] In another aspect, the invention relates to a pharmaceutical composition comprising a pharmaceutically acceptable carrier and a compound of formula:
[0000]
DETAILED DESCRIPTION OF THE INVENTION
[0018] The serosal cavity is a closed body cavity that includes and encloses the peritoneal, pleural, and pericardial cavities of the body, is fluid filled (serosal fluid) and is bounded by the serous membrane. Serosal cells are any cells originating from or found within the serosal cavity or forming or attaching to the serous membrane, and include, but are not limited to, ovarian, endothelial, stomach, intestinal, anal, pancreatic, liver, lung and heart cells. Serosal cancers include the primary cancers that arise within the serosal cavity and secondary cancers that arise by metastasis of other cancer cells into the serosal cavity. Major serosal cancers at different serosal sites include those in (1) pleural effusions, namely mesothelioma, bronchogenic lung cancer, breast cancer, bladder cancer, ovarian cancer, fallopian tube cancer, cervical cancer and sarcoma; (2) peritoneal effusions, namely ovarian cancer, fallopian tube cancer, gastric cancer, pancreatic cancer, colon cancer, renal cancer and bladder cancer; and (3) pericardial effusions, namely mesothelioma, bronchogenic lung cancer, breast cancer, bladder cancer, ovarian cancer, fallopian tube cancer, cervical cancer and sarcoma. The list is not exhaustive, and other cancers that metastasize to a serosal cavity and form tumors can be considered as “serosal cancers.”
[0019] WO2011/057034 discloses a model of the catena-spheroid concept and the role of CSCs in the development of ovarian cancer. According to this model, the initial transformation of ovarian (or fallopian) epithelium progresses via an epithelial-mesenchymal and mesenchymal-catena transition. The catena cells lose all attachment to extracellular matrix or peritoneal mesothelium but remain attached to each other following each round of symmetric division. At this point, the catena is composed predominantly of CSCs. The catenae can release single cells that generate secondary catenae or form spheroids. The catenae can also roll up and form spheres which contain a >10 fold higher frequency of CSC than tumors growing as two-dimensional (2D) monolayers or solid tumors. Spheroids can release new catenae or can attach to the mesothelial wall of the peritoneum to form omental cakes. Catenae may be released from solid tumors by a mesenchymal-catena transition and may reenter the peritoneal ascites or penetrate into blood vessels leading to more distant metastasis. Hyaluronan is a major component of the glycocalyx, which is a predominant morphological feature of catenae and can be removed by treatment with hyaluronidase. The glycocalyx extends up to approximately 20 μm around the catena cells.
[0020] It has now been found that certain 2-amino-4H-naphtho[1,2-b]pyran-3-carbonitriles are capable of penetrating the glycocalyx and inhibiting the growth of catena cells.
[0021] In one aspect, the invention relates to methods employing compounds of formula I:
[0000]
[0022] In some embodiments of the invention, the methods involve administration of compounds of the formula II:
[0000]
[0000] which is a subset of formula I. In these compounds, Y is N and Z is CR 5 . R 5 may be H or CH 3 . In some embodiments of subset II, R 2 and R 3 may be H. In some embodiments of II, R 4 may be H.
[0023] In other embodiments of the invention, which form another subset of the compounds of formula I, the methods involve administration of compounds of the formula III:
[0000]
[0000] In these compounds, Z is N and Y is CR 1 . In some embodiments of subset III, R 2 and R 3 may be H. In some embodiments of III, R 4 may be H.
[0024] In other embodiments of the invention, which form another subset of the compounds of formula I, the methods involve administration of compounds of the formula IV:
[0000]
[0000] In these compounds, Z is CR 5 and Y is CR 1 . In some embodiments of subset IV, R 3 may be halogen. In some embodiments, R 1 and R 3 may be H and R 2 may be halogen, —CF 3 , —NO 2 , or —CN. In some embodiments, R 1 may be (C 1 -C 8 )hydrocarbon. In some embodiments, R 2 and R 3 may be H. In some embodiments of IV, R 4 may be H.
[0025] Throughout this specification the terms and substituents retain their definitions.
[0026] Alkyl is intended to include linear or branched, or cyclic hydrocarbon structures and combinations thereof. A combination would be, for example, cyclopropylmethyl. Lower alkyl refers to alkyl groups of from 1 to 6 carbon atoms. Examples of lower alkyl groups include methyl, ethyl, propyl, isopropyl, cyclopropyl, butyl, s-and t-butyl, cyclobutyl and the like. Preferred alkyl groups are those of C 20 or below; more preferred are C 8 or below. Cycloalkyl is a subset of alkyl and includes cyclic hydrocarbon groups of from 3 to 8 carbon atoms. Examples of cycloalkyl groups include c-propyl, c-butyl, c-pentyl, norbornyl and the like.
[0027] Alkoxy or alkoxyl refers to groups of from 1 to 8 carbon atoms of a straight, branched, or cyclic configuration and combinations thereof attached to the parent structure through an oxygen. Examples include methoxy, ethoxy, propoxy, isopropoxy, cyclopropyloxy, cyclohexyloxy and the like. Lower-alkoxy refers to groups containing one to four carbons.
[0028] Aryl and heteroaryl mean a 5- or 6-membered aromatic or heteroaromatic ring containing 0-3 heteroatoms selected from O, N, or S; a bicyclic 9- or 10-membered aromatic or heteroaromatic ring system containing 0-3 heteroatoms selected from O, N, or S; or a tricyclic 13- or 14-membered aromatic or heteroaromatic ring system containing 0-3 heteroatoms selected from O, N, or S. The aromatic 6- to 14-membered carbocyclic rings include, e.g., benzene, naphthalene, indane, tetralin, and fluorene and the 5- to 10-membered aromatic heterocyclic rings include, e.g., imidazole, pyridine, indole, thiophene, benzopyranone, thiazole, furan, benzimidazole, quinoline, isoquinoline, quinoxaline, pyrimidine, pyrazine, tetrazole and pyrazole. As used herein aryl and heteroaryl refer to residues in which one or more rings are aromatic, but not all need be.
[0029] Arylalkyl means an aryl ring attached to an alkyl residue in which the point of attachment to the parent structure is through the alkyl. Examples are benzyl, phenethyl and the like. Heteroarylalkyl means an alkyl residue attached to a heteroaryl ring. Examples include, e.g., pyridinylmethyl, pyrimidinylethyl and the like.
[0030] C 2 to C 10 hydrocarbon means a linear, branched, or cyclic residue comprised of hydrogen and carbon as the only elemental constituents and includes alkyl, cycloalkyl, polycycloalkyl, alkenyl, alkynyl, aryl and combinations thereof. Examples include benzyl, phenethyl, cyclohexylmethyl, cyclopropylmethyl, cyclobutylmethyl, allyl, camphoryl and naphthylethyl.
[0031] Unless otherwise specified, the term “carbocycle” is intended to include ring systems in which the ring atoms are all carbon but of any oxidation state. Thus (C 3 -C 10 ) carbocycle refers to both non-aromatic and aromatic systems, including such systems as cyclopropane, benzene and cyclohexene; (C 8 -C 12 ) carbopolycycle refers to such systems as norbornane, decalin, indane and naphthalene. Carbocycle, if not otherwise limited, refers to monocycles, bicycles and polycycles.
[0032] Heterocycle means a cycloalkyl or aryl residue in which one to two of the carbons is replaced by a heteroatom such as oxygen, nitrogen or sulfur. Heteroaryls form a subset of heterocycles. Examples of heterocycles include pyrrolidine, pyrazole, pyrrole, imidazole, indole, quinoline, isoquinoline, tetrahydroisoquinoline, benzofuran, benzodioxan, benzodioxole (commonly referred to as methylenedioxyphenyl, when occurring as a substituent), tetrazole, morpholine, thiazole, pyridine, pyridazine, pyrimidine, pyrazine, thiophene, furan, oxazole, oxazoline, isoxazole, dioxane, tetrahydrofuran and the like.
[0033] As used herein, the term “optionally substituted” may be used interchangeably with “unsubstituted or substituted”. The term “substituted” refers to the replacement of one or more hydrogen atoms in a specified group with a specified radical. Substituted alkyl, aryl, cycloalkyl, heterocyclyl etc. refer to alkyl, aryl, cycloalkyl, or heterocyclyl wherein one or more H atoms in each residue are replaced with halogen, haloalkyl, alkyl, acyl, alkoxyalkyl, hydroxyloweralkyl, hydroxy, loweralkoxy, haloalkoxy, oxaalkyl, carboxy, nitro, amino, alkylamino, and/or dialkylamino. In one embodiment, 1, 2 or 3 hydrogen atoms are replaced with a specified radical. In the case of alkyl and cycloalkyl, more than three hydrogen atoms can be replaced by fluorine; indeed, all available hydrogen atoms could be replaced by fluorine.
[0034] The compounds described herein may contain, in a substituent R x , double bonds and may also contain other centers of geometric asymmetry; unless specified otherwise, it is intended that the compounds include both E and Z geometric isomers. Likewise, all tautomeric forms are also intended to be included. The configuration of any carbon-carbon double bond appearing herein is selected for convenience only and, unless expressly stated, is not intended to designate a particular configuration; thus a carbon-carbon double bond depicted arbitrarily herein as trans may be cis, trans, or a mixture of the two in any proportion. The compounds may also contain, in a substituent R x , one or more asymmetric centers and may thus give rise to enantiomers, diastereomers, and other stereoisomeric forms that may be defined, in terms of absolute stereochemistry, as (R)- or (S)-. The present invention is meant to include all such possible isomers, as well as their racemic and optically pure forms. Optically active (R)- and (S)-isomers may be prepared using chiral synthons or chiral reagents, or resolved using conventional techniques.
[0035] As used herein, and as would be understood by the person of skill in the art, the recitation of “a compound” -unless expressly further limited-is intended to include salts of that compound. In a particular embodiment, the term “compound of formula I” refers to the compound or a pharmaceutically acceptable salt thereof. For example, when Y or Z is nitrogen, the compounds of the invention may exist as salts, i.e. cationic species.
[0036] The term “pharmaceutically acceptable salt” refers to salts whose counter ion (anion) derives from pharmaceutically acceptable non-toxic acids including inorganic acids and organic acids. Suitable pharmaceutically acceptable acids for salts of the compounds of the present invention include, for example, acetic, adipic, alginic, ascorbic, aspartic, benzenesulfonic (besylate), benzoic, boric, butyric, camphoric, camphorsulfonic, carbonic, citric, ethanedisulfonic, ethanesulfonic, ethylenediaminetetraacetic, formic, fumaric, glucoheptonic, gluconic, glutamic, hydrobromic, hydrochloric, hydroiodic, hydroxynaphthoic, isethionic, lactic, lactobionic, laurylsulfonic, maleic, malic, mandelic, methanesulfonic, mucic, naphthylenesulfonic, nitric, oleic, pamoic, pantothenic, phosphoric, pivalic, polygalacturonic, salicylic, stearic, succinic, sulfuric, tannic, tartaric acid, teoclatic, p-toluenesulfonic, and the like.
[0037] It will be recognized that the compounds of this invention can exist in radiolabeled form, i.e., the compounds may contain one or more atoms containing an atomic mass or mass number different from the atomic mass or mass number usually found in nature. Alternatively, a plurality of molecules of a single structure may include at least one atom that occurs in an isotopic ratio that is different from the isotopic ratio found in nature. Radioisotopes of hydrogen, carbon, phosphorous, fluorine, chlorine and iodine include 2 H, 3 H, 11 C, 13 C, 14 C, 15 N, 35 S, 18 F, 36 Cl, 125 I, 124 I, and 131 I respectively. Compounds that contain those radioisotopes and/or other radioisotopes of other atoms are within the scope of this invention. Tritiated, i.e. 3 H, and carbon-14, i.e., 14 C, radioisotopes are particularly preferred for their ease in preparation and detectability. Compounds that contain isotopes 11 C, 13 N, 15 O , 124 I and 18 F are well suited for positron emission tomography. Radiolabeled compounds of formulae I and II of this invention and prodrugs thereof can generally be prepared by methods well known to those skilled in the art. Conveniently, such radiolabeled compounds can be prepared by carrying out the procedures disclosed in the Examples and Schemes by substituting a readily available radiolabeled reagent for a non-radiolabeled reagent.
[0038] Although this invention is susceptible to embodiment in many different forms, preferred embodiments of the invention are shown. It should be understood, however, that the present disclosure is to be considered as an exemplification of the principles of this invention and is not intended to limit the invention to the embodiments illustrated. It may be found upon examination that certain members of the claimed genus are not patentable to the inventors in this application. In this event, subsequent exclusions of species from the compass of applicants' claims are to be considered artifacts of patent prosecution and not reflective of the inventors' concept or description of their invention; the invention encompasses all of the members of the genus I that are not already in the possession of the public, and all of the members of the genus I for use in treating cancer where such use is not already in the possession of the public.
[0039] While it may be possible for the compounds of formula I to be administered as the raw chemical, it is preferable to present them as a pharmaceutical composition. According to a further aspect, the present invention provides a pharmaceutical composition comprising a compound of formula I or a pharmaceutically acceptable salt or solvate thereof, together with one or more pharmaceutically carriers thereof and optionally one or more other therapeutic ingredients. The carrier(s) must be “acceptable” in the sense of being compatible with the other ingredients of the formulation and not deleterious to the recipient thereof. The compositions may be formulated for oral, topical or parenteral administration. For example, they may be given intravenously, intraarterially, intraperitoneally, intratumorally or subcutaneously.
[0040] Formulations include those suitable for oral, parenteral (including subcutaneous, intradermal, intramuscular, intravenous and intraarticular), rectal and topical administration. The compounds are preferably administered orally or by injection (intravenous, intramuscular, intraperitoneally, intratumorally or subcutaneous). The precise amount of compound administered to a patient will be the responsibility of the attendant physician. However, the dose employed will depend on a number of factors, including the age and sex of the patient, the precise disorder being treated, and its severity. Also, the route of administration may vary depending on the condition and its severity. The formulations may conveniently be presented in unit dosage form and may be prepared by any of the methods well known in the art of pharmacy. In general, the formulations are prepared by uniformly and intimately bringing into association the active ingredient with liquid carriers or finely divided solid carriers or both and then, if necessary, shaping the product into the desired formulation.
[0041] Formulations of the present invention suitable for oral administration may be presented as discrete units such as capsules, cachets or tablets each containing a predetermined amount of the active ingredient; as a powder or granules; as a solution or a suspension in an aqueous liquid or a non-aqueous liquid; or as an oil-in-water liquid emulsion or a water-in-oil liquid emulsion. The active ingredient may also be presented as a bolus, electuary or paste.
[0042] A tablet may be made by compression or molding, optionally with one or more accessory ingredients. Compressed tablets may be prepared by compressing in a suitable machine the active ingredient in a free-flowing form such as a powder or granules, optionally mixed with a binder, lubricant, inert diluent, lubricating, surface active or dispersing agent. Molded tablets may be made by molding in a suitable machine a mixture of the powdered compound moistened with an inert liquid diluent. The tablets may optionally be coated or scored and may be formulated so as to provide sustained, delayed or controlled release of the active ingredient therein.
[0043] Formulations for parenteral administration include aqueous and non-aqueous sterile injection solutions which may contain anti-oxidants, buffers, bacteriostats and solutes which render the formulation isotonic with the blood of the intended recipient. Formulations for parenteral administration also include aqueous and non-aqueous sterile suspensions, which may include suspending agents and thickening agents. The formulations may be presented in unit-dose or multi-dose containers, for example sealed ampoules and vials, and may be stored in a freeze-dried (lyophilized) condition requiring only the addition of a sterile liquid carrier, for example saline, phosphate-buffered saline (PBS) or the like, immediately prior to use. Extemporaneous injection solutions and suspensions may be prepared from sterile powders, granules and tablets of the kind previously described.
[0044] Preferred unit dosage formulations are those containing an effective dose, as herein below recited, or an appropriate fraction thereof, of the active ingredient.
[0045] It should be understood that in addition to the ingredients particularly mentioned above, the formulations of this invention may include other agents conventional in the art having regard to the type of formulation in question, for example those suitable for oral administration may include flavoring agents.
[0046] As used herein, “treatment” or “treating,” or “palliating” or “ameliorating” are used interchangeably herein. These terms refer to an approach for obtaining beneficial or desired results including but not limited to therapeutic benefit and/or a prophylactic benefit. By therapeutic benefit is meant eradication or amelioration of the underlying disorder being treated. Also, a therapeutic benefit is achieved with the eradication or amelioration of one or more of the physiological symptoms associated with the underlying disorder such that an improvement is observed in the patient, notwithstanding that the patient may still be afflicted with the underlying disorder. For prophylactic benefit, the compositions may be administered to a patient reporting one or more of the physiological symptoms of a disease, even though a diagnosis of this disease may not have been made.
[0047] A comprehensive list of abbreviations utilized by organic chemists (i.e. persons of ordinary skill in the art) appears in the first issue of each volume of the Journal of Organic Chemistry . The list, which is typically presented in a table entitled “Standard List of Abbreviations” is incorporated herein by reference.
[0048] The compounds employed in the invention are commercially available, are known or may be synthesized by processes known in the art. For example, U.S. Pat. Nos. 5,514,699; 5,281,619; and 5,507,762 as well as European patent 537949 describe the synthesis of numerous 2-amino-4H-naphtho[1,2-b]pyran-3-carbonitriles. The disclosures of U.S. Pat. Nos. 5,514,699; 5,281,619 and European patent 537949 as they relate to the synthesis of 2-amino-4H-naphtho[1,2-b]pyran-3-carbonitriles are incorporated herein by reference. In general the synthesis may be schematically described as follows:
[0000]
[0049] Ten examples of compounds of the genus I have been prepared and tested according to the protocol described in WO02011/057034, which is recapitulated here. Ovcar3-GTL-derived catenae were tested for their ability to self-propagate in flat bottom 384-well microtiter plates (Corning). Cultures of Ovcar3-GTL catenae were mechanically or enzymatically dissociated to single cells. For mechanical dissociation, catena cultures were pipetted vigorously, an equal volume of M5-FCS media was added to decrease the viscosity, and the cells were pelleted. For enzymatic dissociation, catena cultures were incubated at 5 mg/ml collagenase IV (Invitrogen) for 10 min at 37° C. followed by centrifugation to pellet the cells. Cells were resuspended in M5-FCS to produce homogenous cultures of single cells which were seeded in 50 microliter aliquots per well at the indicated cell densities and grown for 6 days before addition of test compounds or other reagents.
[0050] To assess cell growth, cells were observed under the microscope and manually counted using a hematocytometer or were treated with alamarBlue by adding 1/10 volume of alamarBlue reagent directly to the culture medium, incubating the cultures for a further 48 hours at 37° C. and measuring the fluorescence or absorbance. Both spectroscopic methods gave comparable results. The amount of fluorescence or absorbance is proportional to the number of living cells and corresponds to the cells metabolic activity. Fluorescence measurement is more sensitive than absorbance measurement and is measured by a plate reader using a fluorescence excitation wavelength of 540-570 nm (peak excitation is 570 nm) and reading emission at 580-610 nm (peak emission is 585 nm). Absorbance of alamarBlue is monitored at 570 nm, using 600 nm as a reference wavelength. Larger fluorescence emission intensity (or absorbance) values correlate to an increase in total metabolic activity from cells.
[0051] Because the components of the pericellular glycocalyx were significantly removed prior to cell seeding by mechanical or enzymatic dissociation of catena, the optimal time for adding compounds to ensure that the catenae had an established glycocalyx is 3-6 days after seeding. In WO2011/057034 it was shown that catena were resistant to 21 out of 23 known anticancer agents. The formation of glycocalyx conferred more than 8,000,000-fold resistance in catenae to paclitaxel, fludelone and 9-10dEpoB. All 10 of the 2-amino-4H-naphtho[1,2-b]pyran-3-carbonitriles described below were found active in this screen, indicating that, unlike most known anticancer agents, the 2-amino-4H-naphtho[1,2-b]pyran-3-carbonitriles are able to penetrate the glycocalyx.
[0052] Compounds tested and found effective were:
[0000]
[0053] The compound designated example 4 above was tested in vivo for toxicity in NSG mice. As used herein, NSG and NSG mice mean the NOD scid gamma (NSG) mice, or an equivalent, available from The Jackson Laboratory and which are the NOD.Cg-Prkdc scid Il2rg tm|wjl /SzJ JAX® Mice strain. The NSG mice were injected intraperitoneally with 1, 2.5, 5, 10, 20 or 40 mg/kg of the compound designated example 4 above for once or three times a week for 4 weeks. The compound designated example 4 above showed no overt toxicity in any concentrations or at any drug administration schedules. | Methods for inhibiting the growth of ovarian cancer cells or other serosal cancer cells are disclosed. The method involves exposing the cells to a 2-amino-4H-naphtho[1,2-b]pyran-3-carbonitrile of formula:
whereinY is CR 1 or N and Z is CR 5 or N. | 2 |
FIELD OF THE INVENTION
The present invention relates generally to measuring the quality of an optical signal transmitted in a photonics network, and, more particularly, to techniques for using an interferometer to separate a modulated, coherent signal from incoherent noise mixed with the signal.
BACKGROUND OF THE INVENTION
As optical transmission distances become longer and photonic networks begin to assume some of the routing functions formerly associated with electronic switching, there is a need for optical performance monitoring, and optical signal-to-noise ratio (OSNR) measurement in particular.
Direct spectrum measurement using tunable filters cannot distinguish between coherent signal power and incoherent noise power. It must rely on baseline measurements at signal-free wavelengths, but such baseline wavelengths may not be present in advanced networks with optical add/drop functions.
Polarization-based techniques offer a way to reject a signal so that the noise can be measured, but are susceptible to errors induced by partial polarization of the noise and by depolarization of the signal.
There remains a need for a system that is well suited to signal integrity monitoring and diagnostics, and that permits measurement of OSNR.
SUMMARY OF THE INVENTION
The present invention addresses the needs described above by providing, in one embodiment of the invention, a method for measuring the signal quality of light present in an optical communication medium, the light including at least one substantially coherent optical signal degraded by substantially incoherent optical noise. The method includes the step of passing at least a portion of the light through an interferometer capable of introducing a specified delay into at least one light beam of a plurality of beams split from the portion of the light. A light output power from the interferometer corresponding to a first specified delay setting is measured, and the coherent optical signal is distinguished from the incoherent optical noise based on the light power measurement.
The step of distinguishing the coherent optical signal from the incoherent optical noise may be based on the light power measured at a given optical frequency.
The method may further include the step of computing a numerical value representing signal quality from relative magnitudes of the coherent optical signal and the incoherent optical noise. In that case, the method may also include the step of determining a numerical value of an optical signal-to-noise ratio.
The optical communication medium may be an optical fiber. The step of distinguishing the coherent optical signal from the incoherent optical noise based on the light power measurement may further comprise extracting an envelope of an interferogram. The at least one coherent optical signal may be modulated with live data traffic during the measuring step.
The method may further comprise the steps of measuring the light output power from an interferometer at a second specified delay setting, and using power measurements corresponding to the first and second specified delay settings to determine a modulation format of the substantially coherent optical signal. Further, the first specified delay and the second specified delay may be provided by adjusting a resettable beam delayer under the control of a delay controller.
In another embodiment of the invention, an apparatus is provided for monitoring an optical signal quality of a light signal transmitted in an optical transmission medium. The apparatus includes a tap connected to the optical transmission medium for tapping off a portion of the light signal, and a splitter for forming two beams from the tapped portion of the light signal. The apparatus further includes a beam delayer for introducing a first specified delay into at least one of the two beams, and instrumentation for measuring a light output power from an interferogram formed from the two beams including the first specified delay. A processor is connected for receiving a measurement of the light output power from the instrumentation. A computer readable medium contains instructions that, when executed by the processor, cause the processor to extract a numerical value from the light output power measurement representing a relative magnitude of coherent and incoherent parts of the light signal.
The computer readable instructions may contain an algorithm for distinguishing a coherent optical signal from an incoherent optical noise based on the light power output measurement. The algorithm for distinguishing the coherent optical signal from the incoherent optical noise based on the light power may be performed on data taken at a given optical frequency. The algorithm may extract an envelope of an interferogram.
The computer readable instructions may further cause the processor to determine a numerical value of an optical signal-to-noise ratio. The optical communication medium may be an optical fiber. The coherent part of the light signal may be modulated with live data traffic.
The apparatus may further comprise a second beam delayer for introducing a second specified delay, and the instrumentation may further be for measuring a light output power from an interferogram formed from the two beams including the second specified delay. In that case, the computer readable instructions further cause the processor to use power measurements corresponding to the first and second specified delays to determine a modulation format of the coherent part of the light signal.
The apparatus may further include a delay controller capable of adjusting a resettable beam delayer to obtain the first specified delay and the second specified delay.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic plot of oscillations of optical power as a function of interferometer delay for a Gaussian-filtered noise source.
FIG. 2 is a schematic plot of oscillations and oscillation envelopes of optical power as a function of interferometer delay for a modulated signal and two broadband noise signals.
FIG. 3 is a plot of experimental interferogram envelopes for a modulated signal and two broadband noise signals.
FIG. 4 is an enlarged view of an area of the plot of FIG. 3 .
FIG. 5 is a schematic diagram of an apparatus according to one embodiment of the invention.
FIG. 6 is a flow chart showing a method according to one embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
The present invention overcomes the above-described problems by determining the OSNR of signals propagating in photonic networks. By using an interferometer, the inventors distinguish between a coherent optical signal and an incoherent noise occupying the same optical band.
Interferometry of CW Light
When a continuous wave (CW) light with frequency ω and the power I 0 enters a Michelson interferometer, the transmitted power I T is given by the following expression:
I
T
=
I
0
2
(
1
+
cos
ω
τ
)
(
1
)
where τ is the delay between two arms of the interferometer expressed in units of time. A rigorous mathematical treatment is given in Hermann Haus, “Waves and Fields in Optoelectronics” at § 3.6, the content of which is incorporated by reference herein. Depending on the interferometer delay, the transmitted power oscillates between I 0 , corresponding to full transmission of the incident power, and zero, corresponding to total reflection of the incident light back to the input port. Those oscillations continue up to very large values of the interferometer delay, determined by the coherence time of the source (at least 100 ns for laser sources).
Interferometry of a Finite Spectral Width Light Source
The equation above can be easily generalized for a light source carrying many frequency components. Assuming that each frequency component ω k has spectral power I k , then the transmitted power I T is given by:
I
T
=
1
2
∑
k
I
k
+
1
2
∑
k
I
k
cos
ω
k
τ
(
2
)
The first term of that equation is half of the total spectral power, and the second term, viewed as a function of the interferometer delay τ, is simply half of the real Fourier transform of the incident spectrum. Thus the shape of the interferogram can be used to determine the complete optical power spectrum.
The result of equation (2) can be easily illustrated for a special case of a source whose width δω is much smaller than its center frequency ω 0 . FIG. 1 is a theoretical plot 100 showing normalized power 110 as a function of interferometer delay 120 . The transmitted power I T still has rapid oscillations with the interferometer delay τ at the center frequency ω 0 , but this oscillatory pattern is confined within a bellshape-like envelope 130 of the width about 1/δω as shown schematically in the plot of FIG. 1 . While the exact shape of the envelope depends on the shape of the incident spectrum, the transmitted power I T , in contrast to the monochromatic case, asymptotically approaches a constant level of I 0 /2 (shown at 140 ) for sufficiently large values of the interferometer delay τ (greater then the inverse width of the incident spectrum 1/δω).
Note that the “broadband” terminology used herein may be confusing. Optical noise sources that are conventionally called “broadband” in the telecommunication community have a width of about 10 nm (1.25 THz), and are centered around 1550 nm (193.5 THz). So all these sources have, in fact, a rather narrow width when it is compared with their center frequency. Thus, the special case considered above fully describes situations that are of interest herein.
Note that numerical calculations of the Fourier transform of a narrow power spectrum centered on high frequency are cumbersome. However, it follows from the convolution theorem that the envelope alone can be obtained by the Fourier transformation of the power spectrum shifted to zero frequency.
Interferometry of a Modulated Signal
In telecom systems, digital information is encoded in the optical signal by modulating a coherent CW laser light with a sequence of 0's and 1's. That modulation causes spectral broadening of the initial laser line. Although a modulated carrier may produce a power spectrum that is quite similar to that of a filtered noise source, its interferogram will, in general, be different. The discussion below considers the most widely-deployed modulation format: simple NRZ OOK modulation. The analysis can be easily extended to other modulation formats.
Coherent and incoherent signals display very different interferogram envelopes. An envelope 210 for a 10 Gb/s signal with pseudorandom OOK modulation is presented in the plot 200 of FIG. 2 . For comparison, there is also plotted the interferograms from a 20 GHz wide square spectrum of incoherent light (line 220 ) and from an incoherent Gaussian spectrum (line 230 ) with a full width of 14 GHz. Comparison of the two broadband noise interferograms reveals that the sharp edges of the square spectrum give rise to ripples in the interferogram. The key difference between the modulated signal interferogram and both broadband noise interferograms is that the latter two have finite width, while the former continues practically indefinitely, similar to the purely monochromatic case of equation (1) above, albeit at a lower level (eventually it will be limited by the coherence time of the laser). The explanation for this is rather simple: various 1's, even when separated by more than a bit period in time, are coherent because of the underlying carrier frequency. Thus, even if the spectra of a modulated signal and incoherent noise may be of a similar width and appear almost identical when observed with a limited spectral resolution, the interferometer can distinguish between the two because of the signal's fundamental coherence.
Another instructive way to determine the envelope of a modulated signal is to repeat the arguments that led to equation (1), but assume that electric fields are modulated by a slow function of time s(t). This produces the following expression for the transmitted power:
I
T
=
I
0
2
(
1
+
cos
ω
τ
)
〈
s
*
(
t
)
s
(
t
+
τ
)
〉
t
(
3
)
In this expression, the oscillatory transmitted power from equation (1) is modified by the autocorrelation function of the modulation signal s(t). Naturally, s(t)s * (t+τ) gives the envelope 210 of the modulated signal shown in FIG. 2 .
Measured Interferograms
The inventors have measured three interferogram envelopes with various sources, using an Exfo model IQ230 interferometer. For broadband noise sources the inventors used ASE from an SOA, which was filtered using commercially available filters from JDS Uniphase: type TB9 diffraction grating filter with bandwidth 75 GHz and type TB4500 angle-tuned thin-film filter with bandwidth 160 GHz. The third source was an unfiltered laser signal with 10 Gb/s OOK modulation, using a pseudorandom data pattern of length 2 23 −1. The results are shown in the plot 300 of FIG. 3 and are in excellent agreement with the simulations discussed above. All curves were normalized, so that the peak power is equal to 1 on each one of them. In particular, the modulated signal 310 is easily distinguished from the shaped noise 320 , 330 at larger interferometer delays.
The plot 400 of FIG. 4 is an enlarged view of an area of the plot of FIG. 3 , showing the wings of the envelopes to show the magnitude of the ripples 410 observed for those two real filters.
DESCRIPTION OF EMBODIMENTS
A schematic diagram of an apparatus 500 according to one embodiment of the invention is shown in FIG. 5 . The apparatus 500 for monitoring an optical signal quality of a light signal transmitted in an optical transmission medium 505 such as an optical fiber, includes a tap 506 connected to the optical transmission medium 505 for tapping off a portion of the light signal. The tap 506 may, for example, be a partially silvered mirror or other similar device for re-routing a small percentage of the light signal in the medium 505 to form a tapped beam 535 .
The tapped beam 535 enters an interferometer 510 that may include a splitter 515 , a delay means 520 and a detector 525 . The splitter 515 may be another partially silvered mirror for forming two beams from the tapped beam 535 .
A first portion 516 of the tapped beam travels directly to a detector 525 . A second portion 517 of the beam travels first through a beam delayer 520 for introducing a delay into the beam 517 . In its simplest form, the beam delayer may be a length of optical fiber or planar wave guide providing a fixed delay. Other means known in the art, such as thermo-optic techniques or a free space moving mirror, may be used to introduce an adjustable delay into the beam 517 .
Output power from the recombined beams 516 , 517 is measured using instrumentation 530 that includes a detector 525 . The beams form an interferogram (not shown) that is a function of the delay, as well as a function of the characteristics of the tapped beam 535 , as discussed above. If the tapped beam 535 is a combination of a coherent modulated signal and incoherent noise, then power output at larger interferometer delays will be close to that of the coherent modulated signal alone. Additional power output measured at zero delay may thereby be attributed to incoherent noise.
A processor 540 receives and processes measurement data of the light output power from the instrumentation 530 . In one embodiment, the processor is a component of a computer (not shown). In addition to the processor 540 , the computer may include memory, a reader for reading computer executable instructions on computer readable media, a common communication bus, a communication suite with external ports, a network protocol suite with external ports and a graphical user interface, as is well known in the art.
The processor includes or is connected to one or more computer readable media 550 , such as a hard or floppy disk in a disk drive, a magnetic tape in a tape drive, a non-volatile programmable ROM chip such as an EPROM, or volatile computer memory.
The computer readable medium 550 contains instructions that, when executed by the processor, cause the processor to compute a numerical value using the light output power measurement. That numerical value represents a relative magnitude of coherent and incoherent parts of the tapped light signal 535 .
A method 600 according to one embodiment of the invention is shown in FIG. 6 . The method measures a signal quality of light present in an optical communication medium. The light includes at least one substantially coherent optical signal degraded by substantially incoherent optical noise.
At least a portion of the light is passed (step 610 ) through an interferometer. The interferometer is capable of introducing a specified delay into at least one light beam of a plurality of beams split from the portion of the light. A light output power from the interferometer, corresponding to a first specified delay setting, is measured (step 620 ).
The coherent optical signal is then distinguished (step 630 ) from the incoherent optical noise based on the light power measurement. The signal may be distinguished by computing (step 640 ) a numerical value representing signal quality from relative magnitudes of the coherent optical signal and the incoherent optical noise.
CONCLUSION
In sum, the inventors have shown that an interferogram envelope from a modulated signal extends far beyond that of shaped broadband noise with similar bandwidth. Thus, by measuring that envelope for the interferometer delay values greater than a bit period of the modulation, it is possible to extract the signal power alone even when the signal is corrupted with optical noise. That capability makes possible new OSNR measurement techniques that are well-suited to signal integrity monitoring and diagnostics in emerging photonic networks.
The foregoing Detailed Description is to be understood as being in every respect illustrative and exemplary, but not restrictive, and the scope of the invention disclosed herein is not to be determined from the Detailed Description, but rather from the claims as interpreted according to the full breadth permitted by the patent laws. For example, while the method of the invention is described herein with respect to the measurement of signal-to-noise ratio in an optical telecommunications network, the method and apparatus of the invention may be used in any situation where a modulated wave signal must be separated from an unmodulated wave signal. It is to be understood that the embodiments shown and described herein are only illustrative of the principles of the present invention and that various modifications may be implemented by those skilled in the art without departing from the scope and spirit of the invention. | Differences in the interferometric patterns of modulated telecommunication signals and broadband optical noise sources are identified and are exploited in measuring the optical signal-to-noise measurements in reconfigurable photonic networks. A light output power from said interferometer corresponding to a specified delay setting in the interferometer is measured, and a coherent optical signal is distinguished from the incoherent optical noise based on the light output power measurement. | 7 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to structural members generally and, more particularly, but not by way of limitation, to a novel tubular column of high resistance to buckling.
2. Background Art
The maximum compressive load that structural bars or slender columns can resist, for a given material of construction and length, is generally a function of its diameter or width and the thickness of the material of construction, with the maximum load increasing with increased width and/or thickness. As a result, structural bars or slender columns for large loads tend to be heavy and expensive.
Accordingly, it is a principal object of the present invention to provide a structural bar or slender column that is lighter in weight than a structural bar or slender column of conventional construction.
It is a further object of the invention to provide such a structural bar or slender column that is simply and economically constructed.
Other objects of the present invention, as well as particular features, elements, and advantages thereof, will be elucidated in, or be apparent from, the following description and the accompanying drawing figure.
SUMMARY OF THE INVENTION
The present invention achieves the above objects, among others, by providing, in a preferred embodiment, a device for sustaining longitudinal compressive loads applied to the ends thereof, comprising: a longitudinally extending tube; means to seal the ends of said tube; a pressurized fluid within said tube, said pressurized fluid having a pressure greater than the external pressure on said tube.
BRIEF DESCRIPTION OF THE DRAWING
Understanding of the present invention and the various aspects thereof will be facilitated by reference to the accompanying drawing figure, submitted for purposes of illustration only and not intended to define the scope of the invention, on which:
FIG. 1 is a side elevational view, in cross-section, of a tubular column constructed according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The basic essence on which the present invention rests is a tubular column subjected to extremely high internal pressures, which internal pressures bring about internal longitudinal tensile stresses of high values. These high internal stresses of longitudinal traction stress the column, with the particularity that they are internal forces which tend to stiffen the column and to preserve its original form.
Following are the mathematical comparative calculations which are the mathematical proof that illustrates the advantage of this invention by comparing it with conventional designs. It will be understood that this mathematical proof is simplified, in that it does not consider second-order effects and that it does not enter into what is called the mathematical theory of elasticity in a totally rigorous and academic manner.
The critical buckling load of a slender bar, according to Euler, is given by:
Pcr=(PI.sup.2 ×E×I)/L.sup.2,
in which
Pcr is the critical buckling load expressed in kilograms,
E is the modulus of elasticity of the material of the bar expressed in kilograms per square centimeter,
I is the minimum moment of inertia of the section normal to the axis of the piece expressed in centimeters to the fourth power, and
L is the equivalent length of the bar expressed in centimeters.
The assumed conditions of the anchoring of the bar are that the bar is articulated at both ends, so that the equivalent Euler length, L, coincides with the actual length of the bar.
The section of the bar under consideration is annular, so the moment inertia of the bar is given by:
I=[PI×(B.sup.4 -A.sup.4)]/4,
in which
I is the moment of inertia expressed in centimeters to the 4th power,
B is the outside radius of the tube expressed in centimeters, and
A is the inside radius of the tube expressed in centimeters.
The surface of the annular section is given by:
F=PI×(B.sup.2 -A.sup.2),
in which
F is the surface of the annular section expressed in square centimeters,
B is the outside radius of the tube expressed in centimeters, and
A is the inside radius of the tube expressed in centimeters.
The tangential stress in the tubular body is given by:
St=[P×(B.sup.2 -A.sup.2)]/(B.sup.2 +A.sup.2),
in which
St is the tangential or circumferential stress to which the wall of the tube that forms the bar is subjected, brought about in the internal pressure, expressed in kilograms per square centimeter,
P is the internal manometric pressure to which the tubular body of the bar is subjected, expressed in kilograms per square centimeter,
B is the outside radius of the tube expressed in centimeters, and
A is the inside radius of the tube expressed in centimeters.
It is considered that the external pressure is atmospheric pressure.
The longitudinal stress in the tubular body is given by:
Sl=(P×A.sup.2)/(B.sup.2 -A.sup.2),
in which
Sl is the longitudinal tensile stress in the tubular body, brought about by the internal pressure, expressed in kilograms per square centimeter,
P is the internal manometric pressure to which the tubular body of the bar is subjected, expressed in kilograms per square centimeter,
B is the outside radius of the tube in centimeters, and
A is the inside radius of the tube in centimeters.
It is considered that the distribution of longitudinal stress is uniform.
The maximum permissible pressure in the interior of the tube is given by:
P=Sf×(B.sup.2 -A.sup.2)/(B.sup.2 +A.sup.2),
in which
Sf is the flow stress of the material of the tube expressed in kilograms per square centimeter,
B is the outside radius of the tube expressed in centimeters, and
A is the inside radius of the tube expressed in centimeters.
For the following calculations, it will be assumed that the tube under consideration has the following characteristics and properties:
Tube: seamless, one-inch diameter, Schedule 40 pipe of low-alloy steel, API Standard 5LX65,
DE outside diameter=3.34 cms,
DI inside diameter=2.07 cms,
ES wall thickness=6.35 mms,
L length=1000 cms,
E modulus of elasticity=2,100,000 kgs/cm2,
B outside radius=1.67 cms,
A inside radius=1.035 cms,
Sf flow stress=4.570 kgs/cm2, and
Sr rupture stress=5,410 kgs/cm2.
First will be calculated the critical buckling load of the tubular bar without internal pressurization, that is, the conventional calculation of resistance/strength.
Inserting the formula for the moment of inertia in the formula for critical buckling load gives:
Pcr=[PI.sup.3 ×E×(B.sup.4 -A.sup.4)]/(4×L.sup.2).
Replacing values gives:
Pcr=[PI.sup.3 ×2,100,000×(1.67.sup.4 -1.035.sup.4)]/(4×1000.sup.2),
or
Pcr=107.9 kilograms.
This value of compressive load is the limit value above which failure of the tubular bar is reached, with the concomitant loss of the stability thereof.
Now, assume that the interior of the tubular bar is pressurized with a working fluid which preferably will be hydraulic, but not excluding at least partially a pneumatic fluid. The maximum permissible internal pressure is:
P=4,570×(1.67.sup.2 -1.035.sup.2)/(1.67.sup.2 +1.035.sup.2),
or
P=2,033 kg/cm 2 .
This very high internal pressure, the limitation of which is controlled by geometric dimensions and the magnitude of the permissible maximum stress of the material, not only brings about circumferential or tangential stresses in the wall of the tube, but also brings about radial stresses, which are of no use in the present invention, and longitudinal stresses, which bring about the mechanical principle of the present invention. The latter stresses stiffen the piece as a whole and are of critical importance when the tubular bar is subjected to a longitudinal compressive external load.
In fact, when the tubular bar is subjected to a high internal, longitudinal tensile stress, produced by the internal pressure, and subsequently when subjecting the bar to an external compressive load, the resultant state of stress will be the composition of both states considered independently, as deduced from the principle of superposition.
The longitudinal tensile stress is:
Sl=(2033×1.035.sup.2)/(1.67.sup.2 -1.035.sup.2),
or
Sl=1,267 kg/cm 2 .
The high internal pressure causes an internal tensile force, N, which is equivalent to the product of the longitudinal stress and the section normal to the axis of the tubular bar, or:
N=Sl×F=Sl×PI×(B.sup.2 -A.sup.2).
Replacing values gives:
N=1,276×PI×(1.67.sup.2 -1.035.sup.2),
or
N=6,837 kilograms.
According to the principle of superposition, if the tubular bar is pressurized to the maximum permissible pressure and the ends of the tubular bar are compressed longitudinally, the failure of the bar will occur when a stress value is reached which is the resultant of the composition of both independent states. That is to say, the new value of the critical buckling load of the tubular bar will be the sum of the value of the critical buckling load of the unpressurized tubular bar plus the value of the internal traction in the pressured tubular bar, or:
Failure load=6,837+107.9=6,944.9 kilograms.
Thus, the compressive strength of the pressurized tubular bar has been increased by a factor of 64 over that of the unpressurized tubular bar.
The above demonstration has disregarded secondary and second-order effects and does not pretend to be academic text, but it is eloquent enough to demonstrate the technological advantage of the present invention. The calculations also do not include the provision of outer circumferential reinforcement of high-strength synthetic fibers bonded to the tubular pipe to sustain the high circumferential stresses which normally double the value of the longitudinal stress that is of use and benefit.
FIG. 1 illustrates a tubular column according to the present invention, generally indicated by the reference numeral 10. Column 10 includes a cylindrical tube 12 having its ends sealed by means of first and second end pieces 14 and 16. End pieces 14 and 16 are constructed of the same material as tube 12, preferably a suitable metallic material (i.e., seamless steel or aluminum), are welded to the ends of tube 12, and have defined therein channels 20 and 22 for the application therethrough of a pressurized fluid to the interior of tube 12. Other means of attaching end pieces 14 and 16 to the ends of tube 12 may be employed as well, including threaded joints.
Surrounding the exterior surface of tube 12 is a layer 30 of synthetic fibers, for example, Kevlar or Araldit fibers, which cooperates in absorbing tangential forces in the tube to increase the maximum permissible pressure thereof, as is described above. The synthetic fibers referred to herein produced from long-chain polyamides (nylons) in which 85% of the amide linkages are attached directly to two aromatic rings called aramids. Nomex and Kelvar from Du Pont Co. and Twaron from Akzo NV are examples of fibers that can be used. Layer 30 is applied to tube 12 and bonded with a suitable resin using known techniques for fabricating such a reinforced structure. The source (not shown) of the pressurized fluid may be any conventional mechanical element, pump or compressor, or from any special installation that keeps tube 12 pressurized. Check valves (not shown) may be provided to maintain pressurization of tube 12.
In use, a fluid (not shown) under pressure "P" is applied to the interior of tube 12 through channels 20 and 22 from external piping (not shown) to assist the tube in resisting compressive forces "F" applied longitudinally to column 10, in the manner described above.
It will thus be seen that the objects set forth above, among those elucidated in, or made apparent from, the preceding description, are efficiently attained and, since certain changes may be made in the above construction without departing from the scope of the invention, it is intended that all matter contained in the above description or shown on the accompanying drawing figures shall be interpreted as illustrative only and not in a limiting sense.
It is also to be understood that the following claims are intended to cover all of the generic and specific features of the invention herein described and all statements of the scope of the invention which, as a matter of language, might be said to fall therebetween. | In a preferred embodiment, a device for sustaining longitudinal compressive loads applied to the ends thereof, the device including: a longitudinally extending tube; devices to seal the ends of the tube; pressurized fluid within the tube, the pressurized fluid having a pressure greater than the external pressure on the tube. | 4 |
CROSS REFERENCE TO RELATED APPLICATION
This application claims priority to U.S. provisional application Ser. No. 60/352,210, filed on Jan. 29, 2002, the entire contents of which are herein incorporated by reference.
FIELD OF THE INVENTION
The present invention relates to real-time in-situ monitoring of a gaseous environment and fault detection during a semiconductor processing step.
BACKGROUND OF THE INVENTION
Advanced process control that comprises in-situ process monitoring and fault detection in semiconductor manufacturing is essential for reproducible production of complex structures. In typical etching and film deposition processes, the wafer parameters are measured using test wafers after the processing steps. If the measured parameters are not within the desired tolerances, the process parameters are adjusted and more test wafers are measured to assure process compliance. This post-process method is time consuming, inefficient, and expensive compared to real-time in-situ monitoring techniques.
These drawbacks reveal that real-time, in-situ process monitoring should be used whenever possible. The data that is acquired during a process step is used to improve the process by optimizing process conditions and detecting trends of departure from target values and early recognition of a possible catastrophic failure of the process equipment. In addition to etching and film deposition processes, chamber cleaning and chamber conditioning processes require in-situ monitoring.
Various spectroscopy methods have been established for real-time process monitoring. These methods include qualitative and quantitative analysis of the gaseous chemical species using techniques such as mass spectroscopy (MS) and optical emission spectroscopy (OES). These techniques provide information on the identity and concentration of gaseous species during the manufacturing process, which in turn can be correlated to various physical properties of the substrates.
Mass spectrometers are readily available instruments for detection, identification, and analysis of the components of a gaseous environment. They offer extreme sensitivity for detecting trace amounts of gaseous substances. In MS, the gaseous material is ionized through various techniques and the ions are then collected by the spectrometer. The ion signals are then translated into a mass spectrum that is used to identify what atoms or molecules are present in the gaseous environment.
Due to the relatively high pressure at the process monitoring point of a typical semiconductor process, the gas sampling in MS usually includes a pressure reduction system. The pressure reduction is carried out using a length of capillary tube or a throttle valve, and the mass spectrometer itself is pumped continuously. In this setup, it is possible that the sampling efficiency of the probe has mass dependence and extensive calibration can be necessary.
MS can provide a wealth of information on a process, yet the data are often complex and difficult to interpret. Complicated ion spectra can result from extensive fragmentation of the parent molecules in the mass spectrometer ionization region.
OES is a widely used method for process monitoring and control in semiconductor processing. OES is a non-invasive technique that has an extremely wide dynamic range and can perform process control (e.g., endpoint detection, etch rate, and partial pressure control) and diagnostics concurrently.
The point of monitoring the gaseous environment in semiconductor processes is frequently the process region since an excitation source such as plasma is needed to excite the gaseous species for analysis. A drawback to accessing the processing region for monitoring is that it can be invasive to the plasma and it is a more costly venture than to access regions downstream from the processing region. If the process monitoring point is downstream from the process zone, and therefore separate from the plasma, alternative means for exciting and/or ionizing the gaseous species are required.
The drawbacks for post-process analysis show that there is a need for real-time in-situ process monitoring of semiconductor processes using spectroscopic means that allow for comprehensive analysis of the gaseous environment. The analysis results are correlated to various physical properties of the substrates and can reduce the use of test wafer reiterative monitoring methods. Furthermore, there is a need for means of excitation of the gaseous environment that avoids fragmentation of the gaseous species. Also, there is a need for a monitoring point for process analysis that is non-invasive to the process region and is located downstream from the process zone.
The method of using metastable electronic energy transfer to excite gaseous species has previously been utilized in other types of semiconductor processes. Examples include selective dissociation of process gases for etching or deposition steps. Tokunaga in U.S. Pat. No. 5,874,013 entitled “Semiconductor integrated circuit arrangement fabrication method,” and Loewenstein in U.S. Pat. No. 5,002,632 entitled “Method and apparatus for etching semiconductor materials,” describe methods to obtain the desired etching species by dispersing an inert gas excited to a metastable state in an etching gas. Markunas in U.S. Pat. No. 5,180,435 titled “Remote plasma enhanced CVD method and apparatus for growing an epitaxial semiconductor layer,” describes a CVD apparatus for growing a layer on a substrate using metastable electronic energy transfer to partially dissociate and activate the CVD precursor gas. This leads to film deposition at lower temperatures than for purely pyrolytic processes.
In another example, Dodge in U.S. Pat. No. 4,309,187 entitled “Metastable energy transfer for analytical luminescence,” describes an alternative excitation method that uses a dielectric discharge to create metastable nitrogen species. The excitation method is shown to have a large dynamic range where concentrations as high as 10 15 atoms/cc can be measured. The wavelength(s) and intensity of emitted light are used to determine the identity and the concentration of the species of interest.
SUMMARY OF THE INVENTION
The present invention provides an apparatus and method for in-situ process monitoring and control using metastable electronic energy transfer to excite and ionize the effluent gas and utilizes OES technique for detection of the emitted light and MS for analysis of the ions that are generated.
In one embodiment, the method of excitation and ionization of the process gas is carried out through interaction with long-lived metastable rare gas atoms.
It is another object of the present invention to carry out the process monitoring at a location downstream from the etching or deposition zone that is non-invasive to the process.
It is a further object of the present invention to correlate resulting gaseous environment in the process chamber with physical properties of the processed wafers.
It is a further object of the present invention to improve the process by optimizing process conditions and detecting trends of departure from target values.
BRIEF DESCRIPTION OF THE DRAWINGS
A more complete appreciation of the invention and many of the attendant advantages thereof will become readily apparent with reference to the following detailed description, particularly when considered in conjunction with the accompanying drawings, in which:
FIG. 1 is a simplified block diagram of a first plasma processing system according to the present invention;
FIG. 2 is a simplified block diagram of a second plasma processing system according to the present invention;
FIG. 3 is a schematic view of one configuration of the apparatus for monitoring a gaseous environment according to the present invention;
FIG. 4 is a flowchart of the steps for creating a process table according to the present invention; and
FIG. 5 is a flowchart of the steps of a monitoring process according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
In general, the present invention provides a method and apparatus for carrying out in-situ process monitoring and endpoint detection of the gaseous environment during a semiconductor process (either in real-time or after a known delay). The invention is capable of detecting and monitoring the chemical environment in a vacuum system using spectroscopic techniques. An apparatus is provided that uses metastable electron energy transfer to electronically excite gaseous atoms and molecules. This energy transfer from the singular excitation source creates ions and also excited species that emit light at wavelengths that are characteristic of the gaseous species present in the gas stream.
The ions that are generated in the metastable electron energy transfer are analyzed by a mass spectrometer that acts as a mass filter and separates and collects the ions according to their mass-to-charge (m/q) ratios. The mass spectrometer can comprise a residual gas analyzer (RGA) or a quadrupole mass spectrometer (QMS). The measured ion current is proportional to the partial pressure of each gaseous species and provides fast real-time responses regarding changes in the process environment. The parameters that can be monitored using the MS data include gas flows, pressure, ratios of gaseous species and gas purities. These parameters are correlated with prior process results and historical data.
In addition to forming ions, the metastable electron energy transfer also raises the energy levels of gaseous species that results in fluorescent emission as the excited species decay to a lower energy state. Detection and spectrum analysis of the fluorescent radiation by OES is used to determine the identity and concentration of the gaseous species.
The extensive MS and OES data obtained with this invention offer detailed information regarding the status of the process. OES only detects excited species that emit characteristic light radiation, and MS detects ionic species in the process environment.
FIG. 1 is a simplified block diagram of a plasma processing system according to the present invention. The system 100 comprises a process chamber 111 that can accommodate semiconductor processes such as etching, chemical vapor deposition (CVD) or physical vapor deposition (PVD). A pump 112 is located downstream from the process chamber 111 for removing the gaseous stream from the process chamber. The pump 112 can be, for example, a turbomolecular pump (TMP). A monitoring system 125 comprises a separate excitation source 113 for generating the metastable species, chamber effluent system 114 , monochromator 121 , detector 122 and mass spectrometer 115 . Chamber effluent system 114 is attached downstream from the pump 112 . A controller 110 controls the process and acquires data from the monitoring equipment. A roughing pump 116 exhausts the gases from the monitoring zone.
FIG. 2 is a simplified block diagram of a plasma processing system according to the present invention. The setup in FIG. 2 differs from the setup in FIG. 1 in that the monitoring system 125 is located upstream from the pump 112 and the pump 116 . The pressure of gaseous environment varies at the different locations of the monitoring system 125 depicted in FIGS. 1 and 2 . In an etching process, the gas pressure in the process chamber is usually lower than the gas pressure downstream from pump 112 . In a CVD process, this is usually reversed. The location of the monitoring system that is selected depends therefore on the type of process that is carried out and the level of monitoring that is required.
Alternatively, the monitoring system 125 can be located downstream from both pump 112 and pump 116 . In various setups, the monitoring system can be a part of an abatement system.
FIG. 3 is a schematic view of one configuration of the apparatus for monitoring a gaseous environment according to the present invention. The monitoring system 125 comprises a downstream chamber effluent system 114 . Desirably, the effluent system is easily modified to accommodate the monitoring system. The metastable species 25 are created in a gas flow system that includes an excitation source 113 such as a dielectric discharge source or microwave plasma source and are introduced into the chamber effluent gas stream downstream from the process zone. The dispersion of the metastable gas stream in the effluent gas flow can be carried out using a variety of different setups.
In FIG. 3 , a monochromator 121 and a mass spectrometer 115 are located near the mixing zone of the effluent gas and the metastable species. Desirably, the downstream distance from the introduction of the metastable species to the mass spectrometer 115 and the monochromator 121 , is long enough to insure good dispersion and short enough to avoid significant sample loss. Since the ions form from the interaction of the metastable species and the effluent gas, a conventional mass spectrometer ionizer is not needed but can be included for ionizing the gas.
The method of ionization described in this invention can remove the need for a conventional pressure reduction apparatus for MS, which makes this invention a true in-situ monitoring method. This is due to the formation of ions using metastable electronic energy transfer instead of using a glowing filament in the ionizer region of the mass spectrometer. Alternatively, pressure reduction methods such as capillary or orifice sampling along with differential pumping can be employed to reduce the pressure inside the mass spectrometer.
Excitation of gas molecules using metastable electronic energy transfer has been shown to allow selective ionization and control over the degree of ion fragmentation. This is due to the fact that the energy that is transferred upon ionization is not only variable but also quantized and the amount of available energy depends on the selection of the metastable atom or molecule. It is desirable to create only one ion per component in a gas mixture to reduce the number of ion species and have most of the ion current in the molecular ion to increase sensitivity.
The maximum internal energy of the resulting ion in metastable electronic energy transfer is E*−IE, where E* is the stored electronic energy of the metastable atom and IE is the ionization energy of the molecule to be analysed. If the metastable species has an excitation just above IE, the difference E*−IE will be close to zero and fragmentation will be substantially reduced or eliminated. Conversely, if the difference E*−IE is large then the extent of fragmentation can be very significant. Thus, the extent of fragmentation can be controlled by the choice of the gas selected to form the metastable species. Reduced fragmentation is advantageous since it simplifies the mass spectra in situations where many ion species and ion fragments can be produced and reduced fragmentation allows for monitoring the molecular ion.
The de-excitation mechanism that results in ionization of a compound by a metastable atom or molecule is called Penning ionization. As a metastable species collides with a neutral molecule BC in the gas phase, an electron from a BC orbital interacts with a vacant orbital of the metastable species A* and an electron is ejected from species A. The ejected electron (e) can take a range of kinetic energies that is defined by the species involved in the gas phase collision. As shown in Table 1, the result of the collision between A* and BC may simply be to ionize BC and form BC + (Eq. 1), fragment BC into B + and C (Eq. 2) (or B and C + ), or create ABC + (Eq. 3). The formation of the molecular ion BC + is usually preferred to reduce the number of ion species and maximize the sensitivity.
TABLE 1
Penning Ionization
Eq.
A* + BC → BC + + A + e
(1)
A* + BC → B + + C + A + e
(2)
A* + BC → ABC + + A + e
(3)
A number of different atoms and molecules can be used as source of metastable species. The rare gases (He, Ne, Ar, Kr or Xe) are frequently used due to their low reactivity and easily accessible metastable levels, but molecules such as N 2 and CO can also be used. As is shown in Table 2, the metastable energies of the various rare gases vary with atomic weight. For example, metastable states of He are 19.8 and 20.6 eV, whereas the metastable states of Ar are 11.6 and 11.7 eV. Desirably, a gas is chosen that is substantially inert when subjected to a discharge and then mixed with the gas to be ionized, and which provides a suitable excitation energy for exciting and/or ionizing the gas molecules in the effluent gas stream.
TABLE 2
Rare gas
Metastable energies of rare gases (eV)
He
19.8, 20.6
Ne
16.6, 16.7
Ar
11.6, 11.7
Kr
9.9, 10.6
Xe
8.3, 9.4
In FIG. 3 , electron bombardment in the excitation source 113 excites the rare gas atoms into a host of excited electronic states. These states decay quickly to the ground state or one of the lower metastable states. As the gaseous species are removed from the excitation region, the metastables and the ground state atoms are dominant. In the case of metastable He atoms, the 2 1 S (20.6 eV) state has the shorter decay time or effective lifetime of 2×10 −8 sec vs. 6×10 −3 sec for the 2 3 S (19.8 eV) state. Therefore, the He gas flow is reduced to a flux of metastable He (2 3 S) atoms and ground state He atoms when it enters the gas-mixing region.
For comparison, various other techniques have been developed to excite and ionize gas phase species for MS. These include electron ionization (EI), chemical ionization and photo ionization with lasers or other intense light sources. In conventional mass spectroscopy, electron ionization is carried out by electron collisions in high-energy mode (70 eV) or in the so-called low-energy mode (˜8-12 eV).
The high-energy mode can present several advantages over the low-energy mode; it is highly sensitive and reproducible which makes it suitable for quantitative and trace analysis. The mass spectra obtained in high energy EI usually contain molecular ions and ion fragments that allow identification of the compound of interest. However, high energy EI can have significant limitations which can include weak or absent molecular ions, lack of ionization selectivity, and result in complex spectra from mixtures since many different ions are created from each compound. This can make data interpretation difficult due to overlapping ion signals with the same mass-to-charge ratio.
Some of the limitations and problems encountered in high energy EI can be reduced by lowering the electron ionization energy to ˜8-12eV. This allows a reduction in fragmentation that can result in simpler spectra and can also allow selective ionization in few cases. However, the reduction in molecular fragmentation is achieved at the expense of a loss in sensitivity and selective ionization is decreased by the presence of an energy spread in the electron source. Furthermore, the use of the low energy mode creates problems in terms of reproducibility due to its sensitivity to source tuning parameters.
FIGS. 4 and 5 show flowcharts of steps that are carried out in the process monitoring and control according to the present invention. The procedures can apply to such processes as etching and thin film deposition.
FIG. 4 is a flowchart of the steps for creating a process table. The flowchart comprises steps that establish a relationship between the gaseous environment for a specific process and physical properties of the processed wafer. The process results can contain physical properties such as etch rate and etch uniformity for an etching process and deposition rate, film uniformity and electrical properties for a deposition processes such as CVD or PVD.
Step 150 starts the monitoring of the gaseous environment associated with a selected process. This step involves establishing a baseline for the monitored signals. For example, the monitored parameters can include pressure, gas flows, gas ratios and gas impurities.
In step 152 , the selected process is initiated and run according to a specific recipe. The process is continuously monitored through the gaseous environment in step 154 . In step 156 , the process is terminated.
In step 158 , the physical properties of the process results are linked to one or more gas species or gas ratios present in the gaseous environment during the process. The results in step 158 for multiple runs can be subjected to analysis using statistical process control. The statistical analysis results are used to establish working tolerances for the process. These results are used to create a process table in step 160 .
FIG. 5 is a flowchart of the steps of a monitoring process using the process table created in FIG. 4 . After a process that leads to a physical property and the corresponding process table 160 from FIG. 4 have been selected in steps 170 and 172 , respectively, the process is started in step 174 . The gaseous environment is continuously monitored in step 176 during the process. The process is ended in step 178 and the process results are evaluated in step 180 .
For example, when an etching process involves endpoint detection, step 176 can be used to indicate when the process endpoint is reached and subsequently the process is terminated in step 178 .
In step 180 , the process evaluation includes determining a difference between the designated physical property and an actual physical property resulting from process steps 152 - 156 in FIG. 4 . In the case of a process step such as thin film deposition, if the monitored gaseous environment is within a range as determined by the process table, then the actual physical property is within the tolerances of the designated property. On the other hand, if the resulting gaseous environment is outside the range, then the actual physical property is outside the tolerances of the designated physical property. In such a case, the method indicates that the wafer is outside the acceptable limits.
The results of step 180 for multiple runs can be subjected to analysis using statistical process control. The statistical analysis results can be used to continuously revise the process as needed to stay within the established tolerances.
This invention provides a method to monitor gas profiles during a semiconductor processing step. The preferred monitoring point is downstream from the process chamber due to practical and economical reasons. Importantly, the monitoring point is non-evasive to the process chamber and can be located where access to the system is physically feasible.
The identification of important gaseous species in the chamber effluent and monitoring ratios of gaseous species provides a fingerprint of important process variables and offers an early warning system. Furthermore, the invention is capable of alerting to changes when process window limits are approached, that will eventually throw the process out of specification. The invention can also be utilized to determine whether or not a given run has produced a satisfactory result. This can be done by comparison of the run profile to a collection of gas profiles that represent, based on previously established criteria, successful or unsuccessful runs. If an unsuccessful run is encountered, the invention provides means for classifying the fault, followed by terminating the process or correcting the fault.
In addition to etching and deposition processes, the invention can also be applied to chamber cleaning and chamber conditioning after chamber cleaning. Chamber cleaning is evaluated by monitoring gaseous etching products and detecting the endpoint of a successful cleaning step. For chamber cleaning it is advantageous to have a monitoring point downstream from the process zone since cleaning process is commonly unwanted material that is deposited near or downstream from the process region. Analogously, chamber conditioning following a chamber clean is also evaluated through monitoring the gaseous environment downstream from the process region.
It should be understood that various modifications and variations of the present invention may be employed in practicing the invention. It is therefore to be understood that, within the scope of the appended claims, the invention may be practiced otherwise than as specifically described herein. | A method and apparatus for real-time monitoring of a gaseous environment during a semiconductor process. The method utilizes metastable electronic energy transfer to excite and ionize the chamber gaseous effluent and correlates the fluorescence signals from the excited species and mass spectroscopy analysis of the ions generated with the process status. In addition to the ability to produce excited species that fluoresce, the method has the ability to generate molecular ions from labile compounds, reduce fragmentation and operate at higher pressures than conventional ionization methods. | 2 |
This application is a continuation of application Ser. No. 08/484,161, filed on Jun. 7, 1995, now abandoned.
BACKGROUND OF THE INVENTION
This invention relates to hinges and collapsible containers in general, and specifically to an improved collapsible container.
In the materials handling and other industries, it can be beneficial to use collapsible containers to transport and store objects and materials. Among other things, such containers can be erected to hold things in a relatively secure manner during transport or storage, and can be collapsed during non-use to minimize the space occupied by the container. Commonly, such containers are provided in reusable, stackable configurations, to further improve their usefulness. An example of containers of this type is illustrated in U.S. Pat. No. 4,917,255 to Foy et al. Drawings from that patent are included herein as FIGS. 1-8, to illustrate certain aspects of prior art containers.
In a common application for such containers, the containers are erected and filled with parts to be used (for example) on an assembly line. A plurality of erected containers are stacked atop one another and loaded into a semi-trailer, which transports them to the location of the assembly line. Upon arrival there, the containers are positioned beside the assembly line adjacent the location at which the parts are to be used. Once a container is emptied of parts, it is collapsed and set aside. The collapsed containers can be gathered together and returned to the parts supplier (or to another supplier) in the collapsed state, where the entire cycle can then be repeated.
In such an application, it is beneficial for such containers to have a high "return ratio". This ratio is the number of collapsed containers that occupies the same space as one erected container. The name "return ratio" is thus apparently derived from an application such as the foregoing, in which the focus is on "returning" the maximum number of collapsed containers (to eventually be refilled by the parts supplier) in the smallest space. By returning a greater number of containers in a given space, the number of shipments required to transport the empty, collapsed containers is thereby reduced. Correspondingly, the amount of space required to store the empty, collapsed containers is reduced, both before and after shipment. Thus, collapsible containers with a relatively high return ratio (current "good" ratios are currently typically 3:1) are in many applications more economical to use and store than are containers with lower return ratios.
In addition, however, the efficiency, speed, quality and profitability of many applications (including those similar to the aforementioned assembly line application) can be improved by simplifying the processes and time required to erect and collapse the containers. To the extent that the containers can be collapsed by the assembly line workers without a great deal of physical effort or mental concentration, the workers can instead focus that effort and concentration on the actual assembly work (hopefully improving that work product). A common configuration which allows rapid erection and collapse is a rectangular or square base and four interlocking sidewalls, each hinged to a side of the base so that the sidewalls fold over the base into a parallel, stacked relationship.
In many prior art containers of this type, these two factors (return ratio versus speed or efficiency) have been a tradeoff. For example, when the required or desired height of the erect container is more than half the width of the container base, and when the walls are hinged to the base along a hinge line near the base itself, opposing pairs of walls cannot be collapsed without overlapping each other. This problem has been resolved in prior art containers in two primary ways, each exemplifying a different balance of the two factors.
In the first approach, each hinge line is raised away from the base. This is done by integrally molding onto the edge of the base what is equivalent to a portion of the erected sidewall. Because it is integrally molded and is not hinged but is instead fixed to the base, this portion cannot be collapsed, and it therefore typically makes the collapsed container taller than it otherwise might be (it reduces the "return ratio" because it spaces the collapsed walls away from the base). Because it reduces the height of the foldable portion of the sidewall, however, it permits the sidewalls to be folded in a relatively simple manner (without overlapping). In other words, moving the hinge line up the side of the container makes it easier to collapse the container (because the collapsed wall portions do not overlap and therefore do not have to be collapsed in any specific order) but prevents the containers from being collapsed as compactly as if the hinge line were nearer the base.
In the second approach, the hinge lines are staggered in distance from the base as compactly as permitted by the thicknesses and configurations of the sidewalls. In other words, the portion of the erected sidewall that is integrally molded onto the edge of the base is minimized. In the overlapped collapsed wall situation, the maximum overall compaction of the container normally occurs if the four collapsed sidewalls are effectively "stacked" on each other and the stack is directly against the base. To accomplish this, the four hinge lines are typically spaced from the base in increments of approximately the thickness of the sidewalls, each of the four hinge lines being progressively further from the base. The tradeoff in this design is that the walls must be collapsed in the specific order in which the hinges are positioned, in order to accomplish the desired "stacking" result (or sometimes even to permit all four of the walls to be collapsed at all). This can make the collapsing process relatively more complicated and slower than in designs in which the walls can be collapsed in any order.
This latter problem is somewhat reduced in designs such as the aforementioned U.S. Pat. No. 4,917,255 because one pair of opposing walls interfits with the other pair such that it is easy for users to see that the first pair must be released and collapsed before the other pair. In that patent, for example, the walls 16 and 18 in its FIG. 1 must be released from their engagement at the corners and then collapsed before the walls 20 and 22 can be collapsed on top of them (see FIG. 14 of that patent similar to FIG. 2 in this application! for an illustration of all four sidewalls in a collapsed condition). Even the type of design in U.S. Pat. No. 4,917,255 requires, however, that a specific wall of each opposing pair be lowered before the other of the pair (thus, in FIG. 1 of the foregoing patent, wall 16 must be lowered before wall 18, and wall 20 before wall 22). This is conveniently described as sequential folding. Although sequential folding maximizes the return ratio for a given configuration of container, sequential folding requires more concentration and effort to manipulate the container into its collapsed condition, and is therefore less efficient in assembly-line processes (and can even be more time-consuming to collapse) than containers in which there is no wall overlap.
If the sidewalls are not collapsed in the precise order required, the containers (including their hinges and other components) can be damaged by assembly line workers who sometimes try to force the sidewall members flat against the base member.
Another drawback of the sequential folding approach is that, in order to provide a container with a uniformly tall top edge when the sidewalls are erect, each sidewall member must be manufactured to its own specific dimensions. In other words, each sidewall member will be a different height and shape than the other sidewall members, because of the four different distances between the hinge pins and the top edge of the erect container. This requires additional investment in manufacturing capacity (for example, four separate sidewall molds must be built and used for injection molded, blow-molded and similar embodiments) and in inventory and distribution (again, four different types of sidewalls must be inventoried and controlled for distribution, assembly, replacement and repair).
Other applications and devices employing hinges or hinged members are similarly limited by the relatively fixed position of the pivot axis of the hinge. Negative effects (such as the need for sequential folding, a reduced return ratio, or the like) result from this limitation.
Objects and Advantages of the Invention
It is, therefore, an object of my invention to provide a hinge means to affix members to each other and permit the members to be moved relatively to each other transversely of the longitudinal hinge axis while remaining hinged to each other. The hinge means of my invention is characterized by the members having leave members with aligned hole means in which hinge pin means is disposed, with the hole means including slot means to permit the desired transverse movement. The hinge pin means of my invention can be in any of a wide variety of configurations, including, for example, a single elongated hinge rod passing through all the aligned hole means on a given sidewall, a plurality of rod members passing through the aligned hole means on a given sidewall, and molding or attaching pin members onto the sidewall itself, in the form of one or more projecting members configured to engage the hole means. The concept of such projecting members is illustrated, for example, in U.S. Pat. No. 4,674,647, at FIG. 9 thereof.
A further object of my invention is the provision of a collapsible container assembly utilizing hinges of the aforementioned character. In the common collapsible container assembly line application described above, my invention reduces the sequential limitations for collapsing the container (and can virtually eliminate the mental concentration required to properly collapse the container; the container can virtually automatically collapse in the proper order once the walls are disengaged from each other) but provides the maximum available return ration (or at least the same return ratio as comparable prior art containers).
An additional object of my invention is the provision of a collapsible container of the aforementioned character, in which sidewall and base components of the erected container are effectively interlocked with each other to a similar degree as prior art containers. In many applications it would be undesirable for the sidewalls to be transversely slidable with respect to their hinge axis when they are erected. Among other things, such movement in the erected position might occur during transportation of the filled container, and might cause a stack of such containers to become unstable and possibly fall or rock undesirably, and/or bind or damage some of the product being carried in the container. A preferred embodiment of such interlocking means is described below as interfitting mortise and tenon members.
Yet another object of my invention is the provision of a collapsible container of the aforementioned character, in which the erected container is stackable with similarly sized and shaped containers.
An additional object of my invention is the provision of a collapsible container of the aforementioned character, in which opposing pairs of sidewalls are interchangeable with each other. As indicated above, this reduces the design, investment and maintenance costs for manufacturing, inventorying, assembling, repairing and distributing the containers. This same benefit attaches to many other applications in which the variety of components required to complete the assembly is reduced.
Another object of my invention is the provision of a collapsible container having a base member and a plurality of sidewall members hinged to the base member so that the sidewall members can be moved between an overlapping collapsed position and an erect position, including hinge means for hinging each the sidewall member to the base member, the hinge means permitting the sidewalls to be collapsed into the overlapping position in various orders. In other words, the precise sequence of folding the sidewalls during collapse would not be as specific as in prior art containers. In certain embodiments similar to that shown in the aforementioned U.S. Pat. No. 4,917,255, there are spring-actuated latches to hold each comer of the erected sidewalls in the erected position. By incorporating my invention into such containers, the sidewalls can automatically collapse in the proper order simply by releasing those latches.
A further object of my invention is the provision of hinge means of the aforementioned character, in which the hinge pin means is slidable within the slot means to permit the hinged members to be pivoted relative to each other at any of a range of positions along the slot means.
Yet another object of my invention is the provision of hinge means of the aforementioned character, in which the hinge pin means is constituted by a plurality of axially aligned hinge pins.
Other objects and advantages of the invention will be apparent from the following specification and the accompanying drawings, which are for the purpose of illustration only.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an isometric view of a prior art collapsible container with its sidewall members in an erect position;
FIG. 2 is an isometric view of the prior art collapsible container of FIG. 1, with its sidewall members in a collapsed position;
FIG. 3 is a side view of the prior art collapsible container of FIG. 2, illustrating the stacking of the sidewall members with respect to the base member and each other, and with a partial broken view of a similar container stacked thereon;
FIG. 4 is similar to FIG. 3, but illustrates the view from an adjacent side of the collapsed container;
FIG. 5 is an elevation view of a portion of the base member and a sidewall member of the prior art collapsible container of FIG. 1, prior to assembly of those members to each other with hinge pin means;
FIG. 6 is a sectional view taken along line 6--6 of FIG. 5;
FIG. 7 is a sectional view taken along line 7--7 of FIG. 5;
FIG. 8 is a sectional view taken along line 8--8 of FIG. 5;
FIG. 9 is an isometric view of a preferred embodiment of a portion of a collapsible container utilizing hinge means in accordance with the teachings of my invention, including a base member, a sidewall member, and hinge pin means prior to their assembly together;
FIG. 10 is similar to FIG. 9, but illustrates the components after their assembly together;
FIG. 10a is similar to FIG. 10, but illustrates the sidewall member and hinge pin means slid in the direction of the arrow U;
FIG. 11 is similar to FIG. 10, but illustrates the sidewall member in an erect position;
FIG. 12 is a broken sectional view taken along line 12--12 of FIG. 1, illustrating a preferred embodiment of the interlocking means of my invention;
FIG. 13 is a side view of a preferred embodiment of a collapsible container showing two sidewall members in collapsed position over the base member; and
FIG. 14 is similar to FIG. 13, but illustrates a different folding sequence for the sidewall members.
DESCRIPTION OF PREFERRED EMBODIMENT
Referring now to the drawings, and particularly to FIGS. 1-8 thereof, I show a typical prior art collapsible container 10. As indicated above, these drawings are similar to some in U.S. Pat. No. 4,917,255, and the function of the various components is explained in additional detail in that patent. Such containers are typically fabricated from blow-molded or injection-molded plastic such as polyethylene, but may be of any suitable material. Examples of such other suitable materials include, without limitation, wood, metal, rubber, glass, fiberglass, etc. The rod (such as one of the hinge pins 30, 32, 34 and 36 discussed below) utilized to hingedly attach the sidewalls to the base is preferably fabricated from fiberglass or other pultruded materials, but could be formed from metal or any other suitable material. Except where otherwise indicated herein, the preferred materials for my invention are similar to those of such prior art devices.
The container includes a base member 12 having a plurality of sides 14. Sidewall members 16, 18, 20 and 22 are hinged to the base member 12 at each of its sides 14. One or more drop doors 24 may be provided in the sidewall members to improve accessibility to the interior of the container when it is in the erected position.
Interfitting webs and flanges 26 are provided on the edges of the sidewall members to provide stability to the erected container. Latches 28 (such as spring-actuated latch members) hold the sidewall members in the erected position. The release of the latches 28 permits the sidewall members to be disengaged from each other and collapsed.
The collapsed position is illustrated in FIGS. 2-4. As illustrated, because of the respective heights of the sidewall members and the width of the base member, the sidewalls overlap in the collapsed position. In order to lie flat in the most compact collapsed arrangement, the sidewall members must be collapsed in the specific order of sidewall member 16, sidewall member 18, sidewall member 20 and finally sidewall member 22. To accomplish this compact collapsed arrangement, hinge pins 30, 32, 34 and 36 attaching the respective sidewall members 16, 18, 20 and 22 are spaced at staggered distances from the base member 12.
The positions of these hinge pins 30, 32, 34 and 36 with respect to the base member 12 are relatively fixed, in that they are disposed through axially aligned holes 38 on the base member 12 (FIGS. 5, 6 and 8) and correspondingly aligned holes 40 on each respective sidewall member (FIGS. 5 and 7). These holes 38 and 40 are commonly provided in interfitting hinge tangs or leaf members 42 and 44, respectively. The holes or troughs 40 on the sidewall members alternate in direction (in and out of the page as shown in FIG. 5) so that, when each sidewall is assembled at its appropriate location on the base member 12 and the respective hinge pin is passed through the aligned holes 38 and 40, the sidewall cannot be separated from the base member 12 without removal or destruction of the hinge pin.
The prior art container 10 is typically injection molding from plastic or other suitable material, although other processes and materials can be used. Persons of ordinary skill in the art will understand that, as described herein, the preferred embodiment of the present invention may be fabricated from similar materials and from similar processes, as well as from other materials and processes, so long as the embodiment functions as described hereinbelow.
A preferred embodiment of the container of my invention is similar to that just described for the prior art container 10. Several important differences between the prior art container and a preferred embodiment of my invention are illustrated in FIGS. 9-14.
In FIG. 9, a base member 50 includes side portions 52 extending therefrom. A sidewall member 54 includes one or more tangs or leaf members 56 and 58 positioned and configured to interfit with tangs or leaf members 60 and 62 on the base side portions 52. After the sidewall members are properly positioned (so that the leaf members 56 and 58 are between leaf members 60 and 62 on the base side portions 52), hinge pin means such as a hinge rod 64 is inserted through one or more holes or openings 70 in the leaf members 60 and through holes or openings 66 and 68 in the leaf members 56 and 58, respectively. The holes or openings 70 are preferably in the form of a straight slot (although curved slots or other openings might also be useful). After the hinge rod 64 is so inserted, it may be retained in the desired assembled positioned by affixing lock washers to each end (or by using other suitable means of retention).
As indicated above, the hinge pin means of my invention can be provided in any of a wide variety of configurations, including the preferred single elongated hinge rod 64 passing through all the aligned hole means on a given sidewall. Among the many alternative embodiments are a plurality of shorter rod members (not shown) passing through the aligned hole means on a given sidewall, and providing molded pin members or attaching pin members onto the sidewall itself, in the form of one or more projecting members configured to engage the hole means. This latter concept of molded projecting members is illustrated, for example, in U.S. Pat. No. 4,674,647, at FIG. 9 thereof.
The slot 70 is preferably sized to permit ready transverse movement of the hinge pin 64 in the direction indicated by the arrow U in FIG. 10a and the direction opposite thereto. This movement is illustrated in FIGS. 10 and 10a, showing the same structure and components but with the hinge pin means 64 at opposite ends of the slot 70. This results in the non-sequential folding order illustrated in FIGS. 13 and 14, which show that either of the two sidewall members 54 could be collapsed or folded before the other (or could be allowed to fall) without affecting the overall height of the collapsed assembly. As discussed above, in some embodiments, the comer latches can be disengaged and the sidewall members released, and the sidewall members will "automatically" fall into the optimum return ratio for the container.
As indicated above, it is sometimes desirable for collapsible containers of this type to be relatively solid and non-shifting when erected. To limit the aforementioned movement of the hinge pin 64 in the direction indicated by the arrow U in FIG. 10a and the direction opposite thereto when the sidewall member 54 is erected, the preferred embodiment of my invention includes interlocking means such as a mortise 72 in the base member side portion 52, and corresponding tenon 74 on the sidewall member 54. The interlocking means can be provided in a wide range of shapes, sizes, and arrangements, but is conveniently illustrated in the drawings as preferably having a substantially rectangular configuration with a wall thickness suitable for injection molding. By way of example and not limitation, the mortise could instead be provided on the sidewall member, and/or could include a plurality of mortises of triangular and circular configurations. The interlocking means (or some part thereof) may be provided as solid plugs rather than thin-walled structures shown in the drawings. Among the many additional alternative embodiments are separately attachable interlocking members, which are not integrally molded or formed as part of the sidewall or base, but instead are operatively affixed by glue, adhesive, screws, welding, fasteners or other expedient.
The erected sidewall member 54 is illustrated in FIGS. 11 and 12. As shown in FIG. 12, the interlocking means may be provided in a tapered cross-sectional configuration, to facilitate engagement of the mortise and tenon as the sidewall member 54 is raised into the erect position.
By precise positioning of the interlocking means on each respective sidewall member, the position of the top edge around the entire erected container (not shown) can be controlled. Normally, this top edge is desired to be of uniform height (similar to that shown as FIG. 1 for the prior art) to facilitate stacking of a plurality of containers.
Because of the slidable nature of the hinge of my invention, opposing members of a device in which it is used (such as opposing sidewall members in a collapsible container) can be provided in interchangeable (and even identical) shapes and sizes. If interlocking means such as mortise and tenon are also utilized, they would preferably also be interchangeably positioned, sized and shaped to facilitate the interchangeability of the sidewall members. As indicated above, this interchangeability has numerous economic benefits.
Thus, by my invention, I provide a hinge means useful in, among other things, collapsible containers in which opposing sidewalls are dimensioned and configured so that they overlap when collapsed. Among the many alternative embodiments and applications in which my invention may be useful are containers having non-rectangular shapes and/or more than four sides (such as hexagonal bases, octagonal bases, etc.).
The apparatus of my invention has been described with some particularity but the specific designs and constructions disclosed are not to be taken as delimiting of the invention in that various modifications will at once make themselves apparent to those of ordinary skill in the art, all of which will not depart from the essence of the invention and all such changes and modifications are intended to be encompassed within the appended claims. | A hinge is provided to affix members to each other and permit a the members to be moved relatively to each other transversely of the hinge axis while remaining hinged to each other. A collapsible container assembly utilizing such hinges is provided, in which a plurality of sidewall members hinged to a base member can be collapsed onto the base member and each other in a stacked arrangement with the resulting height of the stack being the same regardless of which of several stacking orders is utilized. Leave members of the hinge include slot means axially aligned to permit a hinge pin disposed therein to slide transversely of the longitudinal hinge axis while maintaining the hinged relationship of the members. | 1 |
BACKGROUND OF THE INVENTION
The invention relates to a controller for controlling an actuator for a magnetic valve, and more specifically to a controller for an electromagnetic actuator for driving a valve of an engine mounted on such apparatus as an automobile and a boat.
Valve driving mechanism having an electromagnetic actuator has been known and called a magnetic valve. An electromagnetic actuator typically includes a moving iron or an armature which is placed between a pair of springs with given off-set load so that the armature positions at an intermediate part of a pair of electromagnets. A valve is connected to the armature. When electric power is supplied to the pair of electromagnets alternately, the armature is driven reciprocally in two opposite directions thereby driving the valve. Conventionally, the driving manner is as follows.
1) The magnetic attraction power that one of the electromagnets provides to the armature overcomes rebound power by the pair of springs and attracts the armature to make it seat on a seating position. The armature (valve) is released from the seating position by such a trigger as suspension of power supply to the electromagnet, and starts to displace in a cosine function manner by the force of the pair of springs.
2) At a timing according to the displacement of the armature, an appropriate current is supplied to the other electromagnet to produce magnetic flux which generates attraction force.
3) The magnetic flux rapidly grows as the armature approaches the other electromagnet that is producing the magnetic flux. The work by the attraction power generated by the other electromagnet overcomes the sum of (i) a small work by the residual magnetic flux produced by the one electromagnet which acts on the armature to pull it back and (ii) a mechanical loss which accounts for a large portion of the sum of work. Thus, the armature is attracted and seats on the other electromagnet.
4) At an appropriate timing as the armature seats, a constant current is supplied to the other electromagnet to hold the armature in the seated state.
In maintaining the armature in the seated state, it is desirable to supply the minimum driving current that can hold the armature in the seated state so as to minimize power consumption. However, when a minimum current is used every time the armature is to be held in the seated state, the armature moved to a seating position may from time to time leave the seating position due to secular changes of the electromagnetic actuator and/or variations of the movement. When the armature falls or lifts (collectively referred to as “leave”) from the seating position, such situation needs to be detected immediately and power supply needs to be boosted to pull the armature back to the seating position.
Conventionally, leaving of the armature was detected based on signals from a displacement sensor that detects displacement of the armature. Specifically, leaving (falling or lifting) of the armature is determined by detecting a situation that the sensor output does not indicate seated state of the armature in the period that the armature is in the seated state. In response to determination of leaving of the armature, a large current is supplied to the windings of the electromagnet to activate pullback operation immediately so that the armature may be pulled back to the seating position.
However, the conventional method includes the following problems. The air gap between the armature and the yoke of the electromagnet is very small when the armature is seated. The electromagnetic actuator has a very small magnetic reluctance when the armature is seated. When a constant current is supplied for holding the armature in the seated state, if the armature leaves the seating position by a small distance for some reasons, say less than 10 μm from the seating position, the attraction force decreases. It is very difficult to detect such a small movement with the displacement sensor. For example, when the armature moves in the range of 7 mm in order to open and close a valve of an automobile engine, the displacement sensor can only detect the movement of the armature which is larger than {fraction (1/100)} of the moving range. That is, the sensor can only detect armature movement larger than 70 μm due to noise and performance of the sensor. Leaving (falling or lifting) detection at 70 μm point is too late to ensure pullback operation of the armature.
In addition, when pullback operation is activated at 70 μm point, a larger current needs to be supplied, thereby increasing power consumption. This requires to increase the capacity of a driver element such as a field effect transistor, raising the cost of the driving circuit. Furthermore, a large current and the air gap produced by the leaving armature cause a large magnetic energy to be accumulated in the air gap. This magnetic energy is converted into kinetic energy of the armature and valve when the armature is attracted again to the seating position. As a result, seating speed of the armature becomes large producing a large collision sound when the armature seats.
As a specific example, a case for repetitively activating an electromagnetic actuator at a high speed as in the case of a valve train of an engine is described referring to FIG. 15 . The left vertical axis shows the magnitude of displacement of the armature (mm) and current (A) supplied to the electromagnet. The right vertical axis shows attraction power (N) and voltage (V) applied to the electromagnet. As shown in the figures, the minimum attraction power (falling limit or leaving limit) that prevents the armature from leaving from the seating position is 485 N.
FIG. 15 ( a ) shows a case in which the armature seats normally and a stable seated state is maintained. At time 0, the armature is released from one electromagnet and starts to move toward the other electromagnet by the operation of a pair of springs. During the period from time Te to Th, a constant voltage 42V is applied to the other electromagnet (over-excitation operation) to make the armature seat on the other electromagnet. After that, since the attraction force is a little larger than the leaving limit, a stable seated state is maintained. After the armature is seated, switching control of voltages 0 and +12V is performed to supply a constant holding current to the electromagnet.
FIG. 15 ( b ) shows a case where a seated armature leaves the seating position. A displacement sensor detects the leaving movement of the armature when the armature reaches 70 μm point, which is 1% of the lift (movement) range of 7 mm. A pullback operation is immediately initiated. The armature reaches 70 μm point around time 6.33 ms. For 0.5 ms from time 6.33 ms, over-excitation voltage is applied. The voltage application period is determined according to the leaving extent (70 μm).
After voltage application finished, a holding current value is renewed to a value which is larger than the preset normal holding current value by a predetermined value (for example, the predetermined value is 10% of the normal holding current value). Switching control of voltages of ±12V is carried out until the current converges into the renewed target holding current value. In the example shown in the figure, the switching control is carried out for 0.7 ms. Thereafter, switching control of voltages of +12V and 0V is performed so that current supplied to the electromagnet maintains the target holding current value.
In the example shown in FIG. 15 ( b ), the armature leaves the seating position about 0.22 mm and is pulled back. The energy needed for the pullback is about 0.12 J. The seating speed (not shown) of the armature at pullback is approximately 0.6 m/s, which generates collision noise. Thus, activating pullback operation responsive to detection of the leaving armature by the displacement sensor causes delay in the pullback operation and requires a large energy for pullback. It produces a large seating speed leading to collision noise.
Thus, there is a need for a controller for an electromagnetic actuator which enables detection of a minute movement of the armature leaving the seating position and carries out pullback operation responsive to such detection.
SUMMARY OF THE INVENTION
According to one aspect of the invention, a controller is provided for controlling an electromagnetic actuator having a pair of springs acting on opposite directions, and an armature coupled to a mechanical element. The armature is connected to the springs and held in a neutral position given by the springs when the actuator is not activated. The actuator includes a pair of electromagnets for driving the armature between two end positions. The controller comprises current supplying means for supplying holding current to the electromagnet corresponding to one of the end positions when holding the armature in said one of the end positions. The controller includes means for determining that the armature is leaving the seated position when the holding current increases more than a predetermined value while the holding current is supplied to the electromagnet corresponding to said end position.
According to the invention, leaving armature is detected based on the variation of the holding current, which allows earlier detection of the leaving armature.
According to another aspect of the invention, the controller further comprises pullback means, responsive to determination of leaving of the armature, for applying voltage to the electromagnet corresponding to the end position, thereby pulling back the armature to the end position.
Because pullback operation is activated responsive to detection of leaving armature in terms of variation in the holding current, quick pullback is realized with relatively small energy.
According to further aspect of the invention, the current supplying means raises the holding current by a predetermined value. The holding current is supplied to the electromagnet corresponding to the end position after voltage is applied to the electromagnet by the pullback means.
Because the holding current is set to a relatively large value after the armature is pulled back from leaving, the armature will be prevented from leaving thereafter.
According to an aspect of the invention, the controller further includes setting means for setting the period for applying voltage to the electromagnet by said pullback means, in accordance with the difference between the time the armature leaves the seating position as determined by said determination means and a schedule release time of the armature. When the armature leaves, the period of the pullback operation can be controlled according to the timing of the release movement of the armature.
According to another aspect of the invention, the setting means shortens the period of voltage application to the electromagnet by said pullback means when the difference between the time the armature leaves the seating position as determined by said determination means and a scheduled release time of the armature is equal to or less than a predetermined value. Thus, delay of release operation of the armature is avoided.
According to yet another aspect of the invention, the controller includes a counter for counting the number of times the armature is held in the end position without leaving over a sequence of cycles. When the number of times shown by the counter is larger than a predetermined value, the supplying means decreases the holding current to supply to the electromagnet corresponding to said end position. Thus, optimization of the holding current for respective electromagnetic actuators can be realized.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a general block diagram of a controller for an electromagnetic actuator according to one embodiment of the invention.
FIG. 2 shows a mechanical structure of an electromagnetic actuator according to one embodiment of the invention.
FIG. 3 shows the behavior of various parameters according to one embodiment of the invention when the armature leaves the seating position.
FIG. 4 is a functional block diagram of a controller of an electromagnetic actuator according to one embodiment of the invention.
FIGS. 5 a and 5 b shows the behavior of various parameters in pullback operation when the armature leaves the seating position.
FIG. 6 shows the behavior of various parameters in normal operation of the armature according to one embodiment of the invention.
FIG. 7 shows the behavior of various parameters when the armature leaves the seating position around the scheduled release time according to one embodiment of the invention.
FIG. 8 shows the behavior of various parameters when the armature leaves around the scheduled release time, and pullback operation has been carried out according to one embodiment of the invention.
FIG. 9 illustrates relationship between Tr−Tf and Tγ.
FIG. 10 shows the behavior of various parameters according to one embodiment of the invention.
FIG. 11 is a flowchart showing general flow of controlling an electromagnetic actuator according to one embodiment of the invention.
FIG. 12 is a flowchart showing over-excitation operation according to one embodiment of the invention.
FIG. 13 is a flowchart showing holding operation according to one embodiment of the invention.
FIG. 14 is a flowchart showing post-pullback current control according to one embodiment of the invention.
FIGS. 15 ( a ) and ( b ) show behavior of various parameters according to a conventional.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings, specific embodiments of the invention will be described. FIG. 1 is a block diagram showing a general structure of a controller for an electromagnetic actuator. A controller 1 comprises a microcomputer which includes a central processing unit 2 (CPU 2 ), a read only memory (ROM) 3 for storing computer executable programs and data, a random access memory (RAM) 4 providing a working space for the CPU 2 and storing results of operations by the CPU 2 . The controller 1 also includes an input-output interface (I/O interface) 5 .
I/O interface 5 receives signals from various sensors 25 which include signals relating to engine speed (Ne), engine water temperature (Tw), intake air temperature (Ta), battery voltage (VB), and ignition switch (IGSW). I/O interface 5 also receives a signal indicating desired torque, an output from a detector 26 for detecting a required load. For example, the detector 26 can include an accelerator pedal sensor, which detects the magnitude of movement of an accelerator pedal.
A drive circuit 8 supplies electric power provided from a constant voltage source 6 based on a control signal from the controller 1 to a first electromagnet 11 and to a second electromagnet 13 of an electromagnetic actuator 100 . In one embodiment of the invention, electric power for attracting the armature is supplied as a constant voltage, and electric power for holding the armature in a seating position is supplied as a constant current. Constant current control can, for example, be carried out by pulse duration modulation of the voltage supplied from the constant voltage source 6 .
A voltage detector 9 is connected to the drive circuit 8 . The voltage detector 9 detects the magnitude of the voltage supplied to the first and the second electromagnets 11 and 13 , and feedbacks the data to the controller 1 . A current detector 10 is connected to the drive circuit 8 and detects the magnitude of the current supplied to the first and the second electromagnet 11 and 13 . The current detector 10 feedbacks the data to the controller 1 .
Controller 1 determines such parameters as timing of power supply, magnitude of voltage to be supplied, and period of voltage supply, based on inputs from various sensors 25 and required load detector 26 as well as feedback signals from the voltage detector 9 and the current detector 10 , and in accordance with the control program stored in the ROM 3 . The controller 1 outputs a control signal for controlling the electromagnetic actuator 100 to the drive circuit 8 through the I/O interface 5 . Thus, the drive circuit 8 provides optimized current to the first and the second electromagnets 11 and 13 for mileage enhancement, emission reduction and output characteristic enhancement of the internal combustion engine.
FIG. 2 is a sectional drawing which shows the structure of the electromagnetic actuator 100 . A valve 20 is provided at an intake port or an exhaust port (referred to as intake/exhaust port) so as to open and close the intake/exhaust port 30 . The valve 20 seats on a valve seat 31 and closes the intake/exhaust port 30 when it is driven upwardly by the electromagnetic actuator 100 . The valve 20 leaves the valve seat 31 and moves down a predetermined distance from the valve seat to open the intake/exhaust port 30 when it is driven downward by the electromagnetic actuator 100 .
The valve 20 extends to a valve shaft 21 . The valve shaft 21 is accommodated in a valve guide 23 so that it can move in the direction of the axis. A disc-shaped armature 22 made of a soft magnetic material is mounted at the upper end of the valve shaft 21 . The armature 22 is biased with a first spring 16 and a second spring 17 from top and bottom.
A housing 18 of electromagnetic actuator 100 is made of nonmagnetic material. Provided in the housing 18 are a first electromagnet 11 of solenoid type placed above the armature 22 , a second electromagnet 13 of solenoid type located underneath the armature 22 . The first electromagnet 11 is surrounded by a first electromagnet yoke 12 , and the second electromagnet 13 is surrounded by a second electromagnet yoke 14 . The first spring 16 and the second spring 17 are balanced to support the armature 22 in the middle between the first electromagnet 11 and the second electromagnet 13 when no exciting current is supplied to the first electromagnet 11 or the second electromagnet 13 .
When exciting current is supplied to the first electromagnet 11 by the drive circuit 8 , the first electromagnet yoke 12 and the armature 22 are magnetized to attract each other, thereby pulling up the armature 22 . As a result, the valve 20 is driven upwardly by the valve shaft 21 , and seats on the valve seat 31 to form a closed state.
Cutting off the current to the first electromagnet 11 and starting current supply to the second electromagnet 13 will make the second electromagnet yoke 14 and the armature 22 magnetized to produce a force which combined with the potential energy of the springs attracts the armature 22 downwardly. The armature 22 contacts the second electromagnet yoke 14 and stops there. As a result, the valve 20 is driven downwardly by the valve shaft 21 to form an open state.
FIG. 3 shows a case where a larger attraction force is required to hold the armature due to secular change and operational variation. A target holding current that has been preset has become not large enough to hold the armature. The armature leaves a seating position. The armature seats at time about 3.6 ms. The attraction power at this time is larger than the leaving limit 485 N by a predetermined value. However, due to certain causes, the electromagnet fails to maintain an attraction force which is larger than the leaving limit, and the attraction force gradually weakens. The attraction power becomes less than the leaving limit around time 5 ms. The armature begins to leave the seated position around time 5.4 ms.
When the armature leaves the seating position, the air gap between the armature and the electromagnet yoke increases, causing magnetic reluctance to begin to increase. So as to reduce variation of the total magnetic flux through the magnetic path, current flowing through the windings of the electromagnet rises as shown by the reference number 31 in FIG. 3 . When holding of the armature is performed by constant current control, the drive circuit assumes a flywheel operation and no power is supplied from the power source. Therefore, magnetic energy of the electromagnetic actuator is consumed by a rapid rise of the current. As a result, magnetic energy is consumed by copper loss of the windings and eddy current loss, accelerating reduction of the magnetic flux. As a result, leaving of the armature is promoted.
As can be seen in the drawing, a little while after the attraction power becomes lower than the leaving limit, variation of the armature displacement is gentle. Leaving distance becomes 0.2 mm in 1.7 ms. In contrast, the variation of the current through the windings after the armature begins to leave is steep. The current increases about 10% (0.06 A) in about 0.3 ms after the attraction power fell below the leaving limit. Therefore, leaving of the armature can be expected or detected in advance based on variation of the current through the windings. Responsive to the early detection or estimation of leaving of the armature, pullback operation may be initiated at an early stage, which will enable completion of the pullback operation with small energy.
FIG. 4 is a detailed functional block diagram of the electromagnetic actuator controller 1 . An electromagnet controlling unit 50 controls the drive circuit 8 so that a constant voltage is applied to windings of the electromagnet during over-excitation operation for attracting the armature. The control unit 50 controls the drive circuit 8 so that a constant current is supplied to the windings of the electromagnet during holding operation for holding the armature.
Ne, Pb detecting unit 51 detects engine speed Ne based on the output from an engine speed sensor, and detects inlet pipe pressure Pb based on the output from an inlet pipe pressure sensor. Pb is a parameter expressing a load condition of the engine, and Ne is a parameter indicating a rate of the valve of an engine, or a rate of the armature. An armature displacement sensor 53 detects displacement (lift) from a yoke surface (a seating surface) of the armature.
A voltage application period determination unit 52 determines over-excitation start time Te and over-excitation completion time Th based on Ne and Pb. Specifically, the determination unit 52 refers to the relations among Ne, Pb, and Te that are prepared beforehand and are stored in the ROM 3 . It also refers to an over-excitation timing map which indicates the relations among Ne, Pb, and Th. The determination unit 52 determines the starting time Te and the finishing time Th based on present Ne and Pb. The starting time Te and finishing time Th are indicated in terms of the time from the point that the armature is released from the seated surface and moved 1 mm. The over-excitation timing map is made so that application period of voltage gets longer as the load becomes larger.
In another embodiment, the over-excitation timing map indicates relations among Ne, Pb, and application voltage. In this case, the map is prepared such that as the load increases the application voltage becomes bigger. In further another embodiment, the over-excitation timing map includes both of application voltage and application period in addition to Ne and Pb. In addition, the over-excitation timing map may be made based on other parameters such as throttle opening and the temperature of the windings, instead of or in addition to the inlet pipe pressure Pb and the engine speed Ne.
The electromagnet controlling unit 50 , responsive to the signal indicating detection of 1 mm displacement of the armature by the displacement sensor 53 , starts the over-excitation operation. Specifically, voltage application to windings is started at voltage application start time Te given by the application period determination unit 52 . This voltage application continues till application completion time Th.
When voltage application completion time Th has passed, a holding current setting unit 55 refers to the holding current map stored in the ROM 3 to determine a target holding current I obj , which is passed to the electromagnet controlling unit 50 . The electromagnet controlling unit 50 controls power supply to the windings so that the current becomes equal to the target holding current. The holding current map is a map indicating correspondency of Ne, Pb and the target holding current. The larger the load becomes, the larger the target holding current value is according to the map.
An armature state judging unit 54 monitors the current flowing through the windings after the over-excitation completion time Th has passed. If the current reaches the target holding current, a successful seating counter is incremented as it indicates that the armature has successfully seated. The successful seating counter is a counter indicating how many times the armature has consecutively succeeded in seating. One successful seating counter is provided at each of a closed valve side and an open valve side of a single valve.
In the electromagnetic actuator 100 shown in FIG. 2, for example, one successful seating counter is provided to the first electromagnet 11 and another counter is provided to the second electromagnet 13 . The successful seating counter provided to the first electromagnet 11 is incremented when the armature successfully seated on the yoke 12 of the first electromagnet in a close valve operation of valve 20 . The successful seating counter provided to the second electromagnet 13 is incremented when the armature successfully seated on the yoke 14 of the second electromagnet in an open valve operation of valve 20 .
In a holding operation after the armature seated, when the current through the windings increases more than a predetermined value over the target holding current, armature state judging unit 54 determines that the armature is leaving. In this case, the armature state judging unit 54 resets the successful seating counter.
Pullback voltage application period determination unit 58 , responsive to a determination of leaving of the armature by armature state judging unit 54 , determines period Tγ for applying pullback voltage to the the windings so as to pullback the armature to the seating position. In one embodiment of the invention, period Tγ is of a predetermined length (for example, 0.1 ms). In another example period Tγ is determined with reference to a pullback over-excitation map. This map indicates correspondence of period Tγ and the difference between the time armature leaving is determined and the predetermined time planned for releasing the armature. The electromagnet controlling unit 50 controls drive circuit 8 to apply pullback voltage of a predetermined magnitude to the windings during period Tγ given by the application period determination unit 58 .
A holding current setting unit 55 , responsive to a determination of leaving of the armature by armature state judging unit 54 , sets the target holding current to a higher value by a predetermined value. In response, the electromagnet controlling unit 50 controls the drive circuit 8 such that the current through the windings equals the newly set target holding current after the pullback voltage application period.
When the count of the successful seating counter is equal to or more than a predetermined count, that is, when the armature successfully seated a consecutive predetermined number of times without leaving the seating position, the holding current setting unit 55 resets the target holding current to a lower value by a predetermined magnitude, and passes it to the electromagnet controlling unit 50 . In response to this, the electromagnet controlling unit 50 controls the drive circuit 8 so that the current through the windings approaches the new target holding current.
When leaving does not occur after the holding current is made smaller, the target holding current value is lowered little by little until leaving of the armature takes place. In this manner, the holding current is optimized to a lowest possible value in accordance with variation and secular changes of the armature and power consumption is reduced.
Referring to FIG. 5 ( a ), pullback operation of the armature in accordance with one embodiment of the invention will be described. At time 0 ms, the armature is released from the yoke of the electromagnet and starts to displace. When the armature displacement reaches about 2 mm, namely at time Te, over-excitation operation is started by applying voltage 42 V to the windings. Application of voltage continues till time Th where the over-excitation operation terminates and the armature seats. If for some reasons the attraction power falls below the leaving limit 485 N, the armature begins to leave around time 5.4 ms. When the armature leaves, the current through the windings of the electromagnet increases as shown by reference number 71 . In response to detection of this current increase, pullback operation starts.
FIG. 5 ( b ) is a magnified drawing showing that portion of FIG. ( a ) where the armature starts to leave and is pulled back. The armature starts to leave around time 5.4 ms, and starts to displace. In response, the current through the windings of electromagnet starts to increase. When the current increases by a predetermined ratio over the target holding current, it is judged that the armature is leaving. In the drawing, this judgment is made at time 5.728 ms. The predetermined ratio may be set, for example, at 10% of the target holding current.
In response to the judgment of leaving, over-excitation operation for pulling back the armature is started. Over-excitation voltage of 42 V is applied for a predetermined period (in this embodiment, 0.1 ms). As the over-excitation power is supplied, the attraction power becomes larger (530.0 N in the drawing) than the leaving limit. As can be seen from FIG. 5 ( b ), the current rises too.
Over-excitation operation finishes at time 5.828 ms. Then, the target holding current value is set to a value 10% larger than before so as to prevent the armature from leaving. The ratio of increase can be any appropriate value. In order to make the current converge to the new target holding current quickly, −12V is applied (the period of this voltage application is referred to as rapid current regulation period). When the current reaches the new target holding current value at time 5.995 ms, switching control of ±12V is carried out for a very short period (5.995-6.03 ms). This is done in order to make the current through the windings converge to the target holding current value quickly. Then, switching control shifts to switching between +12V and 0V so as to maintain the current at the target holding current value. This shift to switching between +12V and 0V is made to reduce power consumption. As an alternative, switching between +12V and −12V may be continued.
As is apparent from FIG. 5 ( b ), leaving of the armature is limited to a very small distance (about 3.9 μm), and leaving ends in a very short period (about 0.55 ms). Seating speed of the armature in the pullback operation is as small as 0.06 m/s, and no substantial sound is generated. Because the over-excitation period for pullback is 0.1 ms, increase of the used energy is at most 0.004 J.
Thus, in contrast to the conventional scheme that was described heretofore referring to FIG. 15, according to the invention, leaving of the armature is detected at an early stage, and the pullback operation is started at an early stage. Therefore, leaving of the armature is limited to a small distance and the energy required to pull it back is very small.
According to one embodiment of the present invention, the period of the pullback operation is regulated as described hereafter in accordance with the time the armature stars to leave.
FIG. 6 shows a normal seating and releasing operation of the armature where the armature does not leave. At time 0 ms, the armature is released and stars to displace. Voltage 42V is applied to the windings from time Te through Th and the armature seats normally. The attraction force is larger than the leaving limit 485 N till time Tr, which is a scheduled time releasing the armature. Time Tr is predetermined based on valve timing and engine speed Ne. At time Tr, the armature is released. In FIG. 6, the armature displaces or lifts 1 mm at time T 1 , which is 7.2033 ms.
FIG. 7 shows the case where the armature leaves before it is released. For some reasons, attraction power falls to a smaller value (447.24 N) which is below the leaving limit. The armature starts to leave or lift at time 5.4 ms. At the scheduled release time Tr, the armature has already started to fall or lift to cause a displacement. Thus, time T 1 of 1 mm displacement is 7.0355 ms in contrast to 7.2033 ms in the case of FIG. 6 .
Referring to FIG. 8, pullback operation is activated to the leaving state as shown in FIG. 7 . Responsive to judgment of leaving of the armature at time Tf (5.7283 ms), over-excitation operation for pullback is activated and voltage is applied to the windings. With this voltage application, attraction power rises above the leaving limit as shown by reference number 81 . The attraction power remains high at the scheduled release time Tr (6.0 ms). Thus, time T 1 of 1 mm displacement lags to 7.2788 ms in contrast to 7.2033 ms in the case of FIG. 6 .
The armature pullback operation activated immediately before the scheduled release time causes delay in the armature release operation because of a relatively large attraction force. This will cause a delay in the valve timing possibly generating significant adverse effects to the engine. According to one embodiment of the invention, time lag of the valve timing in the pullback operation is avoided by the following steps.
1) calculating the difference between the scheduled armature release time Tr and the judged leaving of the armature time Tf;
2) if the difference Tr−Tf is equal to or larger than a predetermined value, performing a full pullback operation as indicated in FIGS. 5 ( a ) and ( b );
3) if the difference Tr−Tf is smaller than the predetermined value, applying voltage for pullback for shortened period Tγ. As the voltage application period is shortened, the rapid current regulation period thereafter is also shortened correspondingly because increase of the current due to voltage application is lower.
The predetermined value may be determined based on the estimate of the voltage application period required for pullback and the rapid current regulation period. For example, referring to FIG. 5, the voltage application period for pullback is set to 0.1 ms. The period for rapid current regulation is estimated to be 0.167 ms (such estimate can be made based on actual data, for example). The predetermined value can be set to 0.28 ms, that is the sum of the voltage application period of 1 mm and the rapid current regulation period 0.167 ms plus a tolerance.
FIG. 9 illustrates an example of pullback over-excitation map, which indicates the relation between the difference Tr−Tf and the pullback voltage application period Tγ. When Tr−Tf is less than the predetermined value, the period Tγ reduces as the difference Tr−Tf reduces. When Tr−Tf is equal to or more than the predetermined value, the period Tγ is constant, enabling a full pullback operation.
Referring to FIG. 10, a scheme for avoiding delay in the valve timing will be described. At time Tf (5.7283 ms), judgment is made that the armature leaves. Time Tr is the scheduled armature release time. Here, Tr−Tf=6.000−5.7283=0.2717 ms. Assume that the above mentioned predetermined value is set at 0.28 ms for example, the value of Tr−Tf is less than the predetermined value. With reference to the map as shown in FIG. 9, period Tγ corresponding to the value of Tr−Tf is extracted. As a result, pullback operation is performed over a shorter period. Attraction power at time Tr is substantially the same as the attraction power at time Tr in FIG. 6 . Time T 1 of 1 mm displacement is 7.2033 ms, which is the same timing as the normal releasing of the armature in FIG. 6 .
Thus, time lag of the armature release operation can be avoided by adjusting the period of the pullback operation in accordance with the timing that the armature leaves.
FIG. 11 is a flow chart showing the process of controlling the electromagnetic actuator in accordance with one embodiment of the invention. This process is repetitively carried out with a constant interval. In step 101 , initial setting flag is checked to see if it is “1”. This flag is set when initial setting is done. When this process is entered for the first time, the initial setting has not been done. Thus, the process proceeds to step 102 to make the initial settings. That is, the successful seating counter K is set to “0”. Then, the value 1 is set in the initial setting completion flag and value 1 is set to the over-excitation operation permission flag indicating that the next over-excitation operation is permitted.
Next time this routine is entered, the process proceeds to step 103 as the value of the initial setting completion flag is “1”, and over-excitation operation routine is executed to make the armature seated. After completion of the over-excitation operation routine, the process proceeds to step 104 to perform holding operation routine maintaining seated state of the armature. In step 105 , at the scheduled release time of the armature, armature release operation routine starts.
FIG. 12 is a flowchart of the process of the over-excitation operation routine executed in step 103 of FIG. 11 . In step 151 , determination is made whether or not value 1 is set in the over-excitation operation permission flag indicating that the initial setting has been completed. If it is “1”, the process proceeds to step 152 to determine if 1 mm displacement has been detected. If it has not been detected, the process leaves this routine. If it has been detected, pre-stored over-excitation timing map is looked up so as to extract over-excitation starting time Te and over-excitation completion time Th which are set based on the time of 1 mm displacement ( 153 ). In step 154 , an over-excitation timer set to zero is started. This timer counts up.
In step 155 , if the over-excitation timer has not reached over-excitation start time Te, the process exits the routine. If has reached Te, the process proceeds to step 156 . When the time has reached over-excitation start time Te first time from 1 mm displacement detection point, the process proceeds to step 157 to apply over-excitation voltage as decision of step 156 is No. In step 156 , application of over-excitation voltage is carried out till the over-excitation timer reaches over-excitation completion time Th.
When the over-excitation timer reaches over-excitation completion time Th in step 156 , application of voltage finishes. Steps 161 through 167 are performed to make the armature seated. In step 161 , pre-stored holding current map is referred to so as to extract target holding current I obj based on current Ne and Pb. In step 162 , 0V is applied for a predetermined period. This is because the current through the windings is large relative to the target holding current when over-excitation finished.
In step 163 , judgment is made whether the current through the windings is plainly decreasing for the predetermined period. This plain decrease of the current indicates successful seating. When the armature is moving to a seating position with the distance to the seating position decreasing, magnetic energy stored in the gap between the armature and the yoke of electromagnet is being converted into mechanical work and a magnetic path is closing. Accordingly, the current plainly decreases. When the armature has already been seated, magnetic energy is converted into copper loss and eddy current loss, and the current decreases plainly. Plain decrease of the current can be determined by checking the change of the current per unit time. If the change shows a larger decrease than a predetermined value, plain decrease of the current can be determined.
In step 163 , if the current is not decreasing plainly, it indicates that the armature has not seated normally by the voltage application performed in step 157 . Over-excitation operation is performed again ( 167 ) for a predetermined period such as 1 ms.
When this routine is entered after the re-over-excitation and it is determined in step 163 that the current has decreased plainly, the current through the windings is examined to determine if it has reached the target holding current extracted in step 161 (step 164 ). If it has not reached the target holding current, the process exits this routine. If it has reached the target holding current indicating that the armature seated successfully, a successful seating counter is incremented ( 165 ). As the over-excitation operation finished normally, the over-excitation permission flag is set to zero and the holding operation permission flag is set to “1” in order to perform the holding operation ( 166 ).
FIG. 13 is a flowchart showing the holding routine performed in step 104 of FIG. 11 . In step 171 , the holding operation permission flag is examined to determine if it is “1” indicating that the over-excitation operation routine has completed. If it is not “1”, the process exits this routine. If it is “1”, the process proceeds to step 172 to determine if holding operation period has finished. This period is a period that is preset in accordance with the scheduled release time of the armature. When this routine is entered for the first time, the process proceeds to step 173 since the holding operation period has not finished. In step 173 , a post-pullback current control flag is examined to determine if it is “1”, indicating that post-pullback current control is being carried out (step 182 , to be described referring to FIG. 14 ). When this routine is entered for the first time, the post pullback current control has not been performed and the flag just described is “0”. The process proceeds to step 174 .
In step 174 , power supply to the windings is controlled so as to keep the current through the windings at the target holding current I obj that is extracted in step 161 of FIG. 12 . This is done, for example, by performing a switching control with the voltage switched between 0V and +12V. Thus, the armature is held at the seating position.
When the armature leaves the seating position while control is being performed so as to maintain the current at the target holding current, the current through the windings increases automatically. In step 175 , if the current increases more than 10% over the target holding current, it is judged that the armature is leaving the seating position, and the successful seating counter is reset ( 176 ). The target holding current is renewed to a value 10% larger than before ( 177 ).
As described heretofore referring to FIG. 10, voltage application period Tγ is extracted from the pre-stored pullback over-excitation map ( 178 ). The period Tγ is predetermined in accordance with the difference between the time Tf and the time Tr. The period Tγ is set in a pullback over-excitation timer (a down-timer) and the timer is started. In steps 179 and 180 , voltage is applied the windings till the period Tγ ends.
When this routine is entered again, the process proceeds to step 182 if the pullback over-excitation timer has reached zero. Post pullback current control routine (FIG. 14) is performed to make the armature seat.
In step 175 , the process proceeds to step 186 if the current through the windings has not reached a value 10% larger than the target holding current. In 186 , it is determined whether the successful seating counter has a value larger than a predetermined value (for example, 10000) and the engine speed Ne is lower than a predetermined value (for example, 1000 rpm). If the determination is positive, the present target holding current value is set to a value that is 5% smaller than before ( 187 ). This is done in order to revise the holding current value to a lowest possible value necessary for maintaining a seated state. Thus, the target holding current is gradually lowered when leaving of the armature does not take place until resulting in a leaving of the armature takes place. This way, the target holding current value is revised to an optimum value for the electromagnetic actuator.
Revolution speed Ne is included in the conditions for correcting the target holding current value because it is not appropriate to change the holding current when the armature is moving at a high speed. Depending on the applications, revolution speed may not be included in the conditions. The predetermined value of the successful seating counter and the predetermined value of the revolution speed may be set to any desirable values.
When time passes and the preset holding operation period finishes, decision step 172 turns to Yes. The process proceeds to step 185 and the holding operation permission flag is set to zero. The process exits this routine.
FIG. 14 is a flowchart of the post-pullback current control routine to be performed in step 182 of FIG. 13 . In step 191 , the post-pullback current control flag is set to “1” indicating that the post-pullback current control routine is being performed. When this flag is set to “1”, such activities as current control and pullback over-excitation are not performed as described with respect to step 173 of FIG. 13 .
In step 192 , 0V is applied for a predetermined period. This is because the current through the windings is larger than the target holding current when over-excitation operation for pullback finishes. The process proceeds to step 193 to judge whether the current decreases plainly for the predetermined period. Plain decrease of the current indicates a successful seated state as described above.
When the current is not decreasing plainly, the armature has not been pulled back to the seating position yet. The same over-excitation operation as the one carried out in step 180 is carried out again ( 196 ). That is, voltage is applied to the windings of the electromagnet for period Tγ.
After re-over-excitation operation for period Tγ, when the process enters this routine again and plain decrease of the current is detected, the current is examined to see if it reached the target holding current I obj (step 194 ). If the current has not reached the target holding current, the process exits this routine. If it has reached the target current, the post-pullback current control flag is set to zero indicating that pullback to a seating position of the armature was successful.
An embodiment of the invention has been described. The value of applied voltage (42V), the value of voltage in switching control (±12V) are merely examples and are not intended to limit the invention. Different voltages can also be used. For example, holding operation can be carried out with a 42V power source.
While the invention has been described with respect to specific embodiments, such embodiments are not intended to limit the scope of the invention. | A controller for an electromagnetic actuator is provided that enables detection of a minute movement of the armature leaving the seating position and carries out pullback operation responsive to such detection. The electromagnetic actuator has a pair of springs acting on opposite directions, and an armature coupled to a mechanical element such as a exhaust/intake valve of an automobile engine. The armature is held in a neutral position given by the springs when the actuator is not activated. The actuator includes a pair of electromagnets for driving the armature between two end positions. The controller having current supplying means for supplying holding current to the electromagnet corresponding to one of the end positions when holding the armature in said one of the end positions. The controller includes determining that the armature is leaving (falling or lifting) the seated position when the holding current increases more than a predetermined value while the holding current is supplied to the electromagnet corresponding to said end position. Leaving armature is detected based on the variation of the holding current, which allows earlier detection of the leaving armature. | 5 |
FIELD OF THE INVENTION
[0001] The invention relates to a receptacle for a wheeled frame, in particular for the transportation of babies or infants.
BACKGROUND OF THE INVENTION
[0002] Transportation of infants and babies in bicycle trailers is not readily possible, because the bicycle trailer seats are not designed for this. Due to the lack of suitable solutions for this problem, infant seats designed for use in cars are often placed in bicycle trailers and attached therein with belts. While an infant can, in principle, be transported in a bicycle trailer in such manner, this has the distinct disadvantage that infant car seats are very bulky and generally wider than the area of the seat provided for one child. This is particularly problematic with bicycle trailers with two seats, since once the car seat is placed in the bicycle trailers, there is hardly any room left for a second child, let alone a second infant car seat.
[0003] The only option available on the market for transporting babies in a bicycle trailer is a hard polystyrene infant seat made by the German manufacturer Weber Technik Werkzeugbau GmbH, which contrary to the aforementioned car seats has been tailored to the width of the child seat of a bicycle trailer. This carrier has a concave reclining seat area, the bottom area of which is flattened out opposite the back and shoulder area. It has a passage opening in the center just below the bottom area as well as several pairs of passage openings on both sides of the central vertical axis in the shoulder area for the belts of a restraint system. In addition, there are fastener openings in the upper and lower area of the carrier, through which the belts of a bicycle trailer seat can be threaded in order to attach the carrier.
[0004] This carrier, too, has some distinct disadvantages. It is bulky, which makes fastening the carrier in a bicycle trailer seat difficult and does not allow for space-saving storage, for instance in a warehouse or a garage. The carrier is rigid so that it does not adapt to the position and movement of a baby or infant. Finally, the carrier is not breathable, which is particularly uncomfortable on warm days or when sitting in the carrier for an extended period of time.
SUMMARY OF THE INVENTION
[0005] The basic idea of the invention consists in making the body receptacle from a flexible material which can be brought into the shape necessary for transporting the baby/infant by bracing the material externally and/or within itself, as required. Bracing externally means that there are tensioning devices extending from or outside of the body receptacle that are attached to the frame in such a way that they exert tension on the mat. In this case such tensioning devices can be, for example, lengthwise adjustable belts with springs. Bracing “within itself” means that the tensioning devices find support in the material itself when under tension. Such internal bracing is possible, for example, with spring poles which are inserted into hemmed seams in the mat and inserted—under tension—into the anchoring points of the mat, similar to a self-supporting dome tent.
[0006] The body receptacle according to the invention has a variety of advantages over the baby carrier described above. Thus, when not in use, the flexible mat can be folded and stored compactly after the tensioning devices have been removed. Moreover, even in its transport form, it still has a certain degree of flexibility so that the mat adapts somewhat to a body shape. This makes lying/sitting in the body receptacle more comfortable, as does the fact that the flexible mat can be made partially or totally from breathable material. Finally, attaching the body receptacle in a wheeled frame, in particular in a bicycle trailer, is much easier, at least if it is first attached and then brought into its transport form with the help of tensioning devices.
[0007] In a preferred embodiment of the mat, there are sidewalls in the bottom area, which prevent the infant (infants) from slipping out sideways. The sidewalls work together particularly with a restraint system, which prevent the transported infant (infants) from slipping out of the body receptacle by stabilizing the position of the infant's body.
[0008] In order to increase the comfortableness of the mat, the sidewalls are preferably padded and/or made from an air permeable fabric.
[0009] To stabilize the sides of the body receptacle, there are belts that preferably run lengthwise to the mat. While these belts can in principle be located at the level of the supporting area that supports the underside of the body, it is preferable that they run along the upper edges of the sidewalls. Belts are particularly well suited to stabilize the body receptacle because they can be put under considerable tension. Moreover, the ends of the belts can be fitted with fastening elements, with which the body receptacle can be suspended in a frame or braced therein with the help of tensioning devices.
[0010] The lengthwise-arranged belts can be run through tubular sleeves, which are preferably made from a foamed material, so that the belts are padded. The belts can be attached inside the sleeves, by for example sewing or gluing. The sleeves can be embedded in hemmed seams running lengthwise along the sides of the mat or along the upper edges of the sidewalls.
[0011] The sleeves can be elastic and/or foldable, so that they can be folded or rolled compactly with the mat without causing damage to the sleeve material.
[0012] In addition, the sleeves are preferably curved lengthwise and the mat in its supporting area can be preformed concavely in the working position. A preforming of the mat can, for example, be done by sewing the sidewalls and the supporting area together in such a way that it results in a bottom area that is angled from the back and shoulder area. This makes installing and, in particular, pulling the body receptacle into its transport shape easier.
[0013] In another embodiment, the front edge of the mat is fitted with padding, which is raised with respect to the supporting area. On one hand, this helps stabilize the mat crosswise. On the other hand, the padding provides a safeguard against the baby or infant sliding out, in particular while buckling the child into the mat.
[0014] The stabilization of the mat crosswise to its longitudinal axis is preferably done with the help of a strap fastened to the backside of the mat and running crosswise to its longitudinal axis, the ends of which are fitted with fastening elements. In particular, if this strap is located in the bottom area of the supporting area, it can be used to stretch the body receptacle in such a way that this results in an angle between the bottom area and the back and shoulder area of the supporting area, especially when the mat is braced accordingly at the upper and lower ends of its longitudinal direction. Alternatively, it is also possible to provide a strap at each side of the backside of the mat, with which the mat can be braced towards the back.
[0015] In order to adjust the position of the body receptacle and the forces necessary to brace it, it is helpful if the length of the belts can be adjusted at least at one end.
[0016] In order to make installation easier, at least one of the fastening elements can be constructed as a snap buckle working together with its corresponding counter-piece, which is attached to the frame.
[0017] In order to make sitting or lying in the body receptacle more comfortable, at least some of its surfaces can be fitted with fleece, in particular the padded areas.
[0018] Being particularly durable, it is preferable to use textile fabrics for the mat. In particular, it makes sense to use a textile fabric for the bottom of the mat and, in a preferred further embodiment, to cover it with a layer of foamed plastic for padding. That way, the requirements with respect to both the strength of the material and comfortableness can be met as far as the supporting area is concerned, in particular if the padding is also breathable.
[0019] As a restraint system to keep the baby or infant being transported safe in the event of a bump or collision of the frame, the mat can be fitted with safety belts, which is attached in particular in the stabilized areas of the mat, for example in the areas of the lengthwise or crosswise belts. If the frame is already fitted with a restraint system, the supporting area can have openings for the safety belts of the restraint system. The location of the openings can be the same as with the infant car seats described hereinbefore.
[0020] The above leads to the conclusion that the body receptacle is preferably used in the frame of the passenger compartment of a bicycle trailer.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] In the following, the invention is described in further detail with the help of two illustrations showing a preferred embodiment of the invention:
[0022] [0022]FIG. 1 is a perspective drawing of a bicycle trailer with a suspended body receptacle; and
[0023] [0023]FIG. 2 is a cross-section of the body receptacle along the line of cross-section II-II in FIG. 1.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0024] The frame of the bicycle trailer shown in FIG. 1 consists of the following main parts: a chassis 1 as well as a passenger compartment located thereon with one part of the frame forming the front and top of the passenger compartment 2 and a passenger compartment rear side 3 . The partial frame 2 has a cross strut 4 located on its front side above the chassis 1 , which is positioned much lower than a cross tube 5 provided at the upper end of the passenger compartment rear side.
[0025] On the chassis 1 , two crossbars arranged in tandem 6 , 7 are provided, to which, among other things, the front and rear edge of a seating area 8 is anchored. Between the rear crossbar 7 and the cross tube 5 provided at the upper edge of the rear of the frame, a rear wall 9 is inserted, which has a padded backrest 11 sewn to its lower part. In the center of the front edge of the seating area 8 , a crotch strap 12 of a restraint system is anchored, which works together with a shoulder belt 14 via a ring 13 , with both ends of the shoulder belt 14 having snap closures 15 , 16 with which they can be attached to the rear wall 9 . The parts of the snap closures 16 located on the rear wall 9 are attached to belts 17 , 18 positioned side by side in such way that their height can be adjusted.
[0026] Between the cross strut 4 and the cross tube 5 , a body receptacle 19 with a mat forming a lying/sitting area 21 is suspended. The body receptacle is held by two belts 22 , 23 running along its sides, the ends of which are looped around the cross strut 4 and the cross tube 5 , respectively, and fastened with buckles 24 , 25 , 26 , 27 . The belts are run through tubular sleeves 28 , 29 made from a foamed material, that form a part of the side walls of the body receptacle and as such provide a safeguard against the baby slipping out.
[0027] The body receptacle 19 is braced with belts 31 , 32 arranged on both sides of the hip area on the backside of the mat 21 , which via closures 33 , 34 work together with belts 35 attached to the rear crossbar 7 .
[0028] By bracing the mat 21 in this manner, it is angled in the hip area so that the bottom area is angled relative to the back and shoulder area and in particular the bottom area is oriented more horizontally than the back and shoulder area.
[0029] Between the tube-like sleeves 28 , 29 and the mat 21 , mesh fabric 37 is sewn in, which is tapered lengthwise towards the upper and lower edge of the infant carrier so that the height of the side walls is increased, in particular in the bottom area.
[0030] In the mat 21 , openings are provided to lead through the safety harness of the restraint system as follows: one opening 38 slightly below the center of the bottom area for the crotch strap 12 including the ring 13 attached thereto, and three pairs of openings 39 , 41 , 42 arranged one above the other in the shoulder area of the mat 21 on both sides of the central longitudinal axis for leading through the shoulder belt 14 .
[0031] At its lower end, mat 21 ends with a crosswise padded roll 40 which safeguards the baby or infant from slipping out of the body receptacle 19 , in particular prior to or while being buckled in.
[0032] The cross-section shown in FIG. 2 shows particularly well that belts 22 , 23 are run through the tubular sleeves 28 , 29 . The bottom side of the mat 21 is made of a textile material 41 in which the tubular sleeves 28 , 29 are sewn in on both sides of mat 21 . Between the tubular sleeves, the top side of the textile material 43 is covered with foamed, breathable padding 44 .
[0033] Many further modifications to the apparatus described and illustrated will readily occur to those skilled in the art to which the invention pertains. The specific embodiments described and illustrated herein should be considered only as illustrated and not be considered limiting of the scope of the claims.
[0034] While the preferred embodiment of the invention has been illustrated and described, it will be appreciated that various changes can be made therein without departing from the spirit and scope of the invention. | A body receptacle for a wheeled frame allows for the transport of babies in a bicycle trailer. The body receptacle has a flexible mat that is brought into the intended transport form with the help of tensioning devices. | 1 |
FIELD AND BACKGROUND OF THE INVENTION
The present invention relates to cellular telephony and, more particularly, to a searcher for a DSSS cellular telephony system.
In a DSSS cellular telephony system, the base stations identify themselves by transmitting pilot signals. Each pilot signal is a sequence of zero bits, modulated, according to the principles of DSSS encoding, by a pseudonoise (PN) sequence, or an extended pseudonoise sequence.
For example, under the IS-95 interim standard, the PN sequence is 2 15 chips long, with the n-th chip including an in-phase component i(n) and a quadrature component q(n). The initial values of i and q are i(1)=q(1)=1 and i(n)=q(n)=0 for 2≦n≦15. Subsequent values of i and q, up to n=2 15 −1, are obtained recursively as follows:
i(n)=i(n−15)+i(n−10)+i(n−8)+i(n−7)+i(n−6)+i(n−2) (1)
q(n)=q(n−15)+q(n−12)+q(n−11)+q(n−10)+q(n−b 9 )+q(n−5)+q(n−4)+q(n−3) (2)
where the additions are modulo 2. Finally, i(2 15 )=q(2 15 )=0.
The same PN sequence is used by each of the base stations. The base stations are synchronized; and each base station uses the PN sequence with a different delay (also called “PN offset”) to produce the pilot signal. This enables the mobile units of the cellular telephony network to distinguish one base station from another.
The total signal received by a mobile station, as a function of time t s is:
RX ( t ) = ∑ b = 1 B ∑ m = 1 M b C ( b , m , t ) · PN ( t + offset ( b ) + τ ( b , m ) ) · [ 1 + ∑ i = 1 I b α i · D ( i , b , t ) · W ( i , b ) ] + N ( 3 )
Here, b indexes the B base stations; m indexes the M b transmission paths (multipath channels) from base station b to the mobile station; C is the channel gain of multipath channel m; τ is the additional delay introduced to the PN sequence by multipath channel m; the “1” inside the brackets represents the sequence of zeros that is modulated by the base stations to produce the pilot signals; i indexes the I b other users that are transmitting via base station b at time t; α is the power of user i relative to the pilot signal; D is the data transmitted by user i; W is a code sequence (for example, a Hadamard code sequence) that is used in addition to the PN sequence to modulate data D and allow simultaneous transmission on the same physical channel by all the users in addition to the pilot signals; and N is additive noise.
Each mobile unit of the cellular telephony network determines which base station to communicate with (typically, the nearest base station) by correlating this signal with the PN sequence at a set of trial delays. Because data D are modulated by sequences W, the correlation of the part of the signal that comes from other users is negligible. The correlation with the pilot signals also is negligible, except at trial delays that are equal to the PN offsets used by the base stations, as modified by multipath delays τ. Specifically, a pilot signal that arrives at a delay, that is equal to the sum of a base station offset and one of the multipath delays τ associated with transmissions from that base station, gives a significant contribution to the correlation at a matching trial delay; and all other pilot signals contribute negligibly to the correlation at that trial delay. This correlating is performed when the mobile station powers up, and continuously thereafter, to allow hand over from one base station to another when the mobile station crosses a call boundary. The delays of the various base stations are well separated, by more than the largest anticipated multipath delay, so in the absence of additive noise and in the absence of multipath delays, only a small number of correlations, equal to the number of potential nearest base stations, would have to be performed, to identify the base station whose delay gives the highest correlation as the nearest base station. According to the IS-95 standard, this separation is at least 256 chip duration T c . Because the pilot signals and data D are received by the mobile station from each base station via several paths at different delays (PN offset+τ), the various replicas of the signals thus received are combined to suppress the deterministic noise represented by the various multipath delays τ. For example, maximal ratio combining is the optimal combination method in a bit error rate and frame error rate sense. In order to do this combining, the multipath delays must be determined. Therefore, the correlation is performed at a series of delays in a window centered on the nominal delay. The size of this window depends on the local topography, and is provided to the mobile unit by the base station. One typical window size, according to the IS-95 standard, is 60 chip durations.
FIG. 3 is a schematic block diagram of a mobile station receiver 30 . RF signals are received by an antenna 60 , down converted to an intermediate frequency (IF) by a down converter 62 , filtered by a bandpass filter 64 (typically a surface acoustic wave filter) to eliminate signals outside the required bandwidth, and amplified by an automatic gain control 66 . The amplified IF signals are multiplied by an IF sinusoid 65 , without (block 68 i) and with (block 68 q) a 90° phase shift 67 , to produce an in-phase signal I and a quadrature signal Q. In-phase signal I is filtered by a low-pass filter 70 d and digitized by an A/D converter 72 i. Similarly, quadrature signal Q is filtered by a low-pass filter 70 q and digitized by an A/D converter 72 q. A searcher 80 receives the digitized signals and performs the correlations needed to determine the various multipath delays τ inside the target window. The digitized signals are again correlated, at the delays determined by searcher 80 , by the correlators of a correlator bank 74 , and the outputs of correlator bank 74 are combined, in a maximal ratio sense, in a rake combiner 76 to produce the final output signal.
In order to ensure uninterrupted communication as a mobile station crosses from one cell to another, the correlations performed by searcher 80 must be performed rapidly. In fact, it is not necessary to perform the full correlation at each delay in the window. It suffices to perform a correlation that is only long enough to ensure a high detection probability at the right delay and a low false alarm probability at the wrong delay. Typically, the length of the correlation, measured as a multiple N of the chip duration T c is between 500 T c and 20000 T c .
To make the correlations even more efficient, the dual dwell algorithm is used. At each delay in the window, the correlation is performed for a number M of chip durations that is less than N. Only if the correlation value after M chip durations exceeds a certain threshold is the correlation performed for the full N chip durations. The threshold, and the parameters N and M, are chosen to maximize the detection probability while minimizing both the false alarm probability and the time spent correlating. See, for example, M. K. Simon, J. K. Omura, R. A. Scholtz and B. K.
Levitt, Spread Spectrum Communication, Vol. III, Computer Science Press, 1989, chapter 1, particularly section 1.3, and D. M. Dicarlo and C. L. Weber, “Multiple dwell serial search: performance and application to direct sequence code acquisition”, IEEE Transactions on Communications vol. COM-31 no. 5 pp. 650-659, May 1983. In the prior art implementation of this algorithm, several correlators are used by searcher 80 to correlate the received pilot signal with the PN sequence at several adjacent delays in the window. If none of the correlation values exceeds the threshold after M chip durations, then the correlators are used to correlate the received pilot signal with the PN sequence at the next several adjacent delays. If at least one of the correlation values exceeds the threshold after M chip durations, then all the correlations are continued for the full N chip durations, but only the correlation values obtained by the correlators whose correlation values exceeded the threshold after the initial M chip durations are actually considered. The brute force approach to reducing search time, adding more correlators, is inefficient, because the more correlators that are used, the more likely it is that one of the correlators passes the threshold. In that case, the other correlators, which did not pass the threshold, continue to correlate unnecessarily for the full N chip durations.
There is thus a widely recognized need for, and it would be highly advantageous to have, a configuration for a cellular telephony searcher that would allow the efficient use of many correlators.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is herein described, by way of example only, with reference to the accompanying drawings, wherein:
FIG. 1 is a partial block diagram of a searcher of the present invention,
FIG. 2 is a flow chart for the decision of whether to move a correlator to a new delay;
FIG. 3 (prior art) is a schematic block diagram of the receiver of a cellular telephony mobile unit.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention is of a cellular telephony searcher which can be used by a mobile station to identify the several strongest multipath components of nearby base stations faster than presently known searchers.
The principles and operation of a cellular telephony searcher according to the present invention may be better understood with reference to the drawings and the accompanying description.
Referring now to the drawings, FIG. 1 is a partial block diagram of a searcher 10 of the present invention. Searcher 10 includes a PN sequence generator 12 , a delay line 14 that in turn includes several complex delay units 16 , a multiplexer 18 , several correlators 20 , a hold unit 26 and a next location unit 28 . With each correlator 20 is associated an index register 22 and a memory 24 . Memory 24 includes several complex registers and several corresponding integer registers, as discussed below. For illustrational simplicity, only two correlators 20 are shown, and only six delay units 16 are shown in delay line 14 . In practice, the preferred number of correlators 20 is at least 8. The preferred number of delay units 16 is discussed below.
Also shown in FIG. 1 is a receiver 30 and a clock 32 .
Block 30 of FIG. 1 represents prior art receiver 30 of FIG. 3 , except for searcher 80 ; and, in fact, according to the present invention, searcher 10 substitutes directly for searcher 80 in receiver 30 of FIG. 3 . The calculation performed by each correlator 20 is
S K ( v , γ ) = ∑ k = 1 K RX k + v PN k + v - y * ( 4 )
where the RX k are successive values of the received signal of equation (3), the PN k are successive values of the PN sequence received by correlator 20 from PN sequence generator 12 , and the summation index k runs from 1 to an upper limit K. The received signal is not necessarily sampled at the same rate as the PN sequence. In the examples presented herein, new samples RX k are provided to correlators 20 by A/D converters 72 at time intervals of T c /2. The parameter v represents the time at which the correlation performed by a particular correlator 20 starts. The parameter γ represents the delay at which the correlation is performed, relative in the time at which the correlation starts. The samples RX k and PN k are complex, and the asterisk represents complex conjugation: PN k * is the complex conjugate of PN k . For example, in a searcher 10 with four correlators, the correlation performed initially by the first correlator 20 is:
S=RX(0)PN(0)+RX(T c )PN(T c )+RX(2T c )PN(2T c )+RX(3T c )PN(3T c )+ . . . (5)
the correlation performed initially by the second correlator 20 is:
S=RX(T c /2)PN(0)+RX(3T c 2)PN(T c )+RX(ST c /2)PN(2T c )+RX(7T c 2)PN(3T c )+ . . . (6)
the correlation performed initially by the third correlator 20 is:
S=RX(T c )PN(0)+RX(2T c )PN(T c )+RX(3T c )PN(2T c )+RX(4T c )PN(3T c )+ . . . (7)
and the correlation performed initially by the fourth correlator 20 is:
S=RX(3T c /2)PN(0)+RX(ST c /2)PN(T c )+RX(7T c /2)PN(2T c )+RX(9T c /2)PN(3T c )+ . . . (8)
(In equations (5)-(8), RX and PN are shown as functions of time, rather than as sampled values.) Note that correlators 20 do not all start correlating at the same time. In this example, the first correlator 20 starts correlating at time t=0; the second correlator 20 starts correlating at time t=T c /2; the third correlator 20 starts correlating at time t=T c ; and the fourth correlator 20 starts correlating at time t=3T c /2. Note also that, in this example at least, each correlator 20 receives the PN sequence with a delay corresponding to the time at which that correlator 20 starts its calculation. After M chip durations T c (K=M), S k =S M is the first dwell correlation value. After N chip durations T c (K=M), S K S M is the second dwell correlation value.
Similarly, clock 32 is not part of searcher 10 , but is the system clock of the mobile station of which searcher 10 is a high level component. Clock 32 drives PN sequence generator 12 under the control of hold unit 26 , as described below.
PN sequence generator 12 produces a new value PN k every chip duration T c . Each new term in the right hand side of equation (4) also is computed by each correlator 20 once every T c . In any particular T c interval, all correlators 20 receive from A/D converters 72 one of two different values RX k but each correlator 20 receives from PN sequence generator 12 , via delay line 14 and multiplexer 18 , a different value PN k , depending on the value of an index stored in index register 22 associated with that correlator 20 .
Conceptually, once every T c interval, each correlator 20 performs the multiplication RX k PN k * and adds the complex product thus obtained to a correlation value stored in one of the complex registers in memory 24 associated with that correlator 20 . Because the possible values of the PN k samples are either +1 or −1, there is no need to actually perform multiplications. Instead; only additions or subtractions of the in-phase and quadrature components of RX k are actually performed. This allows a significant reduction in the complexity and electrical current consumption of searcher 10 .
For example, let A=Re(RX k )+Im(RX k ) and let B=Re (RX k )−Im(RX k ). If Re(PN k )=1 and Im(PN k )=1, then Re(RX k PN k *)=A, and Im(RX k PN k *)=−B. If Re(PN k )=1 and Im(PN k )=−1, then Re(RX k PN k *)=B and Im(RX k PN k *)=A. If Re(PN k )=−1 and Im(PN k )=−1, then Re(RX k PN k *)=−B and Im(RX k PN k *)=−A. If Re(PN k *)=−1 Im(PN k )=−1, then Re(RX k PN k *)=−A and Im(RX k PN k *)=B. Instead of transferring RX k directly from receiver 30 to correlators 20 , RX k is sent to an arithmetic unit (not shown) that computes A and B and sends A and B to the appropriate correlators 20 . Each correlator 20 then adds ±A or ±B to the real part and the imaginary part of the correlation value, depending on the signs of the values of Re(PN k ) and Im(PN k ) concurrently provided by multiplexer 18 to that correlator 20 .
Another method of avoiding actual multiplications exploits the fact that only the absolute values of the correlation values S are actually needed, to further reduce the number of calculations and achieve a further reduction in electrical current consumption by searcher 10 . If the complex PN sequence of every correlator 20 is rotated 45°, then either the real part or the imaginary part of every PN k sample is equal to zero. Each correlator 20 then adds either ±Re (RX k ) or ±Im(RX k ) to the real part or the imaginary part of S, depending on the sign of the non-zero component of PN k , without the intervention of the arithmetic unit. The rotation as described implicitly divides the complex PN sequence by the square root of 2. If only the relative values of S are required, then the system software uses these values of S as produced by correlators 20 . If the absolute values of S are needed, then the system software normalizes the values of S that it obtains from searcher 10 by multiplying those values by the square root of 2.
Each delay unit 16 receives the PN sequence, either directly from PN sequence generator 12 in the case of the first (leftmost) delay unit 16 , or from the immediately preceding delay unit 16 . Each delay unit passes the PN sequence, with a fixed delay D, to multiplexer 18 and (except for the last (rightmost) delay unit 16 ) to the next delay unit 16 . PN sequence generator 12 also passes the PN sequence directly to multiplexer 18 . Thus, if there are N D delay units 16 in delay line 14 , multiplexer 18 receives N D +1 copies of the PN sequence, with mutual relative delays D. The size of D, and the sampling rate at which RX k samples are provided to correlators 20 , are selected to give searcher 10 the required time resolution. In the example of equations (5)-(8), in which the sampling rate of RX k is (T c /3) −1 , the time resolution of searcher 10 is T c /2.
Searcher 10 functions under the overall control of the system software to search for the delays, in all the relevant windows, that give correlation values that are significantly meaningful (i.e., above background noise) to be useful in identifying the strong neighboring base stations and in demodulating the signals received from these base stations. For each window, the search process is initialized by setting the delay of PN sequence generator 12 to the first (earliest) delay in the window, by setting the indices stored in index registers 22 to values corresponding to the first L delays in the window (L being the number of correlators 20 ), and by zeroing the complex registers of memories 24 . Subsequently, hold unit 26 delays PN sequence generator 12 further, as described below. In all cases, hold unit 26 delays PN sequence generator 12 by blocking timing signals from clock 32 .
Whenever a correlator 20 finishes a correlation over M chip intervals, next location unit 28 decides whether that correlator 20 should continue correlating at its current delay or should move to the next delay. FIG. 2 is a flow chart of this decision. If K=M (block 40 ), correlator 20 has finished the first dwell correlation, so the absolute value of S K =S M is compared to the first dwell threshold (block 42 ). If |S M | is less than or equal to the first dwell threshold, the correlation at the current delay has failed, so correlator 20 is moved to the next delay that needs to be tested (block 48 ). If |S M | exceeds the first dwell threshold, then correlator 20 stays at the current delay (block 46 ) and continues the summation of equation (4) until N terms RX k PN k * have been summed. If K>M (block 40 ), then, in the general case of N>2M, either correlator 20 is in the middle of computing the second dwell correlation value S N (K<N) or correlator 20 has finished computing the second dwell correlation value (K=N)(block 44 ) If correlator 20 is in the middle of computing SN, then correlator 20 remains at the current delay (block 50 ). Otherwise, correlator 20 is moved to the next delay that needs to be tested.
In the special case of N=2M, K>M implies K=N, so the “no” branch of block 40 leads directly to block 48 .
Most preferably, the exact absolute value of S M is not compared to the threshold. Instead the following piecewise linear approximation of |S N |, which is based on a linear approximation of √{square root over (1+x 2 )}, and which is easier to implement in hardware than an exact numerical calculation of the absolute values of S M , is used for the absolute value of S M .
|S M =max(|Re(S M )| p |Im(S M )|)+min(|Re(S M )| p |Im(S M )|)/4 (9)
This approximation is sufficiently accurate for first dwell thresholding, and allows the implementation of the first dwell threshold decision in a hardware unit that is smaller, and consumes less electrical current, than would otherwise be necessary. By contrast, the exact absolute values of S N is computed, for trial delays that pass the first dwell threshold, in software, so that the various |S N |'s can be compared to determine the delays with the largest |S N |s. The fact that only a small number of trial delays pass the first dwell threshold keeps the associated computational load on the system software relatively low, with no sacrifice in accuracy.
Recall that each memory 24 includes several complex registers for storing S K . The register depth, i.e., the number R of complex registers, depends on how often (multiple of MT c ) an interrupt is generated to allow the reading of the most recently calculated value of S and the reading of the index value in the associated integer register. For example, if the interrupt is generated every 2MT c , then R should be at least 2, and in general if the interrupt is generated every yMT c (y being an integer) then R should be at least as great as y. If y<R, then the R complex registers are activated cyclically, giving the system software more time to respond to interrupts. R and y are implementation-dependent parameters. There are several considerations in the selection of the optimum values of y and R. Values of y and R that are too small put too much of a burden on system software. Large values of y and R require a correspondingly long delay time and a larger chip area devoted to memories 24 . The preferred value of both R and y is 2. Most preferably, to minimize the burden on system software, an interrupt is issued to system software only when all correlators 20 have filled their respective memories 24 .
Next location unit 28 also includes a next location register. At the start of correlation in a given window, the value in the next location register is set to the index corresponding to the first delay after the initial L delays. Subsequently, whenever block 48 is reached for a given correlator 20 , the value stored in the next location register is:
(a) copied to index register 22 of that correlator 20 and then (b) changed to the index corresponding to the delay immediately following the delay to which that correlator 20 has now been set.
Every yM chip intervals, while the interrupt service routine reads the output of searcher 10 , the system software determines the delay of the locally generated PN sequence that is to be used now by each correlator 20 , and signals hold unit 26 to pause PN sequence generator 12 until the timing of the generation of the PN sequence by PN sequence generator 12 matches the earliest delay of the forthcoming M chip intervals. At the same time, multiplexer 18 shifts the input of the PN sequence to each correlator 20 correspondingly, to preserve the continuity of input to each correlator 20 . This allows the use of a delay line 14 that is much shorter than the window. Specifically, the minimum values of N D , the number of delay units 16 in delay line 14 , is
L 2 N M + Δ
where Δ is an implementation dependent parameter: Δ=Ly/2, where y is the interrupt interval factor defined above.
Preferably, the components illustrated in FIG. 1 all are implemented in hardware. The details of such a hardware implementation will be obvious to those skilled in the art.
The following is an example of the functioning of searcher 10 , with L=8 correlators 20 and with D=T c /2, M=512, N=3M=1536 and y=2. In this example, the value of the indices in index registers 22 and in the next location register of next location unit 28 are given as (possibly fractional) multiples of T c . In practice, because index registers 22 are integer registers, the values actually stored in index registers 22 are appropriate integral multipliers of D. Similarly, the delays are expressed as multiples of T c relative to the center of the window. A correlator 20 is said to “fail the first dwell threshold” if that correlator 20 produces a first dwell correlation value S M less than or equal in absolute value to the first dwell threshold, and to “pass the first dwell threshold” if that correlator 20 produces a first dwell correlation value S M having an absolute value greater than the first dwell threshold. All correlators 20 have two complex registers in memories 24 for accumulating correlation values.
Following the IS-95 standard, the first correlation is performed at a delay of −30.
TABLE 1
Status at Time = 0
new value in
new index
corresponding
next location
correlator no.
status
value
delay
register
1
0
−30
2
½
−29½
3
1
−29
4
1½
−28½
5
2
−28
6
2½
−27½
7
3
−27
8
3½
−26½
4
TABLE 2
Status at time = 512 T c
new value in
new index
corresponding
next location
correlator no.
status
value
delay
register
1
fail threshold
4
−26
4½
2
fail threshold
4½
−25½
5
3
fail threshold
5
−25
5½
4
fail threshold
5½
−24½
6
5
fail threshold
6
−24
6½
6
pass
6½
−23½
7
threshold
7
fail threshold
7
−23
7½
8
fail threshold
7½
−22½
8
Note: All the correlators have failed the first dwell threshold. Therefore, all the index registers are incremented by 4.
TABLE 3
Status at time = 102.4T c
new value in
new index
corresponding
next location
correlator no.
status
value
delay
register
1
fail threshold
8
−22
8½
2
fail threshold
8½
22½
9
3
pass
5
−25
9
threshold
4
fail threshold
9
−21
9½
5
fail threshold
9½
−20½
10
6
pass
6½
−23½
10
threshold
7
fail threshold
10
−20
10½
8
fail threshold
10½
−29½
11
Note: Correlators 3 and 6 have passed the first dwell threshold. Therefore, these two correlators remain at their old delays, to continue correlating for the second dwell time. The other correlators, having failed the first dwell threshold, are set to the next delays.
Now, an interrupt is generated. Hold unit 26 performs a hold of 5T c , which is delay of the earliest correlator (correlator 3 ) relative to the start of the window, and 5 is subtracted from all the index values and from the value in the next location register.
TABLE 4
Status at time = 1536T c
new value in
correlator
new index
corresponding
next location
no.
status
value
delay
register
1
fail threshold
6
−19
6½
2
fail threshold
6½
−18½
7
3
continue (2 nd )
0
−25
7
4
fail threshold
7
−18
7½
5
fail threshold
7½
−37½
8
6
continue (2 nd )
2½
−23½
8
7
fail threshold
8
−37
8½
8
pass threshold
5½
−19½
8½
Note: Correlator 8, which has passed the first dwell threshold, and correlators 3 and 6, which are correlating in the second dwell time, are kept at their old delays. The other correlations are set to the next delays.
TABLE 5
Status at time = 2048T c
new value in
correlator
new index
corresponding
next location
no.
status
value
delay
register
1
fail threshold
8½
−16½
9
2
fail threshold
6½
−18½
9
3
continue (3 rd )
0
−25
9
4
fail threshold
9
−16
9½
5
fail threshold
9½
−25½
10
6
continue (3 rd )
1½
−23½
10
7
fail threshold
10
−15
10½
8
continue (2 nd )
5½
−19½
10½
Note: Correlator 2, which has passed the first dwell threshold, and correlators 3, 6 and 8, which are correlating in the second dwell time, are kept at their old delays. The other correlations are set to the next delays.
An interrupt is generated, but no hold is performed because the earliest correlator still is correlator 3 .
TABLE 6
Status at time = 2560T c
new value in
correlator
new index
corresponding
next location
no.
status
value
delay
register
1
fail threshold
10½
−14½
11
2
continue (2 nd )
6½
−18½
11
3
finish (new
11
−14
11½
location)
4
fail threshold
11½
−13½
12
5
fail threshold
12
−13
12½
6
finish (new
12½
−12½
13
location)
7
fail threshold
13
−12
15½
8
continue (3 rd )
5½
−19½
10½
Note: Correlator 2 and 8, which are correlating in the second dwell time, remain at their old delays. The other correlators, which either have failed the first dwell thresold or have completed the full first and second dwell correlations, are set to the next delays. In correlators 3 and 6, the active memory registers now store S N , the second dwell correlations value.
TABLE 7
Status at time = 3072T c
new value in
correlator
new index
corresponding
next location
no.
status
value
delay
register
1
fail threshold
13½
−11½
14
2
continue (3 rd )
6½
−18½
13
3
fail threshold
14
−11
14½
4
pass threshold
11½
−13½
14½
5
fail threshold
14½
−10½
15
6
pass threshold
12½
−12½
15
7
fail threshold
15
−20
15½
8
finish (new
15½
−8½
16
location)
An interrupt is again generated by S N is read from the inactive complex registers of the memories of correlators 3 and 6 . The corresponding indicas are read from the corresponding integer registers of the memories of correlators 3 and 6 . Hold unit 26 performs a hold of 6 c because the earliest correlator (correlator 2 ) is advanced by 13T c /2 relative to PN sequence generator 12 . Correspondingly, 6 is subtracted from all of the index values and from the value in the next location register.
The operations performed by searcher 10 are partitioned between hardware and software in a manner that makes optimal use of the relative strengths and weaknesses of hardware and software. Specifically, operations associated with high current consumption are implemented in hardware, and numerically intensive operations are implemented in software. The exceptions are numerically intensive operations that are performed frequently, for example, the approximate computation of |S M | according to equation (9), which also are performed in hardware. The sorting of S N values to find the test delays that pass the second dwell threshold, and the pausing of PN generator 12 , also are done by software.
While the invention has been described with respect to a limited number of embodiments, it will be appreciated that many variations, modifications and other applications of the invention may be made. | A searcher for a mobile station of a cellular telephony network. Pilot signal from nearby base stations are correlated with a pseudonoise sequence inside a search window, using a bank of correlators. Each correlator is assigned a different delay, from among a sequence of delays in the window. At each delay, correlation is performed initially for a first dwell time. If the resulting correlation value exceeds a threshold, the correlation is continued for a second dwell time. Otherwise, the correlator is set to the next delay in the sequence. Only the outputs of second dwell correlations are used to identify the nearest base station. Some correlators may perform first dwell correlations at new delays in the window at the same time that other correlators are still performing second dwell correlations at old delays in the window. | 7 |
CROSS-REFERENCE TO RELATED APPLICATION
This application claims the benefit of the filing dates of U.S. Provisional Patent Application Ser. No. 60/930,837 filed May 18, 2007 and GB Application No. 0709604.3 filed May 18, 2007, the disclosure of each of which is incorporated by reference herein.
FIELD OF THE INVENTION
The present invention generally relates to a method and system for allocating resources for accessing data within a public network and is particularly, but not exclusively, suited to providing access to data when the delivery of data is metered, such as when data are delivered to terminals connected to mobile networks.
BACKGROUND OF THE INVENTION
As is well known, the Internet provides access to huge numbers of web pages; increasingly the web pages include nested links and objects, the delivery of which can require what is sometimes a non-trivial amount of bandwidth. This is typically not a problem for requests received from terminals that are fixedly connected to the Internet (either directly, or via one of several network portions), and of course the transmission of data within the Internet—on a per request basis—is free. However, with the advent of widespread deployment of 3G networks, requests are increasingly being received from terminals connected to wireless networks. Unlike the transmission of data within fixed-line networks, the transmission of data within mobile networks is typically metered on a per transmission basis. As a result, mobile terminals are faced with hitherto unseen costs for accessing web sites.
SUMMARY
In accordance with aspects of the present invention, there is provided methods and systems according to the appended claims.
In some arrangements embodiments provide a method of recording allocation of resources in response to a request, the method comprising:
receiving a request for a data item to be transmitted to a device in the network, the request comprising data indicative of one or more requested items;
accessing a storage system so as to identify data listings having items generating a match with the requested data item;
retrieving data indicative of a network location corresponding to the or each matched data item, the network location providing access to a set of data corresponding to the matched data item;
retrieving data indicative of an amount of data and a resource allocation associated with the set of data accessible via the network location;
on the basis of a network subscription associated with device and the amount of data, evaluating actual usage of network resources when accessing the set of data;
in the event that the set of data are accessed from the network location, offsetting said evaluated actual usage against the resource allocation so as to identify an amount of usage of network resources to be charged to the network subscription; and
updating a record associated with said data listing so as to log said resource allocation event.
These embodiments of the invention therefore provide a means of offsetting access to data from a given web site on the basis of a resource allocation associated with the network location, for example a web site. This can be pre-specified by the information provider associated with the web site. Preferably the data are transmitted to, and the evaluation is performed by, the device from which the request is received, such as a mobile device. However, in other arrangements the amount of data, the resource allocation and the corresponding network location are transmitted to a device other than the mobile device. The requested items can be key words making up a search request or can be web site names indicating web sites of interest to a user associated with the mobile device.
In either arrangement, data indicative of transport costs associated with the network subscription are retrieved and, when the device performing the evaluation is the mobile device associated with the network subscription, the transport costs can be retrieved from a removable storage device associated therewith, or from data provided by the corresponding network operator or input manually.
In the event that one or more data elements from the set are retrieved by the mobile device, data indicative of the actual usage of network resources is transmitted to a billing system maintained by the network operator associated with the network subscription. The actual usage can be used in decrementing an account balance, or, in the event that the resource allocation is accounted for after accessing the data, the actual usage of network resources can be used to increment the account balance associated with the network subscription.
In some embodiments the resource allocation can be weighted according to the size of one or more data element accessible from the network location, the number of nested links, and/or rating data associated with the network location whereby to evaluate said actual usage.
The mobile device can be arranged to display the data listings as a list of selectable links, which are ordered in dependence on the amount of usage of network resources to be charged to the network subscription. The links can be classified on the basis of the amount of usage of network resources to be charged to the network subscription; examples of such classifications include fully subsidised, partially subsidised and non-subsidised.
Embodiments of the invention can also comprise sending information about the network location to the mobile device prior to retrieving the data indicative of an amount of data and the resource allocation associated with the set of data accessible via the network location; typically this involves transmitting the set of data accessible via the network location to the device and receiving data indicative of selected elements from the set of data. These selected elements can then be used to adjust the amount of data (and thence the evaluated usage) associated with the set of data. Typically selection of a given element indicates that the element should be excluded from the download of data from the network location, and so effectively reduces the amount of data to be factored into the evaluation. The selection process can be dependent upon the amount of data to be downloaded, the number of nested links, ratings applied to the data, and other such characteristics.
According to another aspect of the present invention there is provided a mobile terminal configured to evaluate resource requirements in relation to data access from a given network location.
The embodiments are particularly well suited to use in the context of providing search results to a mobile terminal, because the transmission of data over wireless networks is chargeable.
Embodiments of the invention are particularly convenient for use in transmitting search results to a terminal connected to a mobile communications network.
According to a further aspect of the invention there is provided a method of identifying a characteristic of a set of data accessible via a link specifying a network location; the characteristics include size of elements of the set of data rating applied to the set of data, amount of resource that has been allocated in relation to elements of the set of data etc. and the method comprises:
receiving a request for a said characteristic to be transmitted to a device in the network, the request comprising data indicative of a said link;
identifying a link listing generating a match with the requested link, said link listing being identifiable from a list comprising a plurality of link listings;
retrieving data indicative of a set of data accessible from the identified link listing;
identifying a said characteristic from the retrieved set of data on the basis of predefined characteristic request criteria; and
transmitting data indicative of the identified characteristic to the device.
According to a yet further aspect of the present invention there is provided a user interface for a mobile device, the user interface being for use in designating an element of data as having a type of downloadable status (such as “not downloadable” or “downloadable”). The user interface preferably comprises display means arranged to display the set of data in conjunction with a plurality of selectable display objects, each being assigned to a given element of the set of data. The display means is responsive to selection of a given said display object so as to designate the element of data corresponding thereto as having a first type of downloadable status, and the mobile station is arranged to transmit data indicative of elements having said first type of downloadable status to a network node for use in controlling data subsequently transmitted to the mobile station.
This therefore provides a means of explicitly selecting or deselecting individual elements from transmission to the mobile station.
In accordance with further aspects of the invention there is provided a distributed system and apparatus for carrying out the method steps described above.
Further features and advantages of the invention will become apparent from the following description of preferred embodiments of the aspects of the invention, given by way of example only, which is made with reference to the accompanying drawings. It is to be understood that other embodiments may be utilized and structural and functional modifications may be made without departing from the scope and spirit of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic block diagram showing a distributed information system within which embodiments of the invention can operate;
FIG. 2 is a schematic diagram showing fields of several records stored within the search database shown in FIG. 1 ;
FIG. 3 is a schematic block diagram showing components of the search engine shown in FIG. 1 ;
FIG. 4 is a schematic block diagram showing components of a mobile terminal configured according to embodiments of the invention;
FIG. 5 is a timing diagram showing data flows between components of the distributed information system of FIG. 1 when operating according to a process of an embodiment of the present invention;
FIGS. 6 a and 6 b are schematic diagrams showing an example web page output from the search engine during the process shown in FIG. 5 ;
FIG. 7 is a schematic diagram showing an alternative distributed information system within which embodiments of the invention can operate;
FIG. 8 is a timing diagram showing data flows between components of the distributed information system of FIG. 7 when operating according to a process of an embodiment of the present invention; and
FIG. 9 is a schematic flow diagram showing further steps associated with the embodiment shown in FIG. 8 .
DETAILED DESCRIPTION OF THE INVENTION
As described above, embodiments of the present invention are generally concerned with allocating resources for providing providers and/or end users with access to publicly accessible material via devices such as mobile terminals. The nature of the process for quantifying the resource allocation and the criteria relating thereto is described in detail below, but first a description of the infrastructure needed to support some embodiments of the invention will be presented with reference to FIG. 1 , which shows an example of a distributed information system 1 . The current embodiment relates to servicing of search requests—i.e. requests for content corresponding to keywords; however, as will be appreciated from a full reading of the specification the invention applies to servicing a range of types of requests and accordingly is not to be limited to the realm of search engine technologies.
In the current embodiment the distributed information system 1 comprises a plurality of information providers 6 a , 6 b , 6 c , at least some of which are arranged to store content and information, and a search engine 10 , all of which are connected to a network 12 either directly or indirectly (e.g. via the Internet, local area networks (LANs), other wide area networks (WANs), and regional networks accessed over telephone lines, such as commercial information services). Mobile terminals 2 , 4 are adapted to communicate with the various information providers 6 a , 6 b , 6 c via mobile network 14 and an appropriate gateway GW, as shown; the terminals 2 , 4 can be mobile telephones or PDAs, lap top computers and the like, and the mobile network 14 can comprise a licensed network portion (such as is provided by cellular networks using e.g. Global System for Mobile Communications (GSM) technology, Wideband Code Division Multiplex Access (WCDMA); Code Division Multiplex Access (CDMA), WiMax) and/or unlicensed network portions (such as is provided by Wireless LANs and Bluetooth technologies). The gateway GW can be a GPRS support node (GGSN) forming part of the mobile network 14 .
The mobile terminals 2 , 4 comprise browser programs adapted to locate, and access data from, web sites corresponding to the or each information provider 6 a , 6 b , 6 c . The browser programs allow users of the terminals 2 , 4 to enter addresses of specific web sites, typically in the form of Uniform Resource Locators, or URLs, and are typically adapted to receive and display web and WAP pages; in the event that a given terminal 2 is only capable of processing and displaying WAP pages, translation of a web page can be performed by a device in the network or by suitable translation software running on the device 2 . As is known in the art, any given web page can include links nested therein, which, when selected, can provide access to other pages or data such as plain textual information, or digitally encoded multimedia content, such as software programs, audio signals, videos graphics, etc. Accordingly selection of such links results in transmission of further data to the terminals 2 , 4 .
In accordance with conventional systems, the search engine 10 is operable to receive keywords of interest to the users of terminals 2 , 4 , and, by accessing data stored in the search database 20 , to generate search results relating thereto. The search results are organised into a list of hypertext links to content that contain information relevant to these search terms; each link generally corresponds to a network location corresponding to a given information provider 6 a , 6 b , 6 c.
As described above, embodiments of the invention are concerned with allocating resources for providing access to publicly accessible material via devices such as mobile terminals, and provide a mechanism for evaluating delivery costs to be borne by the subscriber and presenting the results in conjunction with these costs; this might be different to the actual delivery costs, since information providers can allocate resources for use in offsetting the actual delivery costs.
For each information provider 6 a , 6 b , 6 c , the search database 20 can hold allocation records comprising data indicative of an allocation of resource for use in offsetting delivery costs associated with providing access to their content. The allocation records can comprise parameters specifying an allocation in absolute terms or in relative terms (e.g. as a percentage of the overall delivery costs), together with parameters specifying temporal data and location data that control applicability of the allocations. Furthermore the search database 20 can hold rating records comprising rating data gathered from third parties and recipients that have already accessed the content. These rating data preferably relate to usability of a given web site from the point of view of a user of a mobile device, and can be collected automatically or manually. The search database 20 can additionally hold resource requirement records, which specify data such as the size of the web page accessible via the URL associated with the information provider 6 a , 6 b , 6 c , links that are nested within the web page, and objects accessible via the web site.
Rather than being stored within the search database 20 , one or more of the allocation, storage and/or rating records can alternatively be held in a database (not shown) maintained by (a) third party/parties, in which case the search engine 10 can query the third party database in order to retrieve this information at the time of collating the search results.
These allocation and resource requirement data can be specified by a given information provider 6 a , 6 b , 6 c via a form or similar (not shown), and in the case of the resource requirements data, software components associated with the search database 20 can be arranged to download the web page so as to verify, or correct, the submitted data. Once the data have been verified, the search database 20 stores the same in a database record corresponding to the information provider 6 a ; an example of a suitable schema is shown in FIG. 2 . As can be seen, in this representation, any given record R comprises a plurality of fields: the URL corresponding to the information provider is stored in field 201 , the keywords in field 203 , the resource allocation amounts in field 205 , site ratings in field 207 , and resource requirements in field 209 . It will be appreciated that FIG. 2 is highly schematic and that for example in the case of field 207 , there the schema will most likely include subfields corresponding to respective elements thereof; for example, there could be a subfield corresponding to automatically generated rankings, manually generated rankings, and ratings specified by other users. Any given record can also include other fields such as an account balance for the information provider (as described in more detail below); conversely any given record can comprise a subset of the fields shown in FIG. 2 .
The processes involved in collating the search results will now be described with reference to FIG. 3 , which shows components of the search engine 10 . The search engine 10 is preferably embodied as a web server, and comprises standard operating system, storage, processor, input/output interfaces, together with includes various bespoke software components 301 , 303 , 305 . These software components are arranged, respectively, to receive a search request, identify keywords within the request (request receiving software component 301 ), to query the search database 20 on the basis of the keywords and generate corresponding search listings (database querying software component 303 ); the search listings are preferably accompanied by the resource allocation data 205 , rating data 207 , resource requirements data 209 in the search database 20 as described above. The request receiving software component 301 is also arranged to identify the terminal 2 to which the search listings are to be transmitted, so that the search results collating software component 305 can deliver the results and accompanying data to this terminal 2 in the form of a results message M 1 . Whilst shown as single units in FIG. 1 , it will be appreciated that the search engine 10 and database 20 can comprise a plurality of units distributed in the Internet 12 .
It will thus be appreciated that in at least some embodiments the data returned to the mobile terminal 2 include, for any given search listing and thus information provider 6 a identified to have content relating to the keywords submitted from the mobile terminal 2 , data indicative of the amount of data retrievable from the information provider 6 a , data indicative of the amount of resources that have been allocated by the information provider 6 a to offset the costs of the mobile terminal 2 accessing the content, and data indicative of ratings applied to the content of the information provider 6 a . Accordingly the mobile terminal 2 includes bespoke software processing components arranged to process these data in order to organise the results into various categories such as “free to access”, “access subsidised”, “fully chargeable”. These software components will now be described with reference to FIG. 4 , which shows components of the mobile terminal 2 .
The mobile terminal 2 has an antenna 401 for communicating across the network 14 in known manner and provides a user interface, having a keypad 403 and display screen 405 , a loudspeaker 407 and a microphone 409 ; alternatively the user interface could comprise components such as touch screens, touch pads and the like. The handset also comprises a processor 411 , an operating environment 413 and various standard software applications such as a browser (as described above); the mobile terminal 2 is also provided with a smart card reader 417 of known type for interacting with a removable or non-removable SIM or a UICC 419 , which may be provided with a processor, operating environment, and software applications. In order to process data according to embodiments of the invention, the mobile terminal 2 includes a search results processing software component 415 , which can be embedded within the browser or can be a separate application running on the mobile terminal 2 . It will be appreciated that the results processing component 415 could comprise means for sending the search request in the first instance, and thus be configured to monitor for the search results message M 1 in response to the query in accordance with standard methods.
Operation of the various components of the distributed information system 1 when servicing a search request will now be described with reference to FIG. 5 , which is a timing diagram showing the various messages and data transmission between components 2 , 10 , 20 , 6 a and 16 . At step S 5 . 1 , the mobile terminal 2 sends a search request to the search engine 10 using the browser application of the terminal 2 , the search request comprising one or more keywords of interest. In addition terminal related information such as data identifying the subscriber and the terminal used by the subscriber associated with the terminal 2 can be sent to the search engine 10 (or a different network component, which is in operative communication with the search engine 10 ); these identifying data are preferably encrypted and can include the International Mobile Subscription Identifier (IMSI), Mobile Station ISDN Number (MSISDN), International Mobile Equipment Identifier (IMEI), terminal type, memory configuration, software configuration, browser type and other identifiers available from the SIM 419 or the terminal 2 or a database in the terminal 2 .
The search request is received by the search engine 10 , having been routed via the mobile network 14 , gateway GW and other network portions, and the request receiving component 301 extracts the keywords from the search request, formulating a query based thereon and sending same to the search database 20 (step S 5 . 3 ). The search database 20 performs a lookup in respect of the keywords and retrieves data indicative of network location and other data stored within fields 201 , 203 , 205 , 207 etc., and creates a message M 1 as described above. The message M 1 is then sent to the mobile terminal 2 (step S 5 . 5 ).
Once the message M 1 has been received, the search results processing software component 415 is arranged to identify the respective search listings therein, which is to say data specifying URL, resource allocation, rating, and resource requirement corresponding to information providers 6 a . . . 6 c identified as having content relevant to the keywords contained within the search request. These data are then processed by the results processing component 415 using various algorithms in order to identify which of the information providers' content can be accessed for free or at a subsidised rate, and optionally, to identify ratings applicable to the content (step S 5 . 7 ).
For example, assuming information provider 6 a has a resource requirement of 3 MB (2 MB+5 click-through links), and that the provider 6 a has specified an allocation of 1 to offset the costs of accessing its content then the results processing software component 415 evaluates a subsidy per KB of content of 1 /3 MB=0.0003 /kbyte. As described above, this effectively represents an amount that the sponsor is willing to subsidise for the mobile terminal 2 to receive data from its network location. Assuming information provider 6 b has a resource requirement of 20 kbyte and has specified that it will pay 0.2 to offset the costs of accessing its content, then the amount of subsidy for accessing the network location corresponding to provider 6 b is 0.2/20=0.01 /kbyte; further, assuming information provider 6 c has an overall resource requirement of 120 kbyte (100 kbyte+2 objects) and has specified “100% sponsorship” for accessing its content, then the entire cost of accessing the content will be offset by the information provider 6 c.
These amounts are then compared against the actual transport costs associated with delivering data from the various network locations to the terminal 2 : this information can be derived from delivery plan data stored either on the SIM 419 , or delivered, upon request, to the terminal, from the operator in respect of which the terminal 2 is a subscriber, or can be entered manually. For example, assuming the costs of transport to terminal 2 are P=0.007 /kbyte, then the costs of accessing data from information providers 6 a , 6 b , 6 c are as follows:
Information provider 6 a : 1 /2 MB=0.0003 /kbyte, which is less than the transport costs, so that, whilst the data is subsidised, it will nevertheless be delivered at a cost. Information provider 6 b : 0.2/20 kbyte=0.01 /kbyte, which is greater than the transport costs, so that data will be delivered at no cost. Information provider 6 c : 0.3/120 kbyte=0.0025 /kbyte, which is less than the transport costs; in any event, the information provider 6 c has indicated that it will cover all of the transport costs, so that the data will be delivered at no cost.
The foregoing passages assume that all of the information providers listed in the search database 20 have submitted a non-zero allocation of resources for use in offsetting the costs of accessing their content. However, the search database 20 will also hold entries corresponding to information providers that are not interested in subsidising access to their content. Since the query performed by the database querying software component 303 will return all data corresponding to all information providers having entries in the database 20 associated with to the keywords specified in the search request, the message M 1 will include entries corresponding to non-paying and paying information providers.
The search listings could be assigned one of the above-mentioned access categories (“free to access”, “access subsidised”, “fully chargeable”), and be presented to the recipient in the form of a URL link together with an indication of the assigned category. The rating data can additionally be presented in conjunction with the category, thereby providing an indication to the recipient of a generally accepted value of the content accessible from respective information providers 6 a , 6 b , 6 c . Examples of possible graphical representations of this information are shown in FIGS. 6 a and 6 b , which show various forms of a results page WI that can be output from the results processing software component 415 . It will be appreciated that these are examples of possible ways of representing the output and that combinations of the various representations are possible.
When a link within the search listings is selected, this causes the terminal 2 to send an account identifier and URL corresponding to the selected listing to the search engine 10 ; the search engine 10 , more specifically the account updating software component 307 thereof, is then responsible for updating the respective account together with providing a means of re-directing the request to the URL of the selected listing. Typically the account identifier is embedded as a parameter in the URL, but it could be embedded within a cookie that is transmitted to, and maintained at, the terminal 2 along with the results message M 1 .
Assuming the user to select one of the links appearing within the subsidised portion (e.g. information provider 6 a ), message M 2 comprising account identification and/or the selected URL is transmitted to the search engine 10 (step S 5 . 9 ). When received, the account updating component 307 sends a standard HTTP retrieval request to the URL listed within message M 2 , the request having, as source address, a network identifier corresponding to the terminal 2 (step S 5 . 1 ).
Alternatively the search engine 10 returns information such a redirecting URL to the browser running on the mobile terminal 2 . As an example, message M 2 can comprise the following data:
http://www.search service.com/url?sa=L=0wSrvIS3D QoAgBUN z-&q=http://www.infoprovider6a.com/p=leuro sponsor sKpNrit4Aw”.
The message M 2 will be analysed by the search engine 10 , causing a redirection message to http://www.inforpovider6a.com to be returned to the terminal 2 .
Data are then transmitted to the terminal 2 under control of the information provider 6 a corresponding to the selected URL in response to the re-directed access request transmitted from the search engine 10 at step S 5 . 11 . It is to be noted that the data can be modified and/or selected based on the capabilities of the terminal 2 , these being requested from the terminal 2 or derivable by the information source 6 a on the basis of information held by the search engine 10 (e.g. based on the information transmitted from the terminal at steps S 5 . 1 or S 5 . 9 ).
Whilst this is shown in FIG. 5 (step S 5 . 13 ), it will be appreciated that transmission of data from the network location occurs independently of the components of data information system 1 , and is shown for completeness only.
The account updating software component 307 accesses the search database 20 on the basis of account identifier retrieved from message M 2 , and at step S 5 . 15 indicates that data have been accessed from this information provider 6 a.
In one arrangement step S 5 . 9 can additionally involve the mobile terminal 2 transmitting a further message M 3 to the search engine 10 , which includes data identifying the cost of accessing data from the information provider 6 a (as identified by the results processing software component 415 at step S 5 . 7 ). The message can include data identifying the subscriber associated with the terminal 2 (preferably encrypted); these identifying data preferably correspond to those data sent at step S 5 . 1 and can include the International Mobile Subscription Identifier (IMSI), Mobile Station ISDN Number (MSISDN), International Mobile Equipment Identifier (IMEI), memory configuration, software configuration, browser type and other identifiers available from the SIM 419 or the terminal 2 or a database in the terminal 2 . In response to receipt of message M 3 the account updating software component 307 can then update the account balance to account for the transport costs associated with delivering the content to the terminal 2 . In such arrangements—those in which the transport costs are accounted for in real time—the search engine 10 can then send a message M 4 to the billing system 16 associated with the mobile network portion 14 shown in FIG. 1 . This message M 4 includes data identifying the subscriber associated with the mobile terminal 2 , derived from the message M 3 sent at step S 5 . 9 , and again preferably formatted in encrypted form. Returning to FIG. 5 , data indicative of the actual cost to the subscriber to receive data from the selected information provider 6 a are thus transmitted to the billing system 16 at step S 5 . 17 , for use in incrementing the subscriber's balance to as to account for the fact that delivery of the content has been sponsored by the information provider 6 a.
In a particularly advantageous arrangement these data are transmitted to the billing system at the same time as, or before, the request for content is transmitted to the information provider 6 a at step S 5 . 11 , thereby ensuring that the subscriber's balance is “topped up” to include the subsidised costs or to ensure that data connection is allowed.
As an alternative to the mobile terminal 2 transmitting the evaluated transport costs to the search engine 10 at step S 5 . 9 , the account updating software component 307 can independently evaluate the transport costs on the basis of whichever data plan is associated with the network operator of the mobile terminal 2 , this having been sourced from the various network operators by virtue of an agreement between the network operator and the search provider. In such arrangements the message M 3 would simply include data identifying the subscriber of the mobile terminal 2 so that the account updating software component 307 can identify the transport costs applicable to delivery of data to this subscriber.
In the above embodiments the mobile terminal 2 is described as sending queries for web pages and documents accessible via the web relating to keywords of interest to the user, and there being a search engine 10 arranged to broker, coordinate and account for user access to such content. However, embodiments of the invention could also be applied to arrangements such as that shown in FIG. 7 , in which there is a service 12 that can simply provide access to a list of web sites. The service 12 is connected to service database 24 , which is arranged to hold records corresponding to those shown in FIG. 2 , with or without the inclusion of keywords characterising data accessible from the web sites. In such arrangements the mobile terminal 2 would additionally be equipped with an application (not shown) for accessing the service 12 and requesting information about the various site, in particular links and objects that are accessible from a given site. In view of the fact that access to data and objects in a given site incurs transport costs, the application would be capable of receiving input from the user identifying those parts of the web site that the user does not want to be receive at the mobile terminal (typically resource intensive links or objects). This process is shown in FIG. 8 , and largely mirrors the steps described above in relation to FIG. 5 : the notable differences to the first embodiment lie in the content sent in message M 5 at step S 8 . 5 : this includes details of the objects and links that are accessible via the URL listed as a web site accessible via service 12 . In addition, step S 8 . 7 involves running an application that allows the user to select objects and links that it does not wish, or wishes to receive from the web site, while message M 6 transmitted at step S 8 . 9 additionally includes details of the selected objects and links. As a result, the service 12 acts as a filter in relation to the content accessible from the information provider 6 a : as shown in FIG. 8 , the service 12 requests data from the website to be transmitted thereto (step S 8 . 11 ), thereby enabling the service 12 to remove those objects and links specified by the contained within message M 6 . Accordingly the data that are transmitted to the mobile station 2 at step S 8 . 17 is a subset of the data accessible from the information provider 6 a . Clearly, in view of the fact that the resource requirements etc. associated with links and objects are specified in the data transmitted in the message M 5 transmitted at step S 8 . 5 , the transport costs can be evaluated based on this selected subset of data.
Thus this embodiment of the invention involves the mobile terminal 2 including an application with a user interface that displays data accessible from a specified web site to the user and enables the user to select therefrom. Alternatively the browser or application running on the terminal 2 can be configured so as to automatically request specific types of objects and elements; such a request can be formulated on the basis of selection rules stored by the terminal 2 , these rules specifying object size (including resolution in the case of images and file size in relation to file types generally), delivery costs, data plan associated with the terminal 2 etc.
As an alternative, the mobile terminal 2 could be equipped with an application that enables the user to enter data indicative of a web site for which transport costs etc. associated with links accessible via the web site are required (i.e. those links for which clicking on the link would lead to the transmission of further data to the mobile terminal); in such arrangements the content of the web site corresponding to the URL entered by the user is downloaded to the mobile terminal, and then forwarded from the mobile terminal to the service 12 . This process flow is illustrated in FIG. 9 , and receipt of the content from the information provider 6 a triggers step S 8 . 1 shown in FIG. 8 . Subsequent forwarding of the content to the service 12 can occur with or without manual intervention on the part of the user; in the case of manual intervention, the user can specify those particular parts of the web site that are to be filtered from the web site. In cases involving automatic forwarding of the data to the service 12 , the application can be configured with access to rules that automatically trigger step S 8 . 1 in response to detection of certain data within the data downloaded from the information source 6 a.
Additional Details and Modifications
The embodiments described in relation to FIG. 8 describe the mobile terminal 2 being configured with a user interface that enables the user to select items from a web site that are to be included/excluded as accessible to the user. The user interface can additionally include means for the user to transmit data indicative of a ranking applied by the user to the content associated with any given information provider 6 a , 6 b , 6 c ; this ranking data can be transmitted to the search database 20 (or database 24 ) or a third party responsible for maintaining the ranking data (which feeds the ranking data into the databases 20 , 24 in the manner described above).
The requests submitted at step S 5 . 1 can be submitted from a terminal other than the one to which the search results are to be delivered; for example, requests could be submitted as part of an automated process, which includes, as one of the input fields, an identifier corresponding to the terminal 2 destined to receive the search results. In addition, search requests could be typed in or entered via speech recognition software.
Each record R i in the search database 20 corresponding to an information provider can additionally comprise a field relating to an account balance for the information provider. The balance is quantified in terms of resources, which can be money or usage of different types of communications services. The latter type of resource are particularly convenient for embodiments of the invention, since communications resources could be directly traded rather than being translated into and out of financial amounts.
Whilst in the above embodiment the results message M 1 is delivered directly to the mobile terminal 2 , the search results could alternatively be transmitted to a search results service, for further processing of the results or delivery thereof to the mobile device.
The term “sponsored link” is to be understood as subsidizing access to content associated with any of the links listed in the message M 1 .
By way of clarification, the term “non-sponsored link” is to be understood as including (but not limited to) a link to a network location associated with an information source whose presence in a list of results is defined purely on the relevance of the content of the data items associated with the web page to the request and is unrelated to any subsidy that might be applied to effect delivery thereof.
Additionally, when the terminal 2 requests data from a service such as information provider 6 a , the browser or application 415 running on the terminal 2 can be configured to request associated ranking and other related information e.g. nested links associated with the information provider 6 a from the service 12 . The information from service 12 can be used by an application or browser in the terminal 2 to inform the user about certain characteristics of links via the user interface. The requested information can include rating information, mobile friendliness, feasibility of the content behind the link for the target terminal, size of the content, price of the delivery etc., and this information enables the user to decide whether or not to access data from the information provider 6 a . The user interface can block or hide some of the links on the basis of predefined screening rules held by the mobile terminal 2 . These screening rules can include rules relating to e.g. feasibility of accessing a link and content type and can be manually configured by the user of the terminal or automatically set by other authorised users such as parents or employers. Such screening rules can be automatically set on the basis of information uploaded to the service 12 by the authorised users, and then downloaded to the mobile terminal 2 for use in controlling access thereto.
The above embodiments are to be understood as illustrative examples of the invention. It is to be understood that any feature described in relation to any one embodiment may be used alone, or in combination with other features described, and may also be used in combination with one or more features of any other of the embodiments, or any combination of any other of the embodiments. Furthermore, equivalents and modifications not described above may also be employed without departing from the scope of the invention, which is defined in the accompanying claims. | A method of recording allocation of resources in response to a request for a data item to be transmitted to a device in the network where the request comprises data indicative of one or more requested items. The device is typically a mobile device and the requested items can be key words making up a search request or can be web site names indicating web sites of interest to the user. In response to the request, data listings having items generating a match with the requested data item are identified and data indicative of a network location corresponding to the or each matched data item are retrieved. In addition data indicative of an amount of data and a resource allocation associated with the set of data accessible via the network location are retrieved and these data, together with a network subscription associated with device and the amount of data, are used to evaluate actual usage of network resources when accessing the set of data. If data are subsequently requested from the network location the evaluated actual usage is offset against the resource allocation so as to identify an amount of usage of network resources to be charged to the network subscription, and a record associated with said data listing is updated so as to log said resource allocation event. | 7 |
BACKGROUND
[0001] 1. Technical Field
[0002] Methods and example embodiments described herein are generally directed to interconnect architecture, and more specifically, to network on chip system interconnect architecture.
[0003] 2. Related Art
[0004] The number of components on a chip is rapidly growing due to increasing levels of integration, system complexity and shrinking transistor geometry. Complex System-on-Chips (SoCs) may involve a variety of components e.g., processor cores, DSPs, hardware accelerators, memory and I/O, while Chip Multi-Processors (CMPs) may involve a large number of homogenous processor cores, memory and I/O subsystems. In both systems the on-chip interconnect plays a key role in providing high-performance communication between the various components. Due to scalability limitations of traditional buses and crossbar based interconnects, Network-on-Chip (NoC) has emerged as a paradigm to interconnect a large number of components on the chip. NoC is a global shared communication infrastructure made up of several routing nodes interconnected with each other using point-to-point physical links. Messages are injected by the source and are routed from the source router to the destination over multiple intermediate routers and physical links. The destination router then ejects the message and provides it to the destination. For the remainder of the document, terms ‘components’, ‘blocks’ or ‘cores’ will be used interchangeably to refer to the various system components which are interconnected using a NoC. Without loss of generalization, the system with multiple interconnected components will itself be referred to as ‘multi-core system’.
[0005] There are several possible topologies in which the routers can connect to one another to create the system network. Bi-directional rings (as shown in FIG. 1( a )) and 2-D mesh (as shown in FIG. 1( b )) are examples of topologies in the related art.
[0006] Packets are message transport units for intercommunication between various components. Routing involves identifying a path which is a set of routers and physical links of the network over which packets are sent from a source to a destination. Components are connected to one or multiple ports of one or multiple routers; with each such port having a unique ID. Packets carry the destination's router and port ID for use by the intermediate routers to route the packet to the destination component.
[0007] Examples of routing techniques include deterministic routing, which involves choosing the same path from A to B for every packet. This form of routing is independent of the state of the network and does not load balance across path diversities which might exist in the underlying network. However, deterministic routing is simple to implement in hardware, maintains packet ordering and easy to make free of network level deadlocks. Shortest path routing minimizes the latency as it reduces the number of hops from the source to destination. For this reason, the shortest path is also the lowest power path for communication between the two components. Dimension-order routing is a form of deterministic shortest path routing in 2D mesh networks.
[0008] FIG. 2 illustrates an example of XY routing in a two dimensional mesh. More specifically, FIG. 2 illustrates XY routing from node ‘34’ to node ‘00’. In the example of FIG. 2 , each component is connected to only one port of one router. A packet is first routed in the X dimension till it reaches node ‘04’ where the x dimension is same as destination. The packet is next routed in the Y dimension until it reaches the destination.
[0009] Source routing and routing using tables are other routing options used in NoC. Adaptive routing can dynamically change the path taken between two points on the network based on the state of the network. This form of routing may be complex to analyze and implement and is therefore rarely used in practice.
[0010] Software applications running on large multi-core systems can generate complex inter-communication messages between the various blocks. Such complex, concurrent, multi-hop communication between the blocks can result in deadlock situations on the interconnect. Deadlock occurs in a network when messages are unable to make progress to their destination because they are waiting on one another to free up resources (e.g. at buffers and channels). Deadlocks due to blocked buffers can quickly spread over the entire network, which may paralyze further operation of the system. Deadlocks can broadly be classified into network level deadlocks and protocol level deadlocks.
[0011] Deadlock is possible within a network if there are cyclic dependencies between the channels in the network. FIG. 3 illustrates an example of network level deadlock. In the example of FIG. 3 , starting at a state with all buffers empty, the blocks initiate the message transfer of A→C, B→D, C→A and D→B simultaneously. Each block takes hold of its outgoing channel and transmits the message toward its destination. In the example of FIG. 3 , each channel can hold only one message at a time. From this point on, each channel waits on the next channel to move the message further. There is a cyclic dependency in the wait graph and the network becomes deadlocked. Such network layer deadlock or low-level deadlocks can be avoided by construction using deadlock free routing or virtualization of paths.
[0012] Network end points may not be ideal sinks, i.e. they may not consume all incoming packets until some of the currently outstanding packets are processed. If a new packet needs to be transmitted during the processing of an outstanding packet, a dependency may be created between the NoC ejection and injection channels of the module. The dependency may become cyclic based upon the message sequence, position of components and routes taken by various messages. If the deadlock is caused by dependencies external to the network layer, this is called a high-level, protocol or an application level deadlock. In related art systems, most high level tasks involve a message flow between multiple modules on the NoC in a specific sequence. Such a multi-point sequence of intercommunication may introduce complex dependencies resulting in protocol level deadlock. The underlying cause of deadlock remains the channel dependency cycle introduced by the inter-dependent messages between multiple components. Independent messages from one end point to another on the network will not cause protocol level deadlocks; however, depending on the routing of such messages on the network, network level deadlocks are still possible in the system.
[0013] FIGS. 4( a ), 4 ( b ) and FIGS. 5( a ) to 5 ( c ) illustrate an example of protocol level deadlock. Consider an example of a three central processing unit (CPU) system connected to memory and cache controller through a crossbar. The cache controller's interface to the interconnect has a single First-In-First-Out (FIFO) buffer which can hold a maximum of three messages. Internally, the cache controller can process up to two requests simultaneously (and therefore process up to two outstanding miss requests to the memory).
[0014] At FIG. 4( a ), all three CPUs send read requests to the cache controller.
[0015] At FIG. 4( b ), read requests are queued in an input buffer to the cache controller from the crossbar.
[0016] At FIG. 5( a ), the cache controller accepts two requests ‘1’ and ‘2’ from input buffer while the third request ‘3’ remains in the input buffer. ‘1’ and ‘2’ have a read miss in the cache, which in turn issues miss refill requests ‘m1’, ‘m2’ to the memory
[0017] At FIG. 5( b ), the memory returns refill data ‘d1’, ‘d2’. This data gets queued behind ‘3’ in the cache controller's input buffer.
[0018] At FIG. 5( c ), the cache controller waits for refill data for the outstanding requests before accepting new request ‘3’. However the refill data is blocked behind this request ‘3’. The system is therefore deadlocked.
[0019] In this system, deadlock avoidance can be achieved by provisioning additional buffer space in the system, or using multiple physical or virtual networks for different message types. In general, deadlock is avoided by manually 1) interpreting the intercommunication message sequence and dependencies, 2) then allocating sufficient buffers and virtual and/or physical channels and 3) assigning various messages in the sequence the appropriate channel.
[0020] In large scale networks such as the internet, deadlocks are of a lesser concern. Mechanisms such as congestion detection, timeouts, packet drops, acknowledgment and retransmission provide deadlock resolution. However such complex mechanisms are too expensive in terms of power, area and speed to implement on interconnection networks where the primary demands are low latency and high performance. In such systems, deadlock avoidance becomes a critical architectural requirement.
SUMMARY
[0021] This invention proposes automatic construction of a system interconnect which is free from both network and application level deadlock, based upon the provided specification of intercommunication message pattern amongst various components of the system. An exemplary implementation of the process is also disclosed, wherein deadlock avoidance is achieved while keeping the interconnect resource cost minimal.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] FIGS. 1( a ) and 1 ( b ) illustrate Bidirectional ring and 2D Mesh NoC Topologies
[0023] FIG. 2 illustrates an example of XY routing in a two dimensional mesh.
[0024] FIG. 3 illustrates an example of network level deadlock.
[0025] FIGS. 4( a ), 4 ( b ) illustrate an example memory subsystem with three CPUs issuing read requests to cache controller.
[0026] FIGS. 5( a ) to 5 ( c ) illustrate message exchange in the memory subsystem causing protocol level deadlock.
[0027] FIG. 6 illustrates an example of communication sequence on a cache read miss in a memory subsystem.
[0028] FIGS. 7( a ) and 7 ( b ) illustrate an example of deadlock in the memory subsystem.
[0029] FIGS. 8( a ) and 8 ( b ) illustrates an example of an implementation of automatic deadlock avoidance in the memory subsystem, in accordance with an example embodiment.
[0030] FIG. 9 illustrates a flowchart for deadlock free traffic mapping on a NoC, in accordance with an example embodiment.
[0031] FIG. 10 illustrates an example computer system on which example embodiments may be implemented.
DETAILED DESCRIPTION
[0032] Complex dependencies introduced by applications running on large multi-core systems can be difficult to analyze manually to ensure deadlock free operation. Example embodiments described herein are based on the concept of automatically constructing deadlock free interconnect for a specified inter-block communication pattern in the system. An example process of the automatic deadlock free interconnect construction is also disclosed.
[0033] Applications running on multi-core systems often generate several sequences of inter-dependent messages between multiple blocks, wherein a message arriving at a block must generate another message for a different block, before it completes processing and releases the resources at the block for new messages. For a hypothetical example, consider a task running on block A which requests an operation to be performed on block B. On receiving the request message, block B completes part of the operation and sends partial results to a third block C which performs another part of the operation and sends the partial results to block D. Block D performs consolidation and sends the final results back to block A. Completion of the operation on block A required a sequence of messages to be generated and exchanged between multiple blocks on the network. There are higher level dependencies between the messages for successful completion of task on the originating block. At the network interface of intermediate blocks there is a dependency of the incoming channel on the outgoing channel of the block. Any cycles in such channel dependencies can result in protocol level deadlock in the system.
[0034] Traditional systems may employ semi-automatic analysis for detecting potential deadlocks in multi-core systems, however the results are manually analyzed and suitable modifications to the interconnect are made to avoid potential deadlocks.
[0035] Communications in the system are specified in its entirety to capture all high level message dependencies. Example embodiments then takes a holistic view of messages on the interconnect, allocates channel resources, and assigns messages to the allocated channel resources to ensure that the generated interconnect is deadlock free at both network and protocol level. The example embodiments remove cyclic resource dependencies in the communication graph through the use of virtual channels. Virtual channels provide logical links over the physical channels connecting two ports. Each virtual channel has an independently allocated and flow controlled flit buffer in the network nodes. Each high level communication in the system needs to be specified in the form of grouped end-to-end sequence of multiple blocks between which the message flows. In the hypothetical example presented above, the sequence would be represented as A→B→C→D→A. Routing paths on the network, between each source-destination pair i.e. sections making up the above sequence, are either made available to the algorithm used in example embodiments, or the algorithm automatically determines to avoid deadlock.
[0036] The flow of the example embodiments begins with the most complex message sequence and uses its routed path on the network to create a channel dependency graph. The example embodiments use the lowest virtual channel ID on the physical links and then pick up progressively less complex message sequences and continue to map their route to the existing global channel dependency graph. When mapping a path between two blocks, if a cycle is detected in the dependency graph, the example embodiments backtrack and re-map the section that contains the dependency by using the next highest virtual channel ID on the path to remove the cycle from the dependency graph. As a rule, example embodiments first attempt to map on to any pre-allocated virtual channels in increasing order of channel ID value and if no other pre-allocated virtual channels remain on the path, allocate free virtual channel IDs also in increasing order of channel ID value. This process continues till network routes of all the specified message sequences are mapped on the global graph without any cycles. The algorithm aborts the effort if a deadlock free mapping of the specified system messages cannot be achieved with the constraint on the number of available virtual channels. Further details are provided in the examples below and in the flowchart of FIG. 9 . Other variations of the scheme are possible. For example, instead of using the same virtual channel for all physical links of a route between end points of a section of a message sequence, it is possible to use different virtual channels on each physical link of a route. It is also possible for the algorithm to attempt to use different routes for various messages in order to reduce the virtual channels usage, or for load balancing while maintaining deadlock avoidance.
[0037] In an example system, the CPU communicates with a memory subsystem that includes a cache and external DRAM memory. The CPU issues a read request which has a read miss in the cache. As a result, the cache controller issues a read refill request to the external memory controller. Refill data returns from the memory to cache controller which in turn issues read response to the CPU.
[0038] FIG. 6 illustrates an example of communication sequence on a cache read miss. The example communication pattern described above is expressed as a sequence as shown in FIG. 6 . In the cache read miss sequence example, a read request 600 is sent from CPU (A) to Cache (B). At Cache (B), a cache read miss occurs and a read refill request 601 is generated which proceeds to Memory (C). At Memory (C), read refill response 602 is generated and sent back to Cache (B). Cache (B) then sends read response 603 back to CPU (A).
[0039] FIGS. 7( a ) and 7 ( b ) illustrate an example of deadlock in the memory subsystem. Specifically, FIG. 7( a ) shows a simple topology in which the CPU, cache and memory are interconnected by physical links. Each physical link on the network is assumed to have a single virtual channel. FIG. 7( b ) illustrates a possible channel dependency graph for the above communication sequence. Specifically, the communication sequence on a cache read miss as depicted in FIG. 6 are illustrated in FIG. 7( b ) based on the physical links of FIG. 7( a ). The graph has a cycle indicating potential application level deadlock. For example, deadlock may occur when CPU (A) sends a subsequent read request message to Cache (B) by physical channel c before Cache (B) receives a response from Memory (C), through the same physical channel for the earlier refill request. Cache (B) thereby becomes deadlocked as it cannot process the subsequent read request message from CPU (A) without first processing its pending refill request, and cannot process the pending refill request as the response to the refill request from Memory (C) is in the queue for physical channel c, behind the subsequent read request message. Similarly, deadlock may occur when Cache (B) attempts to return a response to the message from CPU (A) through physical channel d, but cannot send the message through the channel if Memory (C) has not processed previous messages sent from Cache (B) to Memory (C).
[0040] FIGS. 8( a ) and 8 ( b ) illustrates automatic deadlock avoidance implemented in the example system of FIG. 6 , in accordance with an example embodiment. As shown in FIG. 8( a ), virtual channel ID 0 is utilized on communication sections A→B and B→C without seeing any deadlocks. However, when the subsystem tries to map section C→B on VC ID 0, a loop is detected (e.g., at physical channel c due to the deadlock as described in FIG. 7( b )). The subsystem back tracks and tires to remap C→B path using VC ID 1 (leaving VC ID 0 unused), which does not cause any cycles in the graph. The subsystem proceeds to map path B→A starting with VC ID 0, which creates a cycle in the graph (e.g., at physical channel d due to the deadlock as described in FIG. 7( b )). The subsystem then tries VC ID 1 which maps successfully without cycles in the graph. Thus the subsystem has successfully mapped the entire communication sequence while avoiding potential deadlocks.
[0041] FIG. 9 illustrates a flowchart for deadlock free traffic mapping on a NoC, in accordance with an example embodiment. In the implementation as depicted in FIG. 9 , at 900 , the system selects a user specified message sequence (e.g., receiving a message sequence from the user). At 901 , the system selects network end-points to define a section of the sequence. At 902 , the system selects a route between the section end points based on a routing scheme. At 903 , an internal counter may be set from zero to count how many of the available virtual channels are tested to map the specified traffic. At 904 , the system utilizes the next available virtual channel as indicated by the counter to add a link on the route to the global channel dependency graph. At 905 , the system checks (e.g. automatically) for a cyclic dependency in the current dependency graph. At 906 , if a cycle is detected, then the system proceeds to 907 to remove and reset the current section of the message sequence from the dependency graph. The system proceeds then to 908 to increment the counter to the next available virtual channel, and determines at 909 if all of the available virtual channels have been exhausted. The system proceeds back to 904 if the available virtual channels have not been exhausted. However, if all available virtual channels have been attempted, then the system proceeds to 910 to end the process and to indicate (e.g. message to user) that the specified traffic cannot be mapped with the available virtual channels.
[0042] If no cycle is detected, then the system proceeds to 911 to determine if the current section is fully mapped. If the current section is not fully mapped, then the system proceeds to 904 to utilize the virtual channel (as indicated by the counter) to add the next link on the route.
[0043] If the current section is fully mapped, then the system proceeds to 912 to determine if the current sequence has been fully mapped. If the current sequence has not been fully mapped, then the system proceeds to 901 to select end-points for the next section of the sequence.
[0044] If the current sequence has been fully mapped, then the system proceeds to 913 to determine if all sequences have been fully mapped. If all sequences have not been fully mapped then the system proceeds to 900 to use the next message sequence from the user specification. If all sequences have been fully mapped, the system proceeds to 914 to indicate (e.g., message to the user) a possible deadlock free mapping of the specified traffic.
[0045] FIG. 10 illustrates an example computer system 1000 on which example embodiments may be implemented. The computer system 1000 includes a server 1005 which may involve an I/O unit 1035 , storage 1060 , and a processor 1010 operable to execute one or more units as known to one of skill in the art. The term “computer-readable medium” as used herein refers to any medium that participates in providing instructions to processor 1010 for execution, which may come in the form of computer-readable storage mediums, such as, but not limited to optical disks, magnetic disks, read-only memories, random access memories, solid state devices and drives, or any other types of tangible media suitable for storing electronic information, or computer-readable signal mediums, which can include transitory media such as carrier waves. The I/O unit processes input from user interfaces 1040 and operator interfaces 1045 which may utilize input devices such as a keyboard, mouse, touch device, or verbal command.
[0046] The server 1005 may also be connected to an external storage 1050 , which can contain removable storage such as a portable hard drive, optical media (CD or DVD), disk media or any other medium from which a computer can read executable code. The server may also be connected an output device 1055 , such as a display to output data and other information to a user, as well as request additional information from a user. The connections from the server 1005 to the user interface 1040 , the operator interface 1045 , the external storage 1050 , and the output device 1055 may via wireless protocols, such as the 802.11 standards, Bluetooth® or cellular protocols, or via physical transmission media, such as cables or fiber optics. The output device 1055 may therefore further act as an input device for interacting with a user.
[0047] The processor 1010 may execute one or more modules. The route construction module 1011 is configured to automatically construct a path comprising of physical links of the interconnect for routing messages from a source block to a destination block in the multi-core system. The virtual channel allocation module 1012 may be configured to allocate one of the available virtual channels for a link in the route between endpoints of a section in a message sequence of the multi-core system and add it to the global channel dependency graph. The dependencies module 1013 may be configured to automatically check for cyclic dependencies among the channels by detecting loops in the channel dependency graph.
[0048] The route construction module 1011 , the virtual channel allocation module 1012 , and the dependencies module 1013 may interact with each other in various ways depending on the desired implementation. For example, the route construction module 1011 may select network end-points to define a section of a sequence, and select a route between the section end points based on a routing scheme, based on load balancing, based on resource minimization or other possible factors. The virtual channel allocation module 1012 may set an internal counter may be set from zero to count how many of the available virtual channels are tested to map the specified traffic. The virtual channel allocation module may allocate virtual channels based on resource sharing and minimization, load balancing or other possible factors.
[0049] The route construction module 1011 may instruct the virtual channel allocation module 1012 to utilize the next available virtual channel (e.g. as indicated by the counter in the virtual channel allocation module) to add a link on the route to the global channel dependency graph. Then, the route construction module 1011 may instruct the dependency module 1013 to checks (e.g. automatically) for a cyclic dependency in the current dependency graph. If the dependency module 1013 detects a dependency, the route construction module 1011 may remove and reset the current section of the message sequence from the dependency graph, wherein the virtual channel allocation module 1012 may increment the counter to the next available virtual channel, and check if the available virtual channels are exhausted. If all available virtual channels have been attempted, then the route construction module 1011 may abort and indicate (e.g. message to user) that the specified traffic cannot be mapped with the available virtual channels.
[0050] If no cycle is detected by the dependency module 1013 , then the route construction module 1011 may determine if the current section is fully mapped. If the current section is determined not to be fully mapped, then the route construction module 1011 attempts to utilize the allocated virtual channel to add the next link on the route, and to recheck the dependency.
[0051] If the current section is determined to be fully mapped, then the route construction module 1011 may determine if the current sequence has been fully mapped. If the current sequence is determined not to be fully mapped, then the route construction module 1011 may proceed to select end-points for the next section of the sequence and attempt to select another route between the new end points based on a routing scheme.
[0052] If the current sequence is determined to be fully mapped, then the route construction module determines if all sequences have been fully mapped. If all sequences are determined not to be fully mapped, then the route construction module 1011 selects the next message sequence from the user specification and attempts to map the next message sequence. If all sequences are determined to be fully mapped, then the route construction module 1011 may indicate (e.g., message to the user) a possible deadlock free mapping of the specified traffic.
[0053] The route construction module may also conduct the automatic construction of a map by being configured to receive a specification of the multi-core system containing a deadlock; to instruct the allocation module 1012 to automatically reallocate virtual channels until the deadlock is resolved; and to construct the map based on the reallocation.
[0054] Furthermore, some portions of the detailed description are presented in terms of algorithms and symbolic representations of operations within a computer. These algorithmic descriptions and symbolic representations are the means used by those skilled in the data processing arts to most effectively convey the essence of their innovations to others skilled in the art. An algorithm is a series of defined steps leading to a desired end state or result. In the example embodiments, the steps carried out require physical manipulations of tangible quantities for achieving a tangible result.
[0055] Moreover, other implementations of the example embodiments will be apparent to those skilled in the art from consideration of the specification and practice of the example embodiments disclosed herein. Various aspects and/or components of the described example embodiments may be used singly or in any combination. It is intended that the specification and examples be considered as examples, with a true scope and spirit of the embodiments being indicated by the following claims. | Systems and methods for automatically building a deadlock free inter-communication network in a multi-core system are described. The example embodiments described herein involve deadlock detection during the mapping of user specified communication pattern amongst blocks of the system. Detected deadlocks are then avoided by re-allocation of channel resources. An example embodiment of the deadlock avoidance scheme is presented on Network-on-chip interconnects for large scale multi-core system-on-chips. | 7 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a semiconductor device. More specifically, the present invention relates to a semiconductor device and its manufacturing method in which a leak current between elements due to a parasitic transistor formed at an element isolation part is reduced by using an SOI (Silicon On Insulator) substrate as a semiconductor substrate and using a LOCOS (Local Oxidation of Silicon) method as an element isolation technology for the SOI substrate.
[0003] 2. Description of the Related Art
[0004] Recently, for the purpose of improving a threshold characteristic and reducing a parasitic capacity, an SOI substrate with a silicon layer formed on an insulative layer called BOX oxide film is in heavy usage as a substrate to form a semiconductor element.
[0005] Element isolation is implemented on the silicon layer (SOI layer) by a trench structure (trench isolation method) or a LOCOS method. A MOSFET element on the SOI substrate is manufactured on the SOI substrate through a process similar to the one of manufacturing a conventional MOSFET element. The manufacturing process of MOSFET element on an SOI substrate using a LOCOS method will be explained as follows.
[0006] Element isolation by a LOCOS method is disclosed in the document “J. W. Thomas et al., Proceedings IEEE Intr. SOIconf., 116 (1995)”. First, according to the document, an oxide film to be a pad oxide film is formed on an SOI substrate. Second, patterning is implemented by a conventional photolithography method using a resist as an optical mask after a nitride film is accumulated. And then the pad oxide film and the nitride film in an element isolation region are removed.
[0007] Next, heat treatment is implemented to form a field oxide film (LOCOS oxide film) in an element isolation region. Due to the limit of the thickness of SOI layer, the field oxide layer does not become far thicker than the SOI layer, different from that of a MOSFET with bulk structure. After forming the LOCOS oxide film, the nitride film and the pad oxide film are removed. After that, a gate oxide film, an electrode, a source and a drain are formed similar to the process of manufacturing a conventional MOSFET.
[0008] The manufacturing process as explained above is only one example, and there are some modifications of the process in which, for example, an LDD (Lightly Doped Drain) structure is formed in forming a MOSFET with a conventional substrate. However, the explanations of the modifications are omitted here since the explanations have no relation with the substance of the present invention.
[0009] In this LOCOS method, an edge region, a silicon layer, with the section of triangular shape, is formed between a BOX oxide film and the LOCOS oxide film, and the layer becomes a parasitic MOSFET. This parasitic MOSFET has a bad influence on the MOSFET element, a leak current is increased and a hump characteristic in which a hump seems to be at a current characteristic of the element is caused. For this reason, the threshold voltage in the MOSFET with the parasitic MOSFET becomes lower than the one in the MOSFET without the parasitic MOSFET.
[0010] On the other hand, a trench structure in which a silicon layer is etched to form a groove and in which an oxide film is embedded in the groove is disclosed in the document “IEEE ELECTRON DEVICE LETTERS, VOL. 6, JUNE 1995” and so on. Also, there is disclosed in the document “S-W Kang IEEE EDL-16, no. 6 1995” that the trouble of hump characteristic causing trouble in the LOCOS method can be resolved by the trench structure (trench isolation method).
[0011] The trench isolation method, however, needs to include a step of forming a groove in an element isolation region and removing an oxide film deposited on the part other than the groove, which increases the manufacturing steps comparing to the LOCOS method and makes the manufacturing cost high. For this reason, the isolation method cannot be employed to an element with low cost needed.
[0012] In view of this problem, a method of improving the hump characteristic using the LOCOS method is disclosed in the following patent documents. A method of improving a LOCOS edge shape on which a parasitic MOSFET is formed is disclosed in Japanese Patent Laid-open Publication No. 2000-306994 and a method of preventing a parasitic MOSFET from turning on by implanting an impurity into an edge region to increase an edge concentration is disclosed in Japanese Patent Laid-open Publication No. 2003-124303.
[0013] Also, a method of restraining a leak current by implanting an impurity by forming a groove in a LOCOS isolation region is disclosed in Japanese Patent Laid-open Publication No. 07-115125, and a method of reducing a leak current in an element isolation method in an element isolation method using the trench structure is disclosed in Japanese Patent Laid-open Publication No. 01-138730 and Japanese Patent Laid-open Publication No. 2001-148418. Further, a structure with fluorine implanted into a gate insulating film so that the concentration distribution can be appropriate, for the purpose of improving a dielectric breakdown resistance, is disclosed in Japanese Patent Laid-open Publication No. 2001-102571.
[0014] However, even those methods cited above are employed to the element isolation using the LOCOS method, the hump characteristic cannot be completely restrained, and, in a method of increasing an edge concentration by implanting an impurity into an edge region, the impurity in the edge region is diffused into the element part to have a bad influence on the characteristic of the element.
SUMMARY OF THE INVENTION
[0015] The present invention has been achieved in view of aforementioned problems. The object of the present invention is to provide a novel and improved semiconductor device and its manufacturing method capable of reducing the influence of leak current due to a parasitic transistor as much as possible and capable of restraining the hump characteristic of element in a semiconductor substrate with element isolation implemented.
[0016] In one aspect of the present invention to achieve the above object, there is provided a semiconductor device in an element isolation region using a LOCOS method comprising: a silicon layer having an inclined part in a sectional shape; a metal oxide film for generating a fixed electric charge, formed on the silicon layer having the inclined part; and a field oxide film formed on the metal oxide layer.
[0017] With this structure, since the threshold voltage of a parasitic transistor formed between the silicon layer and the field oxide film can be made high by forming the metal oxide film generating a fixed electric charge on the silicon layer in the element isolation region, the influence of leak current can be reduced and the hump characteristic of element can be restrained. Here, the structure of element may be a bulk structure. However, when the silicon layer has an SOI structure with the silicon layer formed on an insulating layer, the fixed electric charge can be generated from a metal oxide film formed on an edge region of the silicon layer at a border with the element isolation region and the threshold voltage of the parasitic transistor formed in the edge region can be made high. Consequently, the hump characteristic can be effectively restrained.
[0018] To obtain the semiconductor device as described above, there is provided a method of manufacturing a semiconductor device comprising the steps of: forming a pad oxide film and a nitride film sequentially on a silicon layer in an element region; forming a metal oxide film for generating a fixed electric charge on the nitride film and on the silicon layer in an element isolation region; forming a field oxide film in the element isolation region by implementing an oxidation treatment; and removing the metal oxide film on the nitride film, the nitride film and the pad oxide film.
[0019] Or, in another aspect of the present invention, there can be provided a method of manufacturing a semiconductor device comprising the steps of: forming a pad oxide film and a nitride film sequentially on a silicon layer in an element region; forming a field oxide film in an element isolation region by implementing an oxidation treatment; implanting an impurity into the field oxide film to generate a fixed electric charge on the field oxide film; and removing the nitride film and the pad oxide film.
[0020] According to the present invention as described above, by forming a metal oxide film generating a fixed electric charge between a silicon layer and a field oxide film each in an element isolation region, or by generating a fixed electric charge on a field oxide film on a silicon layer, the threshold voltage of a parasitic transistor formed between the silicon layer and the field oxide film can be made high and the influence of leak current can be reduced and the hump characteristic of element can be restrained.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] The above and other features of the invention and the concomitant advantages will be better understood and appreciated by persons skilled in the field to which the invention pertains in view of the following description given in conjunction with the accompanying drawings which illustrate preferred embodiments.
[0022] FIG. 1 is a sectional view showing a semiconductor device in the first embodiment.
[0023] FIG. 2A is a sectional view of process showing schematically a method of manufacturing a semiconductor device in the first embodiment and a process after a pad oxide film and a nitride film are formed on an SOI layer.
[0024] FIG. 2B is a sectional view of process showing schematically a method of manufacturing a semiconductor device in the first embodiment and a process after a pad oxide film and a nitride film in an element isolation region are removed.
[0025] FIG. 2C is a sectional view of process showing schematically a method of manufacturing a semiconductor device in the first embodiment and a process after a metal oxide film is formed.
[0026] FIG. 2D is a sectional view of process showing schematically a method of manufacturing a semiconductor device in the first embodiment and a process after a field oxide film is formed.
[0027] FIG. 2E is a sectional view of process showing schematically a method of manufacturing a semiconductor device in the first embodiment and a process after a pad oxide film and a nitride film are removed.
[0028] FIG. 2F is a sectional view of process showing schematically a method of manufacturing a semiconductor device in the first embodiment and a process after a gate oxide film and a gate electrode are formed.
[0029] FIG. 3A is a sectional view of process showing schematically a method of manufacturing a semiconductor device in the second embodiment and a process after a pad oxide film and a nitride film are formed in an element region.
[0030] FIG. 3B is a sectional view of process showing schematically a method of manufacturing a semiconductor device in the second embodiment and a process after a field oxide film is formed.
[0031] FIG. 3C is a sectional view of process showing schematically a method of manufacturing a semiconductor device in the second embodiment and a process after an ion implantation of fluorine ion is implemented.
[0032] FIG. 3D is a sectional view of process showing schematically a method of manufacturing a semiconductor device in the second embodiment and a process after a pad oxide film and a nitride film are removed.
[0033] FIG. 3E is a sectional view of process showing schematically a method of manufacturing a semiconductor device in the second embodiment and a process after a gate oxide film and a gate electrode are formed.
[0034] FIG. 4 is an illustration showing a comparison between the relation of drain current and gate voltage in the first embodiment and the one in the related art.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0035] Hereinafter, the preferred embodiment of the present invention will be described in reference to the accompanying drawings. Same reference numerals are attached to components having same functions in following description and the accompanying drawings, and a description thereof is omitted.
[0036] (First Embodiment)
[0037] FIG. 1 is a sectional view showing a border between an element part and an element isolation region in a channel direction of a semiconductor device having an SOI structure in this embodiment. Referring to FIG. 1 , each element is electrically isolated by a field oxide film 160 using a LOCOS method in the semiconductor device. In an element region S, a gate oxide film 170 is formed on e.g., a P-type silicon layer 130 formed on a BOX oxide film layer 120 of a substrate 110 . And a gate electrode 175 is formed on the gate oxide film 170 to form an N-channel MOSFET.
[0038] In an element isolation region A, a metal oxide film 180 , e.g., aluminum oxide (Al 2 O 3 ) is formed on the silicon layer 130 having an inclined part in a sectional shape and on the BOX oxide film layer 120 . And the field oxide film 160 is formed thereon.
[0039] Especially, in the element isolation region A, a triangular-shaped edge region 135 of the silicon layer 130 surrounded with the BOX oxide film layer 120 and the field oxide film 160 becomes a parasitic MOSFET (N-channel MOSFET), causes a hump characteristic and has a bad influence on the characteristics of the element. With the structure of the element isolation region A in this embodiment, by forming the metal oxide film 180 (e.g., Al 2 O 3 ), a reaction is induced with Al 2 O 3 at an Si interface of the silicon layer 130 and a defect is formed at the interface of Si.
[0040] Since a negative fixed electric charge is included in the defect of Al 2 O 3 , the flat band voltage of the edge region increases and the threshold value of the parasitic N-channel MOSFET can also be raised. Thereby the parasitic N-channel MOSFET becomes difficult to turn on, the hump characteristic is restrained and the influence on the element can be reduced. Although Al 2 O 3 is employed in this embodiment, other metal oxide film including a negative fixed electric charge, e.g., hafnium oxide can be employed.
[0041] When an SOI layer is N-type and the element is a P-channel MOSFET, a parasitic P-channel MOSFET is formed in the edge region, as a matter of course. In this case, since the opposite effect is produced by forming Al 2 O 3 , it is preferable to form an oxide film including a positive fixed electric charge. In this embodiment, an explanation will be provided in the case of N-channel MOSFET.
[0042] Next, a method of manufacturing a semiconductor device in this embodiment will be explained. FIGS. 2 A-F are sectional views of processes showing a border between an element part and an element isolation region in a channel direction of a semiconductor device in this embodiment. First, the BOX oxide film layer 120 with a thickness of approximately 1500 Å and the silicon layer 130 with a thickness of approximately 500 Å are sequentially formed on the substrate 110 , and a pad oxide film 140 is formed on the silicon layer 130 at a thickness of approximately 70 Å, and further, a nitride film 150 is accumulated thereon at a thickness of approximately 1000 Å ( FIG. 2A ). The pad oxide film 140 has the effect of improving the adhesion between the silicon layer 130 and the nitride film 150 .
[0043] After that, patterning is implemented by a photolithography method to remove the pad oxide film 140 and the nitride film 150 each in the element isolation region, and the silicon layer 130 becomes exposed ( FIG. 2B ). Next, aluminum oxide (Al 2 O 3 ) 185 , for example, is formed as a metal oxide film on the nitride film 150 and on the silicon layer 130 , at a thickness of approximately 20 Å, by using a sputtering device or a CVD method ( FIG. 2C ).
[0044] Implementing heat treatment with Al 2 O 3 185 formed, the field oxide film 160 is formed in the element isolation region in the direction of thickness at a thickness of approximately 1000 Å ( FIG. 2D ). This heat treatment is implemented by dry oxidation for 60 minutes and at a temperature of approximately 1000° C., for example. By forming the field oxide film 160 , elements adjacent to each other are electrically isolated. And at the part near the element region, the nitride film 150 is lifted to form the edge region 135 referred to as bird's beak of the silicon layer 130 at a length of approximately 500 Å.
[0045] The edge region 135 is a part to be a parasitic MOSFET, as described above. In the parasitic MOSFET in this embodiment, however, since Al 2 O 3 185 , a metal oxide film, is formed on the silicon layer 130 and a negative fixed electric charge is generated at the interface of the silicon layer 130 in Al 2 O 3 185 , the flat band voltage of the edge region and the threshold value of the parasitic N-channel MOSFET increase.
[0046] And then, as in the related art, removing the nitride film 150 and the pad oxide film 140 as shown in FIG. 2E , the gate oxide film 170 is formed at a thickness of approximately 30 Å as shown in FIG. 2F , and a gate electrode 175 of, for example, polysilicon and source/drain regions (not shown) are formed, and then the element region is completed. The above formation of oxide film, nitride film and so on are implemented by, for example, a CVD method. In addition, this first embodiment is characterized in that the metal oxide film is formed on the silicon layer in the element isolation region before the field oxide film is formed. With regard to other manufacturing processes, other various methods can be employed.
[0047] FIG. 4 shows Id-Vg characteristic in this embodiment. In addition, FIG. 4 shows that the effects are obtained that the threshold value of the parasitic N-channel MOSFET generated in the edge region in the element isolation region can be raised, that the hump characteristic can be more restrained than in the related art and that the leak characteristic can be improved.
[0048] (Second Embodiment)
[0049] A method of manufacturing a semiconductor device in the second embodiment will be explained. FIGS. 3 A-E are sectional views showing a border between an element part and an element isolation region in a channel direction of a semiconductor device having an SOI structure in this embodiment. The processes up until the step of forming a field oxide film are the same as the ones in the related art. First, a BOX oxide film layer 220 with a thickness of approximately 1500 Å and a P-type silicon layer 230 with a thickness of approximately 500 Å are sequentially formed on a substrate 210 , and a pad oxide film 240 is formed on the silicon layer 230 at a thickness of approximately 70 Å, and further, a nitride film 250 is accumulated thereon at a thickness of approximately 1000 Å. After that, patterning is implemented by a photolithography method to remove the pad oxide film 240 and the nitride film 250 in the element isolation region ( FIG. 3A ). The element is an N-channel MOSFET.
[0050] Implementing heat treatment, a field oxide film 260 is formed in the element isolation region in the direction of thickness at a thickness of approximately 1000 Å ( FIG. 3B ). This heat treatment is implemented by dry oxidation for 60 minutes and at a temperature of approximately 1000° C., for example. By forming the field oxide film 260 , elements adjacent to each other are electrically isolated. And at the part near the element region, an edge region 235 to be a parasitic MOSFET is formed.
[0051] Next, in order to generate a negative fixed electric charge on the field oxide film 260 as shown in FIG. 3C , an impurity, for example, a fluorine ion F 280 is implanted into the whole surface of the substrate by an ion implantation method after forming the field oxide film 260 . At this time, it is preferable to implement at an angle of approximately 30°-45° in order to implant the fluorine ion 280 effectively into the field oxide film 260 on the inclined silicon layer 230 in the edge region 235 . It is also preferable to set the energy of implantation approximately at 10-15 keV.
[0052] And then, as in the related art, removing the nitride film 250 and the pad oxide film 240 as shown in FIG. 3D , a gate oxide film 270 is formed at a thickness of approximately 30 Å as shown in FIG. 3E , and a gate electrode 275 of, for example, polysilicon and source/drain regions (not shown) are formed, and then the element region is completed. In addition, this second embodiment is characterized in that a fluorine ion is implanted into an edge region after a field oxide film is formed. With regard to other manufacturing processes, other various methods can be employed.
[0053] By implanting the fluorine ion 280 into the field oxide film 260 at the interface of the silicon layer in the edge region 235 , since a negative fixed electric charge is generated at the interface of the silicon layer 230 in the field oxide film 260 , the flat band voltage of the edge region and the threshold value of the parasitic N-channel MOSFET increase.
[0054] According to the second embodiment as described above, since a negative fixed electric charge in the oxide film generated by fluorine ion implantation raises the threshold value of the parasitic MOSFET in the edge region, the parasitic N-channel MOSFET becomes difficult to turn on, the hump characteristic is restrained and the influence on the element can be reduced.
[0055] Although the preferred embodiment of the present invention has been described referring to the accompanying drawings, the present invention is not restricted to such examples. It is evident to those skilled in the art that the present invention may be modified or changed within a technical philosophy thereof and it is understood that naturally these belong to the technical philosophy of the present invention. | This invention provides a semiconductor device with an element isolation implemented by a method of manufacturing a semiconductor device comprising the steps of: forming a pad oxide film 140 and a nitride film 150 sequentially on a silicon layer 130 in an element region S; forming a metal oxide film 180 for generating a fixed electric charge on the nitride film 150 and on the silicon layer 130 in an element isolation region A; forming a field oxide film 160 in the element isolation region A by implementing an oxidation treatment; and removing the metal oxide film 180 on the nitride film 150, the nitride film 150 and the pad oxide film 140. In the semiconductor device, the threshold voltage of a parasitic transistor is made high and prevented from turning on, and the influence of leak current is reduced and the hump characteristic of element is restrained. | 7 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims the benefit under 35 U.S.C. §119(e) of the U.S. Provisional Patent Application Ser. No. 60/968,772, filed on Aug. 29, 2007, the content of which is incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to methods and compositions for in vivo endoscopic diagnosis and surgical treatment in a living animal, bird, or man. Specifically, the present invention relates to a bioluminescent endoscopy methods, and compounds for use in bioluminescent endoscopy, by which images may be obtained by the use of appropriate cameras and signal processing algorithms, if necessary, from tissues which contain a bioluminescent compound and/or mixture of compounds which are injected, administered, or by any means whatsoever placed within said tissue.
BACKGROUND OF THE INVENTION
[0003] In recent years endoscopes capable of viewing a patient or test subject have been widely employed. An endoscope can observe organs or other structures. Further, an endoscope can be used for providing therapeutic treatments or surgical interventions by inserting treatment tools into a treatment tool channel provided therein. A typical example of this would be a rigid endoscope including a hard insertion section, which incorporates an image capturing device. With this rigid endoscope, a light guide cable and a scope cable are integrated within the rigid endoscope main body. Flexible endoscopes may also be used to observe anatomic structures. Many different types of electronic endoscopes using a solid state imaging device such as a charge coupled device (CCD) or complementary metal-oxide-semiconductor sensor (CMOS) as imaging means have also been considered and/or used.
[0004] However, certain anatomical structures are difficult to observe in conventional endoscopes under normal visible lighting conditions. For example, the common bile duct is not infrequently damaged in laparoscopic resection of the gallbladder because of its size, location and visual perception limitations inherent in endoscopic surgical techniques (Way L W, Stewart L, Gantert W, Liu K, Lee C M, Whang K, Hunter J G. “Causes and prevention of laparoscopic bile duct injuries: analysis of 252 cases from a human factors and cognitive psychology perspective.” Annals of Surgery 2003 April; 237(4):460-9). Similarly, the ureter can be damaged in surgery, especially in pelvic operations. Although these injuries can be repaired, they may not be apparent until after the conclusion of the procedure. Commonly in the case of the bile duct, infusion of the duct structures with an X-ray contrast agent may be performed, and an X-ray photograph or fluoroscopic image is taken in the form of an intraoperative cholangiogram. This necessitates stopping the surgical procedure and requires bringing an X-ray machine into the operating theater. Furthermore, the operator and assistants must put on lead gowns making this procedure inconvenient and time consuming. For this reason, many surgeons may be resistant to this X-ray examination. An extensive review on the role of intraoperative cholangiography in avoiding bile duct injury the data suggest that the use and correct interpretation of IOC decreases the rate of common bile duct injury and that its broader use will improve patient safety (Massarweh N N, Flum D R. (2007). “Role of intraoperative cholangiography in avoiding bile duct injury.” Journal American College Surgery 204(4):656-64. However, selective intraoperative cholangiography as compared to routine intraoperative cholangiography (IOC) techniques in itself increases the risk of injury to the common bile duct (Flum D R, Dellinger E P, Cheadle A, Chan L, Koepsell T (2003) “Intraoperative cholangiography and risk of common bile duct injury during cholecystectomy.” Journal American Medical Association 289(13):1639-44).
[0005] As described in more detail herein, the present invention provides for bioluminescent endoscopy methods, and compounds for use in bioluminescent endoscopy, to avoid such problems in surgery. However, and potentially much more significantly, the present invention also has a significant use in the detection and treatment of cancer, including specifically, breast cancer and melanoma.
[0006] Radical mastectomy was first demonstrated nearly 100 years ago by Halstead as a potentially effective surgical response to breast cancer. Fifty years later, Patey proved that modified radical mastectomy could yield similar survival with limited morbidity. Since the time of Halstead to the current day, the status of the regional nodal basin remains the single most important independent variable in predicting prognosis. Advocates of axillary dissection contend that there is a benefit for breast cancer patients because axillary dissection provides direct regional control of axillary disease. Axillary lymph node dissection (ALND) provides excellent regional tumor control, and the pathologic information gained is pivotal to the planning of adjuvant therapy. Axillary lymph node metastasis in patients with early breast cancer is the single most important prognostic factor for recurrence and survival and forms the basis for important therapeutic decisions. Critics of axillary dissection maintain that overall survival depends on the development of distant metastases and is not influenced by axillary dissection in most patients. They contend that patients with microscopic axillary metastases might be cured with adjuvant chemotherapy with or without nodal irradiation in the absence of axillary dissection. Many have even advocated abandoning axillary dissection in early breast cancer. Axillary lymph node dissection is a major operation; ALND is associated with acute complication rates of 20% to 30% and chronic lymphedema rates of 7% to 37%. The majority of women who undergo ALND for breast cancer experience enduring surgery-related symptoms such as scarring, pain, numbness, lymphedema and weakness and stiffness of the ipsilateral arm and shoulder, as well as decreased sweat production in the distribution of the intercostobrachial nerve. Postoperative studies have shown that the degree of total pain was significantly associated with the number of lymph nodes dissected. These controversies have been amplified by the fact that the fundamental biology of lymphatic metastasis remains poorly understood. There is as yet an incomplete understanding of functional lymphatic biology, and a general lack of appropriate experimental models (Tanis, P. J., M. C. van Rijk, et al. (2005). “The posterior lymphatic network of the breast rediscovered.” Journal of Surgical Oncology 91(3): 195-8.; Barrett, T., P. L. Choyke, et al. (2006). “Imaging of the lymphatic system: new horizons.” Contrast Media & Molecular Imaging 1(6): 230-45.; Estourgie, S. H., O. E. Nieweg, et al. (2004). “Lymphatic drainage patterns from the breast. [see comment].” Annals of Surgery 239(2): 232-7.)
[0007] Systematic studies in breast cancer have shown that breast cancer spreads via the lymphatic system to one or a few lymph nodes before it spreads to other axillary nodes. These first affected lymph nodes are often labeled as “sentinel lymph node(s)” (SLNs), Sentinel-lymph-node biopsy (SNB) was developed for the axillary staging of breast carcinoma. See Chetty, U., P. K. Chin, et al. (2008). “Combination blue dye sentinel lymph node biopsy and axillary node sampling: the Edinburgh experience.” European Journal of Surgical Oncology 34(1): 13-6.; Christiansen, P., E. Friis, et al. (2008). “Sentinel node biopsy in breast cancer: five years experience from Denmark.” Acta Oncologica 47(4): 561-8.; Cochran, A. J., S. J. Ohsie, et al. (2008). “Pathobiology of the sentinel node.” Current Opinion in Oncology 20(2): 190-5.; Fenaroli, P., M. Merson, et al. (2004). “Population-based sentinel lymph node biopsy in early invasive breast cancer.” European Journal of Surgical Oncology 30(6): 618-23.
[0008] If the SLN does not contain metastasis, then patients and surgeons may choose to delay or omit ALND, with a favorable effect on patients' quality of life. Despite few controlled clinical studies of SNB, this procedure has become widely practiced in the United States, Europe, and Australia. Currently, at most major cancer centers in the United States, SNB is performed without ALND if no disease is found in the SLN. (Bankhead, C. (2007). “Debate over sentinel node biopsy continues.” Journal of the National Cancer Institute 99(10): 751-3.) The American Society of Clinical Oncology (ASCO) officially supports the use of SNB for staging disease in most women with clinically negative axillary lymph nodes. They continue to recommend routine ALND for patients with a positive SLN according to routine histopathological examination. (Lyman, G. H., A. E. Giuliano, et al. (2005). “American Society of Clinical Oncology guideline recommendations for sentinel lymph node biopsy in early-stage breast cancer. [see comment].” Journal of Clinical Oncology 23(30): 7703-20.) SNB is not recommended for large or locally advanced invasive breast cancers (Boileau, J. F., A. Easson, et al. (2008). “Sentinel nodes in breast cancer: relevance of axillary level II nodes and optimal number of nodes that need to be removed.” Annals of Surgical Oncology 15(6): 1710-6.)
[0009] The SNL biopsy is typically evaluated by classical staining methods, or preferably in combination with the immunohistochemical staining of lymph nodes. The histological status of the axillary nodes remains the single best predictor of survival in patients with breast cancer. Ideally, the SNL biopsy would involve intraoperative frozen-section examination, involving complete sectioning of the entire lymph node and examination of a large number of sections. Unfortunately, until quite recently this has been difficult to perform in the intraoperative setting in a definitive manner, and even now, rapid immunohistochemical analysis of the sections remains difficult.
[0010] Therefore, various methods for lymphatic imaging have been used during the interoperative procedures. Lymphatic connection with the tumor can be identified by using Lymphazurin vital blue dye, various other vital stains, a radiolabeled colloid, or a combination thereof. Indeed, the greatest proportion of successful mappings and the lowest false-negative rates were associated with studies in which both blue dye and radiolabeled colloid were used. (Kitai, T., T. Inomoto, et al. (2005). “Fluorescence navigation with indocyanine green for detecting sentinel lymph nodes in breast cancer.” Breast Cancer 12(3): 211-5.; Koizumi, M., E. Nomura, et al. (2004). “Radioguided sentinel node detection in breast cancer patients: comparison of 99 mT c phytate and 99 m T c rhenium colloid efficacy.” Nuclear Medicine Communications 25(10): 1031-7.; Anan, K., S. Mitsuyama, et al. (2006). “Double mapping with subareolar blue dye and peritumoral green dye injections decreases the false-negative rate of dye-only sentinel node biopsy for early breast cancer: 2-site injection is more accurate than 1-site injection. [see comment].” Surgery 139(5): 624-9; Lin, K. M., T. H. Patel, et al. (2004). “Intradermal radioisotope is superior to peritumoral blue dye or radioisotope in identifying breast cancer sentinel nodes.” Journal of the American College of Surgeons 199(4): 561-6; Mariani, G., P. Erba, et al. (2004).; “Lymphoscintigraphic and intraoperative detection of the sentinel lymph node in breast cancer patients: the nuclear medicine perspective.” Journal of Surgical Oncology 85(3): 112-22.; Nour, A. (2004). “Efficacy of methylene blue dye in localization of sentinel lymph node in breast cancer patients.” Breast Journal 10(5): 388-91;
[0011] In some medical centers, lymphoscintigraphic imaging using a gamma camera is routinely performed before intraoperative probe detection of radioactivity in sentinel nodes at surgery for axillary staging of breast cancer, typically with 99m Tc sulfur colloid agents. This is not always easy to do. There is substantial variability in the frequency of imaging visualization of internal mammary nodes, ranging from under 10% to nearly 40% in some series. See Celebioglu, F., L. Perbeck, et al. (2007). “Lymph drainage studied by lymphoscintigraphy in the arms after sentinel node biopsy compared with axillary lymph node dissection following conservative breast cancer surgery.” Acta Radiologica 48(5): 488-95.). PET scanning has been employed (Zornoza, G., M. J. Garcia-Velloso, et al. (2004). “ 18 F-FDG PET complemented with sentinel lymph node biopsy in the detection of axillary involvement in breast cancer.” European Journal of Surgical Oncology 30(1): 15-9). The frequency of internal mammary nodal visualization may be dependent on the type of colloid used and route of injection as well as the time from imaging until injection (Barranger, E., A. Cortez, et al. (2004). “Laparoscopic sentinel node procedure using a combination of patent blue and radiocolloid in women with endometrial cancer.” Annals of Surgical Oncology 11(3): 344-9.; Barranger, E., K. Kerrou, et al. (2007). “Place of a hand-held gamma camera (POCI) in the breast cancer sentinel node biopsy.” Breast 16(5): 443-4.)
[0012] In SNB, pathologists receive either single lymph nodes dissected free of fat or axillary fat containing one or more lymph nodes. Fatty nodules are carefully dissected to identify all lymph nodes. Lymph nodes are inspected for blue dye color, if such dye has been used, measured, and cut into sections generally no thicker than 2.0 mm through and parallel to the longest meridian. Each SLN is submitted in a separate cassette or identified by colored ink to permit accurate assessment of the total number of lymph nodes and number of involved lymph nodes; all node sections are submitted for microscopic examination. Radioactivity is quantified in the samples in each cassette if a radioactive tracer has been used.
[0013] The sentinel node concept has also been validated in malignant melanoma (Chakera, A. H., K. T. Drzewiecki, et al. (2004). “Sentinel node biopsy for melanoma: a study of 241 patients.” Melanoma Research 14(6): 521-6; Gipponi, M., C. Di Somma, et al. (2004). “Sentinel lymph node biopsy in patients with Stage I/II melanoma: Clinical experience and literature review.” Journal of Surgical Oncology 85(3): 133-40. Essner, R. (2006). “Experimental frontiers for clinical applications: novel approaches to understanding mechanisms of lymph node metastases in melanoma.” Cancer & Metastasis Reviews 25(2): 257-67).
[0014] The sentinel node concept has potential application in other types of cancer, due to the known fact that the lymphatic system serves as a primary route for the dissemination of many solid tumors, particularly those of epithelial origin including colon and prostate. The feasibility and diagnostic reliability of sentinel node mapping of lung cancers is currently under study by a number of investigators. (Bustos, M. E., J. J. Camargo, et al. (2008). “Intraoperative detection of sentinel lymph nodes using Patent Blue V in non-small cell lung cancer.” Minerva Chirurgica 63(1): 29-36.), gynecological (Ayhan, A., H. Celik, et al. (2008). “Lymphatic mapping and sentinel node biopsy in gynecological cancers: a critical review of the literature.” World Journal of Surgical Oncology 6: 53) and gastrointestinal cancers (Arigami, T., S, Natsugoe, et al. (2006). “Evaluation of sentinel node concept in gastric cancer based on lymph node micrometastasis determined by reverse transcription-polymerase chain Mutter, D., F. Rubino, et al. (2004). “A new device for sentinel node detection in laparoscopic colon resection.” Journal of the Society of Laparoendoscopic Surgeons 8(4): 347-51. Mayinger, B. (2004). “Endoscopic fluorescence spectroscopic imaging in the gastrointestinal tract.” Gastrointestinal Endoscopy Clinics of North America 14(3): 487-505.; Mayinger, B., M. Jordan, et al. (2004). “Evaluation of in vivo endoscopic autofluorescence spectroscopy in gastric cancer.” Gastrointestinal Endoscopy 59(2): 191-8. Ishizaki, M., A. Kurita, et al. (2006). “Evaluation of sentinel node identification with isosulfan blue in gastric cancer.” European Journal of Surgical Oncology 32(2): 191-6.; Ishikawa, K., K. Yasuda, et al. (2007). “Laparoscopic sentinel node navigation achieved by infrared ray electronic endoscopy system in patients with gastric cancer.” Surgical Endoscopy 21(7): 1131-4).
SUMMARY OF THE INVENTION
[0015] We have found that instillation of a bioluminescent solution into the bile duct, intestinal anastomosis, or ureter during surgery allows excellent instantaneous visualization to the surgeon, potentially preventing damage to these structures. These techniques may also facilitate recognition of leaks or injuries, greatly expediting the surgical procedure. This visualization may be performed using a conventional endoscope or in some methods a modified cooled CCD or CMOS camera specifically adapted for these procedure. These methods are not limited to the above examples, but rather can be applied to any anatomic tube, duct, lumen, vessel, chamber or hollow structure.
[0016] We have further found that sentinel node analysis may be performed utilizing coelenterazine and membrane permeant analogs of coelenterazine can be used for the bioluminescent analysis of lymphatic connection to the sentinel node of a tumor. To do this, the enzyme luciferase, typically but not limited to that from Renilla reniformis , is injected into the lymphatics which surround the tumor in the manner that technetium colloid or blue dye is administered. Then, upon biopsy of the sentinel node, the biopsy specimen is treated with coelenterazine or a membrane permeant analog of coelenterazine. Bioluminescence may be detected using a camera or a luminometer or by visual inspection.
[0017] The present invention further comprises specific compositions, namely membrane permeant analogs of coelenterazine useful in the above methods, and methods of making such membrane permeant coelenterazine analog compositions.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1 is a schematic illustration of the process of bioluminescence by oxidation of coelenterazine.
[0019] FIG. 2 is an illustration of the chemical structure of coelenterazine (Structure I).
[0020] FIG. 3 is an illustration of the changes in the chemical structure of coelenterazine during bioluminescence.
[0021] FIG. 4 is an illustration of the chemical structure of a membrane permeant analog of coelenterazine (Structure II).
[0022] FIG. 5 is an illustration of the chemical structure of a membrane permeant analog of coelenterazine (Structure III).
[0023] FIG. 6 is an illustration of the chemical structure of a membrane permeant analog of coelenterazine (Structure IV).
[0024] FIG. 7 is an illustration of the chemical structure of a membrane permeant analog of coelenterazine (Structure V).
[0025] FIG. 8 is an illustration of the chemical structure of a membrane permeant analog of coelenterazine (Structure VI).
[0026] FIGS. 9-11 are an illustration of the steps of, and associated changes in the chemical structure of compounds used in the preparation of substituted glyoxal for coupling with coelenterazine.
[0027] FIG. 12 is an illustration of glyoxal synthesis step 1 used in the preparation of substituted glyoxal for coupling with coelenterazine.
[0028] FIG. 13 is an illustration of glyoxal synthesis step 2 used in the preparation of substituted glyoxal for coupling with coelenterazine
[0029] FIG. 14 is an illustration of glyoxal synthesis step 3 used in the preparation of substituted glyoxal for coupling with coelenterazine
[0030] FIG. 15 is an illustration of glyoxal synthesis step 4 used in the preparation of substituted glyoxal for coupling with coelenterazine
[0031] FIG. 16 is an illustration of glyoxal synthesis step 5 used in the preparation of substituted glyoxal for coupling with coelenterazine
[0032] FIG. 17 is an illustration of glyoxal synthesis step 6 used in the preparation of substituted glyoxal for coupling with coelenterazine
[0033] FIG. 18 is an illustration of glyoxal synthesis step 7 used in the preparation of substituted glyoxal for coupling with coelenterazine
[0034] FIG. 19 is a photograph showing a rat which has been administered with bioluminescent compounds in accordance with the present invention.
[0035] FIG. 20 is a photograph showing a rat liver which has been administered with bioluminescent compounds in accordance with the present invention.
[0036] FIG. 21 is a photograph showing a head of a rat which has been administered with bioluminescent compounds in accordance with the present invention.
[0037] FIG. 22 is a photograph showing a duodenal loop of a rat which has been administered with bioluminescent compounds in accordance with the present invention.
[0038] FIG. 23 is a photograph showing the duodenum of a rat which has been administered with bioluminescent compounds in accordance with the present invention.
[0039] FIG. 24 is a photograph showing a swine gallbladder as viewed in visible light.
[0040] FIG. 25 is a photograph showing a swine gallbladder which has been administered with bioluminescent compounds in accordance with the present invention.
[0041] FIG. 26 is a monochrome photograph showing a swine gallbladder which has been administered with bioluminescent compounds in accordance with the present invention.
[0042] FIG. 27 is an inverse image monochrome photograph showing a swine gallbladder which has been administered with bioluminescent compounds in accordance with the present invention.
[0043] FIG. 28 is a photograph showing a swine bowel anastomosis as viewed in visible light.
[0044] FIG. 29 is a photograph showing a swine bowel anastomosis which has been administered with bioluminescent compounds in accordance with the present invention.
[0045] FIG. 30 is a photograph showing a swine lung as viewed in visible light.
[0046] FIG. 31 is a photograph showing a swine lung which has been administered with bioluminescent compounds in accordance with the present invention.
[0047] FIG. 32 is a photograph showing a swine heart as viewed in visible light.
[0048] FIG. 33 is a photograph showing a swine heart which has been administered with bioluminescent compounds in accordance with the present invention.
[0049] FIG. 34 is a photograph showing a swine small intestine as viewed in visible light.
[0050] FIG. 35 is a photograph showing a swine small intestine which has been administered with bioluminescent compounds in accordance with the present invention.
[0051] FIGS. 36-39 are an illustration of the steps of, and associated changes in the chemical structure of compounds used in the synthesis of the membrane permeant analogs of coelenterazine illustrated in FIGS. 4-8 .
DETAILED DESCRIPTION OF THE INVENTION
[0052] A. Definitions
[0053] Unless defined otherwise, all technical and scientific terms used herein have the same meaning as is commonly understood by one of skill in the art to which this invention belongs. All patents and publications of referred to herein are incorporated by reference in their entirety.
[0054] As used herein, “chemiluminescence” refers to a chemical reaction in which energy is specifically channeled to a molecule causing it to become electronically excited and subsequently to release a photon thereby emitting visible light. Temperature does not contribute to this channeled energy. Thus, chemiluminescence involves the direct conversion of chemical energy to light energy.
[0055] As used herein, “luminescence” refers to the detectable electromagnetic radiation, generally, UV, IR or visible light radiation that is produced when the excited product of an exergic chemical process reverts to its ground state with the emission of light. Chemiluminescence is luminescence that results from a chemical reaction. Bioluminescence is chemiluminescence that results from a chemical reaction using biological molecules or synthetic versions or analogs thereof as substrates and/or enzymes.
[0056] As used herein, “bioluminescence,” which is a type of chemiluminescence, refers to the emission of light by biological molecules, particularly proteins. The essential condition for bioluminescence is molecular oxygen, either bound or free in the presence of an oxygenase, a luciferase, which acts on a substrate, a luciferin. Bioluminescence is generated by an enzyme or other protein (luciferase) that is an oxygenase that acts on a substrate luciferin (a bioluminescence substrate) in the presence of molecular oxygen and transforms the substrate to an excited state, which upon return to a lower energy level releases the energy in the form of detectable electromagnetic radiation.
[0057] As used herein, the substrates and enzymes for producing bioluminescence are generically referred to as “luciferin” and “luciferase”, respectively. The luciferases and luciferin, activators and other factors, such as O 2 , Mg ++ , Ca ++ are referred to as “bioluminescence generating reagents”, “agents”, or “components.” Typically, a subset of these reagents will be provided or combined with an article of manufacture. When reference is made to a particular species thereof, for clarity, each generic term is used with the name of the organism from which it derives, for example, bacterial luciferin or firefly luciferase.
[0058] “Luciferase” refers to oxygenases that catalyze a light emitting reaction. For instance, bacterial luciferases catalyze the oxidation of flavin mononucleotide [FMN] and aliphatic aldehydes, which reaction produces light. Another class of luciferases, found among marine arthropods, catalyzes the oxidation of Cypridina (also known as Vargula ) luciferin, and another class of luciferases catalyzes the oxidation of Coleoptera luciferin. Thus, luciferase refers to an enzyme or photoprotein that catalyzes a bioluminescent reaction (a reaction that produces bioluminescence). Luciferase enzymes such as firefly and Renilla luciferases act catalytically and are unchanged during the bioluminescence generating reaction. Luciferase photoproteins, such as the aequorin photoprotein to which luciferin is non-covalently bound, are changed, such as by release of the luciferin, during bioluminescence generating reaction. Luciferases employed in the present invention are proteins that occur naturally in an organism, and also variants or mutants thereof, such as a variant produced by mutagenesis that has one or more properties, such as thermal stability, that differ from the naturally-occurring protein. Luciferases and modified mutant or variant forms thereof are well known. For purposes of this application, reference to luciferase refers to either or both luciferase enzymes and photoproteins and their mutant, variant, and synthetic forms. Thus, reference, for example, to “ Renilla luciferase” means an enzyme isolated from member of the genus Renilla or an equivalent molecule obtained from any other source, such as from another Anthozoa, or that has been prepared synthetically.
[0059] Bioluminescence is produced upon contacting the combination of and luciferin and any activators, factors or reagents. Bioluminescence has been used for quantitative determinations of specific substances in biology and medicine. For example, luciferase genes have been cloned and exploited as reporter genes in numerous assays, for many purposes. Since the different luciferase systems have different specific requirements, they may be used to detect and quantify a variety of substances.
[0060] As used herein, “not strictly catalytically” means that the photoprotein acts as a catalyst to promote the oxidation of the substrate, but it is changed in the reaction, since the bound substrate is oxidized and bound molecular oxygen is used in the reaction. Such photoproteins are regenerated by addition of the substrate and molecular oxygen under appropriate conditions known to those of skill in this art.
[0061] As used herein, “bioluminescence substrate” refers to the compound that is oxidized in the presence of a luciferase, and any necessary activators, and generates light. These substrates, referred to as “luciferin” herein, are substrates that undergo oxidation in a bioluminescence reaction. These bioluminescence substrates include any luciferin or analog thereof or any synthetic compound with which a luciferase interacts to generate light. Preferred substrates are those that are oxidized in the presence of a luciferase or protein in a light-generating reaction. Bioluminescence substrates, thus, include those compounds that those of skill in the art recognize as luciferins. Luciferins, for example, include firefly luciferin, Cypridina (also known as Vargula ) luciferin (coelenterazine), bacterial luciferin, as well as synthetic analogs of these substrates or other compounds that are oxidized in the presence of a luciferase in a reaction the produces bioluminescence.
[0062] As used herein, “capable of conversion” into a bioluminescence substrate means susceptible to chemical reaction, such as oxidation or reduction, that yields a bioluminescence substrate. For example, the luminescence producing reaction of bioluminescent bacteria involves the reduction of a flavin mononucleotide group (FMN) to reduced flavin mononucleotide (FMNH 2 ) by a flavin reductase enzyme. The reduced flavin mononucleotide [substrate] then reacts with oxygen [an activator] and bacterial luciferase to form an intermediate peroxy flavin that undergoes further reaction, in the presence of a long-chain aldehyde, to generate light. With respect to this reaction, the reduced flavin and the long chain aldehyde are substrates.
[0063] As used herein, “bioluminescence system” or “bioluminescence generating system” refers to the set of reagents required to conduct a bioluminescent reaction. Thus, the specific luciferase, luciferin and other substrates, solvents and other reagents that may be required to complete a bioluminescent reaction form a bioluminescence system. Thus a bioluminescence system refers to any set of reagents that, under appropriate reaction conditions, yield bioluminescence. In general, bioluminescence systems include a bioluminescence substrate, luciferin, a luciferase, which includes enzyme luciferases and photoproteins, and one or more activators. A photoprotein combines a luciferin, a cofactor such as oxygen, and a catalyzing protein (equivalent to a luciferase.). A specific bioluminescence system may be identified by reference to the specific organism from which the luciferase derives; for example, the Vargula [also called Cypridina ] bioluminescence system (or Vargula system) includes a Vargula luciferase, such as a luciferase isolated from the ostracod, Vargula or produced using recombinant means or modifications of these luciferases. This system would also include the particular activators necessary to complete the bioluminescence reaction, such as oxygen and a substrate with which the luciferase reacts in the presence of the oxygen to produce light.
[0064] “Appropriate reaction conditions” refers to the conditions necessary for a bioluminescence reaction to occur, such as pH, salt concentrations and temperature.
[0065] As used herein, a “surgical viewing” refers to any procedure in which an opening is made in the body of an subject. Such procedures include traditional human and animal surgeries and diagnostic procedures, such as but not limited to laparoscopy, thoracoscopy and arthroscopy procedures. Surgical viewing also refers to any procedure in which a natural orifice is accessed or obturated with a rigid or flexible scope such as but not limited to esophago-gastro-duodenoscopy, colonoscopy or bronchoscopy. Surgical viewing also refers to any angiography, venography, lymphangiography where vessels or tissue beds are cannulated or injected, such as but not limited to diagnostic mapping or completion intraoperative angiography for testing and verification of patency, integrity (leak), or arteriovenous fistula status. Surgical viewing also refers to open operations that do not typically employ an endoscope, rather benefit from a camera and open lens not inserted into a surgical opening or natural orifice, but positioned within close focal length of the operative field for anatomic structure identification. Surgical viewing also refers to open or micro-access operations employing a surgical microscope, such as but not limited to nervous system tumor resections Finally, surgical viewing refers to visualization with the naked eye alone.
[0066] As used herein, “Bioluminescence Enhanced Surgical Technology” (“BEST”) refers to any combination of techniques or methods that use a bioluminescence generating system with an optical system that thus provides for improved surgical viewing, as defined above. It is anticipated that depending on the specific anatomical structure that is the subject of this bioluminescence enhancement, including but not limited to tubes, ducts, lumens, chambers, vessels and hollow organs, different bioluminescence generating systems will be chosen. Similarly, depending on the specific anatomical structure, different technologies for surgical viewing will be chosen. This technology may range from but is not limited to the surgeon's naked eye, to the various endoscopes, open lens cameras and microscopes, as defined above. This technology may also include use of various filters such as but not limited to a blue-green wavelength filter for the endoscope visualizing the bioluminescence enhanced image and a red filter for selective background illumination of the operative field. Similarly, this technology may include any post image capture processing algorithms used to enhance the analog or digital images obtained, such as but not limited to processing by digital imaging computer software programs. This technology may range from but is not limited to simple refinement of the image, to fusion of 2 or more images in a composite still or movie format.
[0067] Amino acids which occur in the various amino acid sequences appearing herein are identified according to their well-known, three-letter or one-letter abbreviations. The nucleotides, which occur in the various DNA fragments, are designated with the standard single-letter designations used routinely in the art. ATP, AMP, NAD + and NADH refer to adenosine triphosphate, adenosine monophosphate, nicotinamide adenine dinucleotide (oxidized form) and nicotinamide adenine dinucleotide (reduced form), respectively.
[0068] As used herein, “production by recombinant” means by using recombinant DNA methods means the use of the well known methods of molecular biology for expressing proteins encoded by cloned DNA. Such expression may be carried out in a bacterial system, such as E. Coli , in a mammalian cell line, in yeast or another plant cell line, or in an insect cell line using a baculovirus vector, (see U.S. Pat. No. 6,814,963, Baculovirus Based Expression System, Nov. 9, 2004).
[0069] As used herein, “substantially identical” to a product means sufficiently similar so that the property of interest is sufficiently unchanged so that the substantially identical product can be used in place of the product.
[0070] The present invention is intended to include all isotopes of atoms occurring in the present compounds. Isotopes include those atoms having the same atomic number but different mass numbers. By way of general example, and without limitation, isotopes of hydrogen include tritium and deuterium and isotopes of carbon include 11 C, 13 C, and 14 C.
[0071] Certain compounds are described herein using a general formula that includes variables, e.g. B, R 1 , R 2 , R 3 , R 4 , R 5 , R 6 , and R 7 . Unless otherwise specified, each variable within such a formula is defined independently of other variables. Thus, if a group is said to be substituted, e.g. with 0-2 R*, then said group may be substituted with up to two R* groups and R* at each occurrence is selected independently from the definition of R*. Also, combinations of substituents and/or variables are permissible only if such combinations result in stable compounds. When a group is substituted by an “oxo” substituent a carbonyl bond replaces two hydrogen atoms on a carbon. An “oxo” substituent on an aromatic group or heteroaromatic group destroys the aromatic character of that group, e.g. a pyridyl substituted with oxo is a pyridone.
[0072] The term “substituted”, as used herein, means that any one or more hydrogens on the designated atom or group is replaced with a selection from the indicated group, provided that the designated atom's normal valence is not exceeded. When a substituent is oxo (i.e., ═O), then two hydrogens on the atom are replaced. Combinations of substituents and/or variables are permissible only if such combinations result in stable compounds or useful synthetic intermediates. A stable compound or stable structure is meant to imply a compound that is sufficiently robust to survive isolation from a reaction mixture, and subsequent formulation into an effective therapeutic agent. Unless otherwise specified substituents are named into the core structure. For example, it is to be understood that when (cycloalkyl)alkyl is listed as a possible substituent the point of attachment of this substituent to the core structure is in the alkyl portion.
[0073] The phrase “optionally substituted” indicates that such groups may either be unsubstituted or substituted at one or more of any of the available positions, typically 1, 2, 3, or 4 positions, by one or more suitable groups such as those disclosed herein.
[0074] Suitable groups that may be present on a “substituted” position include, but are not limited to, e.g., halogen; cyano; hydroxyl; azido; alkanoyl (such as a C 2 -C 6 alkanoyl group such as acyl or the like); carboxamido; alkyl groups (including cycloalkyl groups, having 1 to about 8 carbon atoms, or 1 to about 6 carbon atoms); alkenyl and alkynyl groups (including groups having one or more unsaturated linkages and from 2 to about 8, or 2 to about 6 carbon atoms); alkoxy groups having one or more oxygen linkages and from 1 to about 8, or from 1 to about 6 carbon atoms; aryloxy such as phenoxy; alkylthio groups including those having one or more thioether linkages and from 1 to about 8 carbon atoms, or from 1 to about 6 carbon atoms; alkylsulfinyl groups including those having one or more sulfinyl linkages and from 1 to about 8 carbon atoms, or from 1 to about 6 carbon atoms; alkylsulfonyl groups including those having one or more sulfonyl linkages and from 1 to about 8 carbon atoms, or from 1 to about 6 carbon atoms; aminoalkyl groups including groups having one or more N atoms and from 1 to about 8, or from 1 to about 6 carbon atoms; aryl having 6 or more carbons and one or more rings, (e.g., phenyl, biphenyl, naphthyl, or the like, each ring either substituted or unsubstituted aromatic); arylalkyl having 1 to 3 separate or fused rings and from 6 to about 18 ring carbon atoms, with benzyl being an exemplary arylalkyl group; arylalkoxy having 1 to 3 separate or fused rings and from 6 to about 18 ring carbon atoms, with benzyloxy being an exemplary arylalkoxy group; or a saturated, unsaturated, or aromatic heterocyclic group having 1 to 3 separate or fused rings with 3 to about 8 members per ring and one or more N, O or S atoms, e.g. coumarinyl, quinolinyl, isoquinolinyl, quinazolinyl, pyridyl, pyrazinyl, pyrimidinyl, furanyl, pyrrolyl, thienyl, thiazolyl, triazinyl, oxazolyl, isoxazolyl, imidazolyl, indolyl, benzofuranyl, benzothiazolyl, tetrahydrofuranyl, tetrahydropyranyl, piperidinyl, morpholinyl, piperazinyl, and pyrrolidinyl. Such heterocyclic groups may be further substituted, e.g. with hydroxy, alkyl, alkoxy, halogen and amino.
[0075] The exception to naming substituents into the ring is when the substituted atom is listed with a dash (“-”) or double bond (“═”) that is not between two letters or symbols. In that case the dash or double bond symbol is used to indicate a point of attachment for a substituent. For example, —CONH 2 is attached via a single covalent bond through the carbon atom.
[0076] As used herein, “alkyl” is intended to include both branched and straight-chain saturated aliphatic hydrocarbon groups, having the specified number of carbon atoms. Thus, the term C 1 -C 6 alkyl as used herein includes alkyl groups having from 1 to about 6 carbon atoms. When C 0 -C n alkyl is used herein in conjunction with another group, for example, (aryl)C 0 -C 2 alkyl, the indicated group, in this case aryl, is either directly bound by a single covalent bond (C 0 ), or attached by an alkyl chain having the specified number of carbon atoms, in this case from 1 to about 2 carbon atoms. Examples of alkyl include, but are not limited to, methyl, ethyl, n-propyl, isopropyl, n-butyl, t-butyl, n-pentyl, and sec-pentyl.
[0077] “Alkenyl” as used herein, indicates a hydrocarbon chain of either a straight or branched configuration having one or more carbon-carbon double bond bonds, which may occur at any stable point along the chain. Examples of alkenyl groups include ethenyl and propenyl.
[0078] “Alkynyl” as used herein, indicates a hydrocarbon chain of either a straight or branched configuration having one or more triple carbon-carbon bonds that may occur in any stable point along the chain, such as ethynyl and propynyl.
[0079] “Alkoxy” represents an alkyl group as defined above with the indicated number of carbon atoms attached through an oxygen bridge. Examples of alkoxy include, but are not limited to, methoxy, ethoxy, n-propoxy, i-propoxy, n-butoxy, 2-butoxy, t-butoxy, n-pentoxy, 2-pentoxy, 3-pentoxy, isopentoxy, neopentoxy, n-hexoxy, 2-hexoxy, 3-hexoxy, and 3-methylpentoxy.
[0080] “Alkanoyl” indicates an alkyl group as defined above, attached through a keto (—(C═O)—) bridge. Alkanoyl groups have the indicated number of carbon atoms, with the carbon of the keto group being included in the numbered carbon atoms. For example a C 2 : alkanoyl group is an acetyl group having the formula CH 3 (C═O)—.
[0081] As used herein, the terms “mono- or di-alkylamino” or “mono- and di-alkylamino” indicate secondary or tertiary alkyl amino groups, wherein the alkyl groups are as defined above and have the indicated number of carbon atoms. The point of attachment of the alkylamino group is on the nitrogen. Examples of mono- and di-alkylamino groups include ethylamino, dimethylamino, and methyl-propyl-amino. A mono- or di-(C 3 -C 7 cycloalkylamino)C 0 -C 2 alkylamino group is an alkyl amino substituent in which a first alkyl group is chosen from C 3 -C 7 alkyl and an second alkyl group is chosen from C 0 -C 2 alkyl, wherein C 0 indicates the absence of a second alkyl group, i.e. a mono-C 3 -C 7 alkylamino. The point of attachment to the core structure is on the second, C 0 -C 2 alkyl group.
[0082] The term “alkylthio” indicates an alkyl group as defined above attached through a sulfur linkage, i.e. a group of the formula alkyl-S—. Examples include ethylthio and pentylthio.
[0083] As used herein, the term “aminoalkyl” indicates an alkyl group as defined above substituted with at least one amino substituent. Similarly, the term “hydroxyalkyl” indicates an alkyl group as defined above, substituted with at least one hydroxyl substituent. In certain instances the alkyl group of the aminoalkyl or hydroxyalkyl group may be further substituted.
[0084] As used herein, the term “aryl” indicates aromatic groups containing only carbon in the aromatic ring or rings. Typical aryl groups contain 1 to 3 separate, fused, or pendant rings and from 6 to about 18 ring atoms, without heteroatoms as ring members. When indicated, such aryl groups may be further substituted with carbon or non-carbon atoms or groups. Such substitution may include fusion to a 5 to 7-membered saturated cyclic group that optionally contains 1 or 2 heteroatoms independently chosen from N, O, and S, to form, for example, a 3,4-methylenedioxy-phenyl group. Aryl groups include, for example, phenyl, naphthyl, including 1-naphthyl and 2-naphthyl, and biphenyl
[0085] In the term “(aryl)alkyl”, aryl and alkyl are as defined above, and the point of attachment is on the alkyl group. This term encompasses, but is not limited to, benzyl, phenylethyl, and piperonyl. Similarly, in the terms (aryl)alkoxy and (aryl)alkylthio, aryl, alkylthio, and alkoxy are as defined above and the point of attachment is through the oxygen atom of the alkoxy group or the sulfur group of the alkylthio. If the alkoxy is a C 0 alkoxy the aryl is attached through an oxygen bridge; if the alkylthio is a C 0 alkylthio the aryl is attached through the sulfur. Likewise (aryl)alkyl(C═O)— is an arylalkyl attached to the core structure through a keto group.
[0086] “Cycloalkyl” as used herein, indicates saturated hydrocarbon ring groups, having the specified number of carbon atoms, usually from 3 to about 8 ring carbon atoms, or from 3 to about 7 carbon atoms. Examples of cycloalkyl groups include cyclopropyl, cyclobutyl, cyclopentyl, or cyclohexyl as well as bridged or caged saturated ring groups such as norborane or adamantane, and cubane.
[0087] In the terms “(cycloalkyl)alkyl,” and “(cycloalkyl)alkoxy” the terms cycloalkyl, alkyl, carbohydryl, and alkoxy are as defined above, and the point of attachment is on the alkyl, carbohydryl, or alkoxy group respectively. These terms include examples such as cyclopropylmethyl, cyclohexylmethyl, cyclohexylpropenyl, and cyclopentylethyoxy.
[0088] The term “(cycloalkyl)alkylamino” indicates an amino group substituted with at least one (cycloalkyl)alkyl or cycloalkyl (when the alkyl is a C 0 alkyl). The amino group may be a secondary, in which case the other nitrogen atom valence is occupied by a hydrogen atom or a tertiary amino wherein containing an additional alkyl or (cycloalkyl)alkyl substituent.
[0089] “Haloalkyl” indicates both branched and straight-chain saturated aliphatic hydrocarbon groups having the specified number of carbon atoms, substituted with 1 or more halogen atoms, generally up to the maximum allowable number of halogen atoms. Examples of haloalkyl include, but are not limited to, trifluoromethyl, difluoromethyl, 2-fluoroethyl, and penta-fluoroethyl.
[0090] “Haloalkoxy” indicates a haloalkyl group as defined above attached through an oxygen bridge. Examples of haloalkoxy include, but are not limited to, trifluoromethoxy, difluoromethoxy, 2-fluoroethyoxy, and pentafluoroethoxy. Halo” or “halogen” as used herein includes fluoro, chloro, bromo, and iodo.
[0091] As used herein, substantially pure means sufficiently homogeneous to appear free of readily detectable impurities as determined by standard methods of analysis, such as thin layer chromatography (TLC), gel electrophoresis and high performance liquid chromatography (HPLC), used by those of skill in the art to assess such purity, or sufficiently pure such that further purification would not detectably alter the physical and chemical properties, such as enzymatic and biological activities, of the substance. Methods for purification of the compounds to produce substantially chemically pure compounds are known to those of skill in the art. A substantially chemically pure compound may, however, be a mixture of stereoisomers. In such instances, further purification might increase the specific activity of the compound.
[0092] As used herein “equivalent,” when referring to two sequences of nucleic acids means that the two sequences in question encode the same sequence of amino acids or equivalent proteins. When “equivalent” is used in referring to two proteins or peptides, it means that the two proteins or peptides have substantially the same amino acid sequence with only conservative amino acid substitutions that do not substantially alter the activity or function of the protein or peptide. When “equivalent” refers to a property, the property does not need to be present to the same extent (e.g., two peptides can exhibit different rates of the same type of enzymatic activity), but the activities are preferably substantially the same.
[0093] “Complementary,” when referring to two nucleotide sequences, means that the two sequences of nucleotides are capable of hybridizing, preferably with less than 25%, more preferably with less than 15%, even more preferably with less than 5%, most preferably with no mismatches between opposed nucleotides. Preferably the two molecules will hybridize under conditions of high stringency.
[0094] The term “substantially” identical or homologous or similar varies with the context as understood by those skilled in the relevant art and generally means at least 70%, preferably means at least 80%, more preferably at least 90%, and most preferably at least 95% identity.
[0095] As used herein, “biological activity” refers to the in vivo activities of a compound or physiological responses that result upon administration of a compound, composition or other mixture. Biological activities may be observed in vitro systems designed to test or use such activities. Thus, for purposes herein the biological activity of a luciferase is its oxygenase activity whereby, upon oxidation of a substrate, light is produced.
[0096] As used herein, a “composition” refers to any mixture. It may be a solution, a suspension, liquid, powder, a paste, aqueous, non-aqueous or any combination thereof.
[0097] As used herein, a “combination” refers to any association between two or among more items.
[0098] As used herein, “fluid” refers to any composition that can flow. Fluids thus encompass compositions that are in the form of semi-solids, pastes, solutions, aqueous mixtures, gels, lotions, creams and other such compositions.
[0099] B. Bioluminescence
[0100] Luminescence is a phenomenon in which energy is specifically channeled to a molecule to produce an excited state. Return to a lower energy state is accompanied by release of a photon (hv). Luminescence includes fluorescence, phosphorescence, chemiluminescence and bioluminescence. Bioluminescence is the process by which living organisms emit light that is visible to other organisms. Luminescence may be represented as follows:
[0000]
A+B→X*+Y
[0000]
X*→X+hν
[0101] Where X* is an electronically excited molecule and hν represents light emission upon return of X* to a lower energy state. Where the luminescence is bioluminescence, creation of the excited state derives from an enzyme catalyzed reaction. The color of the emitted light in a bioluminescent (or chemiluminescent or other luminescent) reaction is characteristic of the excited molecule, and is independent from its source of excitation and temperature.
[0102] Though rare overall, bioluminescence is more common in marine organisms than in terrestrial organisms. Bioluminescence has developed from as many as thirty evolutionarily distinct origins and, thus, is manifested in a variety of ways so that the biochemical and physiological mechanisms responsible for bioluminescence in different organisms are distinct. Bioluminescent species span many genera and include microscopic organisms, such as bacteria (primarily marine bacteria including Vibrio species), fungi, algae and dinoflagellates, to marine organisms, including arthropods, mollusks, echinoderms, and chordates, and terrestrial organism including annelid worms and insects.
[0103] C. Bioluminescence Generating Systems
[0104] A bioluminescence generating system includes the components that are necessary and sufficient to generate bioluminescence. These include a luciferase, luciferin and any necessary co-factors or conditions. Virtually any bioluminescent system known to those of skill in the art will be amenable to use in the methods provided herein.
[0105] In general, bioluminescence refers to an energy-yielding chemical reaction in which a specific chemical substrate, a luciferin, undergoes oxidation, catalyzed by an enzyme, a luciferase. An essential condition for bioluminescence is the use of molecular oxygen, either bound or free in the presence of a luciferase. Luciferases, are oxygenases, which act on the substrate, luciferin, in the presence of molecular oxygen and transform the substrate to an excited state. Upon return to a lower energy level, energy is released in the form of light. This process is illustrated in FIG. 1 : The oxidized reaction product is termed oxyluciferin, and certain luciferin precursors are termed etioluciferin. Thus, for purposes herein bioluminescence encompasses light produced by reactions that are catalyzed by (in the case of luciferases that act enzymatically) or initiated by (in the case of the photoproteins, such as aequorin, that are not regenerated in the reaction) a biological protein or analog, derivative or mutant thereof. Bioluminescent reactions are easily maintained, requiring only replenishment of exhausted luciferin or other substrate or cofactor or other protein, in order to continue or revive the reaction. Bioluminescence generating reactions are well-known to those of skill in this art and any such reaction may be adapted for use in combination with articles of manufacture as described herein.
[0106] Luciferases include enzymes such as the luciferases that catalyze the oxidation of luciferin, emitting light and releasing oxyluciferin. Also included among luciferases are photoproteins, which catalyze the oxidation of luciferin to emit light but are changed in the reaction and must be reconstituted to be used again. The luciferases may be naturally occurring or may be modified, such as by genetic engineering to improve or alter certain properties. As long as the resulting molecule retains the ability to catalyze the bioluminescent reaction, it is encompassed herein.
[0107] Any protein that has luciferase activity (catalysis of oxidation of a substrate in the presence of molecular oxygen to produce light as defined herein) may be used herein. The preferred luciferases are those that are described herein or that have minor sequence variations. Such minor sequence variations include, but are not limited to, minor allelic or species variations and insertions or deletions of residues, particularly cysteine residues. Suitable conservative substitutions of amino acids are known to those of skill in this art and may be made generally without altering the biological activity of the resulting molecule. Those of skill in this art recognize that, in general, single amino acid substitutions in non-essential regions of a polypeptide do not substantially alter biological activity. Other substitutions are also permissible and may be determined empirically or in accord with known conservative substitutions. Any such modification of the polypeptide may be effected by any means known to those of skill in this art.
[0108] It is understood that a bioluminescence generating system may be isolated from natural sources, or may be produced synthetically. In addition, for uses herein, the components need only be sufficiently pure so that mixture thereof, under appropriate reaction conditions, produces a glow so that cells and tissues can be visualized during a surgical procedure. Thus, in some embodiments, a crude extract or merely grinding up the organism may be adequate. Generally, however, substantially pure components are used. Also, components may be synthetic components that are not isolated from natural sources. DNA encoding luciferases is and synthetic and alternative substrates have been devised. Any bioluminescence generating system, whether synthetic or isolated from natural sources, is intended for use in the methods provided herein. The luciferases may be obtained commercially, isolated from natural sources, expressed in host cells using DNA encoding the luciferase, or obtained in any manner known to those of skill in the art. The luciferin substrates for the reaction or for inclusion in the conjugates include any molecule(s) with which the luciferase reacts to produce light. Such molecules include the naturally-occurring substrates, modified forms thereof, and synthetic analogues.
[0109] There are numerous organisms and sources of bioluminescence generating systems, and some representative genera and species that exhibit bioluminescence are set forth in Hastings, in (1995) Cell Physiology: Source Book, N. Sperelakis (ed.), Academic Press, pp 665-681]. Other bioluminescent organisms contemplated for use herein are Gonadostomias, Gaussia, Watensia, Halisturia , Vampire squid, Glyphus , Mycotophids (a fish), Vinciguerria, Howella, Florenciella, Chaudiodus, Melanocostus and Sea Pens.
[0110] Examples of luciferases include, but are not limited to, those isolated from the ctenophores Mnemiopsis (mnemiopsin) and Beroe ovata (berovin), those isolated from the coelenterates Aequorea (aequorin), Obelia (obelin), Pelagia , the Renilla luciferase, the luciferases isolated from the mollusca Pholas (pholasin), the luciferases isolated from fish, such as Aristostomias, Pachystomias and Poricthys and from the ostracods, such as Cypridina (also referred to as Vargula ).
[0111] The majority of commercial bioluminescence applications are based on firefly luciferase [ Photinus pyralis ]. One of the first and still widely used assays involves the use of firefly luciferase to detect the presence of ATP. It is also used to detect and quantify other substrates or co-factors in the reaction. Any reaction that produces or utilizes NAD(H), NADP(H) or long chain aldehyde, either directly or indirectly, can be coupled to the light-emitting reaction of bacterial luciferase.
[0112] Another luciferase system that has been used commercially for analytical purposes is the Aequorin photoprotein system. The purified jellyfish photoprotein, aequorin, is used to detect and quantify intracellular Ca ++ and its changes under various experimental conditions. The Aequorin is relatively small [about 20 kDa], nontoxic, and can be injected into cells in quantities adequate to detect calcium over a large concentration range [3×10 −7 to 10 −4 M].
[0113] Because of their analytical utility, many luciferases and substrates have been studied and well-characterized and are commercially available. Firefly luciferase is available from Sigma, St. Louis, Mo., and Boehringer Mannheim Biochemicals, Indianapolis, Ind.; recombinantly produced firefly luciferase and other reagents based on this gene or for use with this protein are available from Promega Corporation, Madison, Wis.; the aequorin photoprotein luciferase from jellyfish and luciferase from Renilla are commercially available from Prolume, Inc. (Pinetop, Ariz.); coelenterazine, the naturally-occurring substrate for these luciferases, is available from Invitrogen Molecular Probes (Carlsbad, Calif.) and Prolume, Inc. (Pinetop, Ariz.). These luciferases and related reagents are used as reagents for diagnostics, quality control, environmental testing and other such analyses.
[0114] Preferred luciferases for use herein are the Aequorin protein, Renilla luciferase and Cypridina (also called Vargula ) luciferase. Also, preferred are luciferases which react to produce red and/or near infrared light. These include luciferases found in species of Aristostomias , such as A. scintillans, Pachystomias, Malacosteus , such as M. niger.
[0115] The bioluminescent generating systems may also require additional components known to those of skill in the art. All bioluminescent reactions require molecular oxygen in the form of dissolved or bound oxygen. Thus, molecular oxygen, dissolved in water or in air or bound to a photoprotein, is the activator for bioluminescence reactions. Depending upon the form of the components, other activators include, but are not limited to, ATP (for firefly luciferase), flavin reductase for regenerating FMNH 2 from FMN (for bacterial systems), and Ca ++ or other suitable metal ions. While most of the systems provided herein will generate light when the luciferase and luciferin are mixed and exposed to air or water, the systems that use photoproteins that have bound oxygen, such as aequorin, will require exposure to Ca ++ or other suitable metal ion, which can be provided in the form of an aqueous composition of a calcium salt. In these instances, addition of a Ca ++ or other suitable metal ion to a mixture of aequorin luciferase and coelenterazine luciferin will result in generation of light. The Renilla system and other Anthozoa systems also require Ca ++ other suitable metal ion.
[0116] Ctenophores, such as Mnemiopsis (mnemiopsin) and Beroe ovata (berovin), and coelenterates, such as Aequorea (aequorin), Obelia (obelin) and Pelagia , produce bioluminescent light using similar chemistry. The Aequorin and Renilla systems are representative and are described in detail herein as exemplary and as among the presently preferred systems. The Aequorin and Renilla systems can use the same luciferin and produce light using the same chemistry, but each luciferase is different.
[0117] The Aequorin luciferase aequorin, as well as, for example, the luciferases mnemiopsin and berovin, is a photoprotein that includes bound oxygen and bound luciferin, requires Ca ++ (or other suitable metal ion) to trigger the reaction, and must be regenerated for repeated use. The Renilla luciferase also benefits from Ca ++ or other suitable metal ion but acts as a true enzyme because it is unchanged during the reaction and it requires dissolved molecular oxygen. See, e.g., Allen, D. G., J. R. Blinks, et al. (1977) “Aequorin luminescence: relation of light emission to calcium concentration—a calcium-independent component.” Science 195(4282): 996-8; Blinks, J. R., F. G. Prendergast, et al. (1976) “Photoproteins as biological calcium indicators.” Pharmacological Reviews 28(1): 1-93.; Charbonneau, H., K. A. Walsh, et al. (1985). “Amino acid sequence of the calcium-dependent photoprotein aequorin.” Biochemistry 24(24): 6762-71; Cormier, M. J., D. C. Prasher, et al. (1989). “The enzymology and molecular biology of the Ca 2+− activated photoprotein, aequorin.” Photochemistry & Photobiology 49(4): 509-12.; Hannick, L. I., D. C. Prasher, et al. (1993). “Preparation and initial characterization of crystals Inouye, S. (2007). “Expression, purification and characterization of calcium-triggered luciferin-binding protein of Renilla reniformis.” Protein Expression & Purification 52(1): 66-73.; Inouye, S, and Y. Sahara (2008). “Identification of two catalytic domains in a luciferase secreted by the copepod Gaussia princeps.” Biochemical & Biophysical Research Communications 365(1): 96-101; Inouye, S, and S. Sasaki (2006). “Blue fluorescent protein from the calcium-sensitive photoprotein aequorin: catalytic properties for the oxidation of coelenterazine as an oxygenase.” FEBS Letters 580(8): 1977-82.; Inouye, S, and S. Sasaki (2007). “Imidazole-assisted catalysis of luminescence reaction in blue fluorescent protein from the photoprotein aequorin.” Biochemical & Biophysical Research Communications 354(3): 650-5.; Inouye, S, and O, Shimomura (1997). “The use of Renilla luciferase, Oplophorus luciferase, and apoaequorin as bioluminescent reporter protein in the presence of coelenterazine analogues as substrate.” Biochemical & Biophysical Research Communications 233(2): 349-53.; Inouye, S., K. Watanabe, et al. (2000). “Secretional luciferase of the luminous shrimp Oplophorus gracilirostris : cDNA cloning of a novel imidazopyrazinone luciferase(1).” FEBS Letters 481(1): 19-25.; Liu, Z. J., G. A. Stepanyuk, et al. (2006). “Crystal structure of obelin after Ca 2+− -triggered bioluminescence suggests neutral coelenteramide as the primary excited state.” Proceedings of the National Academy of Sciences of the United States of America 103(8): 2570-5.; Loening, A. M., T. D. Fenn, et al. 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Structural changes concomitant with calcium-independent light emission.” Biochemistry 24(16): 4280-7.; Shimomura, O. (1986). “Isolation and properties of various molecular forms of aequorin.” Biochemical Journal 234(2): 271-7.; Shimomura, O. (1995). “Cause of spectral variation in the luminescence of semisynthetic aequorins.” Biochemical Journal 306(Pt 2): 537-43.; Shimomura, O. (1995). “Luminescence of aequorin is triggered by the binding of two calcium ions.” Biochemical & Biophysical Research Communications 211(2): 359-63.; Shimomura, O. (1995). “A short story of aequorin.” Biological Bulletin 189(1): 1-5.; Shimomura, O. (1997). “Membrane permeability of coelenterazine analogues measured with fish eggs.” Biochemical Journal 326(Pt 2): 297-8.; Shimomura, O. (2005). “The discovery of aequorin and green fluorescent protein.” Journal of Microscopy 217(Pt 1): 1-15.; Shimomura, O., P. R. Flood, et al. (2001). “Isolation and properties of the luciferase stored in the ovary of the scyphozoan medusa Periphylla periphylla.” Biological Bulletin 201(3): 339-47.; Shimomura, O. and S. Inouye (1999). “The in situ regeneration and extraction of recombinant aequorin from Escherichia coli cells and the purification of extracted aequorin.” Protein Expression & Purification 16(1): 91-5.; Shimomura, O. and F. H. Johnson (1969). “Properties of the bioluminescent protein aequorin.” Biochemistry 8(10): 3991-7.; Shimomura, O. and F. H. Johnson (1970). “Mechanisms in the quantum yield of Cypridina bioluminescence.” Photochemistry & Photobiology 12(4): 291-5.; Shimomura, O. and F. H. Johnson (1971). “Mechanism of the luminescent oxidation of cypridina luciferin.” Biochemical & Biophysical Research Communications 44(2): 340-6.; Shimomura, O. and F. H. Johnson (1972). “Structure of the light-emitting moiety of aequorin.” Biochemistry 11(9): 1602-8.; Shimomura, O. and F. H. Johnson (1973). “Further data on the specificity of aequorin luminescence to calcium.” Biochemical & Biophysical Research Communications 53(2): 490-4.; Shimomura, O. and F. H. Johnson (1975). “Chemical nature of bioluminescence systems in coelenterates.” Proceedings of the National Academy of Sciences of the United States of America 72(4): 1546-9.; Shimomura, O. and F. H. Johnson (1975). “Regeneration of the photoprotein aequorin.” Nature 256(5514): 236-8.; Shimomura, O. and F. H. Johnson (1978). “Peroxidized coelenterazine, the active group in the photoprotein aequorin.” Proceedings of the National Academy of Sciences of the United States of America 75(6): 2611-5.; Shimomura, O., F. H. Johnson, et al. (1974). “Mechanism of the luminescent intramolecular reaction of aequorin.” Biochemistry 13(16): 3278-86.; Shimomura, O., F. H. Johnson, et al. (1961). “Purification and properties of Cypridina luciferase.” Journal of Cellular & Comparative Physiology 58: 113-23.; Shimomura, O., Y. Kishi, et al. (1993). “The relative rate of aequorin regeneration from apoaequorin and coelenterazine analogues.” Biochemical Journal 296(Pt 3): 549-51.; Shimomura, O., T. Masugi, et al. (1978). “Properties and reaction mechanism of the bioluminescence system of the deep-sea shrimp Oplophorus grachlorostris.” Biochemistry 17(6): 994-8.; Shimomura, O., B. Musicki, et al. (1989). “Semi-synthetic aequorins with improved sensitivity to Ca2+ ions.” Biochemical Journal 261(3): 913-20.; Shimomura, O., B. Musicki, et al. (1993). “Light-emitting properties of recombinant semi-synthetic aequorins and recombinant fluorescein-conjugated aequorin for measuring cellular calcium.” Cell Calcium 14(5): 373-8.; Shimomura, O. and A. Shimomura (1981). “Resistivity to denaturation of the apoprotein of aequorin and reconstitution of the luminescent photoprotein from the partially denatured apoprotein.” Biochemical Journal 199(3): 825-8.; Shimomura, O. and K. Teranishi (2000). “Light-emitters involved in the luminescence of coelenterazine.” Luminescence 15(1): 51-8.; Shimomura, O., C. Wu, et al. (1998). “Evaluation of five imidazopyrazinone-type chemiluminescent superoxide probes and their application to the measurement of superoxide anion generated by Listeria monocytogenes.” Analytical Biochemistry 258(2): 230-5.
[0118] This system is among the preferred systems for use herein. As will be evident, since the aequorin photoprotein includes noncovalently bound luciferin and molecular oxygen, it is suitable for storage in this form as a lyophilized powder or encapsulated into a selected delivery vehicle. The system can be encapsulated into pellets, such as liposomes or other delivery vehicles. When used, the vehicles are contacted with a composition, even tap water, that contains Ca ++ or other suitable metal ion, to produce a mixture that glows.
[0119] It is also understood that these mixtures will also contain any additional salts or buffers or ions that are necessary for each reaction to proceed. Since these reactions are well-characterized, those of skill in the art will be able to determine precise proportions and requisite components. Selection of components will depend upon the apparatus, article of manufacture and luciferase. Factors for consideration in selecting a bioluminescent-generating system, include, but are not limited to: the targeting agent used in combination with the bioluminescence; the medium in which the reaction is run; stability of the components, such as temperature or pH sensitivity; shelf life of the components; sustainability of the light emission, whether constant or intermittent; availability of components; desired light intensity; color of the light; and other such factors.
[0120] D. Methods of Use
[0121] In all embodiments, all but one component, either the luciferase or luciferin, of a bioluminescence generating system will be mixed or packaged together or otherwise combined. The mixture and the remaining component will be separately delivered to a tissue area of interest to activate bioluminescence in the subject.
[0122] In one preferred embodiment for use in surgical procedures, a targeting agent conjugate includes a targeting agent that binds to targeted tissue coupled to either the mixture or the remaining component. The other composition (the remaining component or the mixture) is then administered to the tissue, causing initiation of bioluminescence. For example, the targeting agent conjugate can administered via injection or other suitable route that causes the targeting agent conjugate to bind to targeted tissue by interaction with a tissue-specific cell surface protein. During surgery the tissue is contacted, with the other composition, typically by spraying the area or local injection, and any tissue to which conjugate is bound will glow. This embodiment is typical but not limited to the sentinel lymph node application described herein.
[0123] However, surface binding to target tissue is not a mandatory step or method of the invention. The bioluminescent generating system components may be mixed immediately prior to infusion, or may be mixed during infusion by the use of a simple Y tube, where one arm delivers the enzyme and one arm delivers substrate, or may be activated by sequential administration where one of the components, luciferin or luciferase, is delivered first, follow by subsequent delivery of the other component to achieve bioluminescence.
[0124] The glow should be sufficient to see under dim visible light or, if necessary, in the dark. This is typical but not limited to the bioluminescent cholangiography and bowel anastomotic patency testing methods described herein, whereby the duct or hollow viscus is accessed with an angio-catheter or similar catheter or cannula which is connected to a short length of a Y-tubing which is used to infuse the bioluminescence generating system (or luciferin and luciferase). Surgical viewing may be by naked eye or endoscopic methods as described. For navigational or diagnostic mapping applications intra-operative administration of the bioluminescent agent is via any suitable route, whereby the agent fills and illuminates the tubes, ducts, lumens, chambers, vessels or hollow organs.
[0125] In general, since the result to be achieved is the production of light visible to the naked eye for qualitative, not quantitative, diagnostic purposes, the precise proportions and amounts of components of the bioluminescence reaction need not be stringently determined or met. They must be sufficient to produce light. Generally, an amount of luciferin and luciferase sufficient to generate a visible glow is used; this amount can be readily determined empirically and is dependent upon the selected system and selected application. Where quantitative measurements are required, more precision may be required.
[0126] Higher concentrations may be used if the glow is not sufficiently bright. Alternatively, a microcarrier coupled to more than one luciferase molecule linked to a targeting agent may be utilized to increase signal output. Also because the conditions in which the reactions are used are not laboratory conditions, and the components are subject to storage, higher concentration may be used to overcome any loss of activity.
[0127] E. Reaction Mixture Formulations
[0128] Luciferase for use in accordance with the invention will be provided at a concentration of between about 0.01 mg and 100 mg per liter of reaction mixture (the total of all components of the bioluminescence mixture). In embodiments in which the luciferase acts catalytically and does not need to be regenerated, lower amounts of luciferase can be used. In those in which it is changed during the reaction, it also can be replenished; typically higher concentrations will be selected. In most typical applications, the luciferase will be provided at a concentration of 0.1 to 20 mg, preferably 0.1 to 10 mg, more preferably between about 1 and 10 mg per liter of reaction mixture. Concentrations of at least 1 mg or more are preferred for a brighter result.
[0129] Luciferin will be provided at a concentration of between about 0.01 mg and 100 mg per liter of reaction mixture, and In most typical applications, the luciferin will be provided at a concentration of 0.1 to 20 mg, preferably 0.1 to 10 mg, more preferably between about 1 and 10 mg per liter of reaction mixture. Concentrations of at least 1 mg or more are preferred. Additional luciferin can be added to many of the reactions to continue the reaction. When preparing coated substrates, coating compositions containing higher concentrations of the luciferase or luciferin may be used.
[0130] The reaction mixture will contain additional ingredients as needed to enhance viscosity, adhesion, or to activate the bioluminescent reaction may be included in amounts from about 0.01 mg/l, to about 10 mg/l or more of the reaction mixture. This can include but is not limited to polyethylene glycols of molecular weights from 400 to 20,000; water-soluble cellulose esters such as methylcellulose, ethylcellulose, carboxyethyl cellulose, carboxymethyl celluose; bacterially-derived carbohydrates such as dextran and beta-cyclodextrin, as well as chemically-modified cyclodextrins well known to those skilled in the art; chemically-modified starches; albumin proteins including ovalbumin, human serum albumin, bovine serum albumin, canine serum albumin, and feline serum albumin; simple alcohols such as glycerol, 1,3-propanediol, and ethanol; carbohydrate alcohols such as sorbitol, mannitol, pentaerythreitol, and water soluble esters thereof; non-reducing sugars, biologically-compatible fluorinated compounds which increase oxygen transport, including but not limited to perfluorotributylamine, perfluorodecalin, and perfluoroalcohols and their esters; solubilizers and nonionic and zwiterionic detergents including but not limited to the Tween, Pluronic, Triton series and cholic acid, sodium desoxycholate, CHAPS (Cholamidopropanesulfonate), biologically compatible organic buffers typified by but not limited to TRIS, BIS-TRIS, HEPES, MES, and inorganic ions typified by but not limited to Calcium ion (Ca ++ ).
[0131] Thus, for example, 5 mg of luciferin, such as coelenterazine, in one liter of water will glow brightly for at least about 10 to 20 minutes, depending on the temperature of the water, when about 10 mgs of luciferase, such as aequorin photoprotein luciferase or luciferase from Renilla , is added thereto in presence of Ca ++ . Increasing the concentration of luciferase, for example, to 100 mg/L, provides a particularly brilliant light display.
[0132] It is understood, that concentrations and amounts to be used depend upon the selected bioluminescence generating system but these may be readily determined empirically. Proportions, particularly those used when commencing an empirical determination, are generally those used for analytical purposes, and amounts or concentrations are at least those used for analytical purposes, but the amounts can be increased, particularly if a sustained and brighter glow is desired.
[0133] F. Aequorin Systems
[0134] The bioluminescence photoprotein aequorin is isolated from a number of species of the jellyfish Aequorea . It is a 22 kilodalton [kDa] molecular weight peptide complex. The native protein contains oxygen and a heterocyclic compound coelenterazine, a luciferin, noncovalently bound thereto. The protein contains three calcium binding sites. Upon addition of trace amounts Ca ++ or other suitable metal ion, such as strontium to the photoprotein, it undergoes a conformational change that catalyzes the oxidation of the bound coelenterazine using the protein-bound oxygen. Luminescence is triggered by calcium, which releases oxygen and the luciferin substrate producing apoaequorin. Energy from this oxidation is released as a flash of blue light, centered at 469 nm. Concentrations of calcium ions as low as 10 −6 M are sufficient to trigger the oxidation reaction. Aequorin does not require dissolved oxygen.
[0135] The aequorin luciferin coelenterazine is a molecule having Structure I shown in FIG. 2 , and analogs and sulfated derivatives thereof.
[0136] The reaction of coelenterazine when bound to the aequorin photoprotein with bound oxygen and in the presence of Ca ++ is shown in FIG. 3 .
[0137] Naturally-occurring apoaequorin is not a single compound but rather is a mixture of microheterogeneous molecular species. Aequoria jellyfish extracts contain as many as twelve distinct variants of the protein. DNA encoding numerous forms has been isolated.
[0138] Numerous isoforms of the aequorin apoprotein been isolated. DNA encoding these proteins has been cloned, and the proteins and modified forms thereof have been produced using suitable host cells. DNA encoding apoaequorin or variants thereof is useful for recombinant production of high quantities of the apoprotein. The preferred aequorin is produced using DNA, and known to those of skill in the art or modified forms thereof. The DNA encoding aequorin is expressed in a host cell, such as E. coli , isolated and reconstituted to produce the photoprotein. Of interest herein are forms of the apoprotein that have been modified so that the bioluminescent activity is greater than unmodified apoaequorin.
[0139] The photoprotein can be reconstituted by combining the apoprotein, such as a protein recombinantly produced in E. coli , with the luciferin, coelenterazine (preferably a sulfated derivative thereof, or an analog thereof), such as a synthetic coelenterazine, in the presence of molecular oxygen and a reducing agent such as 2-mercaptoethanol, and also EDTA or EGTA to tie up any Ca ++ to prevent triggering the oxidation reaction until desired. (DNA encoding a modified form of the apoprotein that does not require 2-mercaptoethanol for reconstitution is also possible). The constituents of the bioluminescence generating reaction can be mixed under appropriate conditions to regenerate the photoprotein and concomitantly have the photoprotein produce light.
[0140] For use in certain embodiments herein, the apoprotein and other components of the aequorin bioluminescence generating system are packaged or provided as a mixture, which, when desired, is subjected to conditions under which the photoprotein reconstitutes from the apoprotein, luciferin and oxygen. Particularly preferred are forms of the apoprotein that do not require a reducing agent, such as 2-mercaptoethanol, for reconstitution. The photoproteins and luciferases from related species, such as Obelia are also contemplated for use herein. DNA encoding the Calcium-activated photoprotein obelin from the hydroid polyp Obelia longissima is known and available [see, e.g., Deng, L., S. V. Markova, et al. (2004). “Preparation and X-ray crystallographic analysis of the Ca 2+− -discharged photoprotein obelin.” Acta Crystallographica Section D - Biological Crystallography 60(Pt 3): 512-4.]. In general for use herein, the components of the bioluminescence are packaged or provided so that there is insufficient metal ions to trigger the reaction. When used, the trace amounts of triggering metal ion, particularly Ca ++ is contacted with the other components. For a more sustained glow, aequorin can be continuously reconstituted or can be added or can be provided in high excess.
[0141] The light reaction is triggered by adding Ca ++ at a concentration sufficient to overcome the effects of the chelator and achieve the 10 −6 M concentration. Because such low concentrations of Ca ++ can trigger the reaction, for use in the methods herein, higher concentrations of chelator may be included in the compositions of photoprotein. Accordingly, higher concentrations of added Ca ++ in the form of a calcium salt will be required. Precise amounts may be empirically determined. For use herein, it may be sufficient to merely add water to the photoprotein, which is provided in the form of a concentrated composition or in lyophilized or powdered form. Thus, for purposes herein, addition of small quantities of Ca ++ , such as those present in phosphate buffered saline (PBS) or other suitable buffers or the moisture on the tissue to which the compositions are contacted, should trigger the bioluminescence reaction.
[0142] The photoprotein aequorin, which contains apoaequorin bound to a coelenterate luciferin molecule, and Renilla luciferase, can use the same coelenterate luciferin. The aequorin photoprotein catalyses the oxidation of coelenterate luciferin [coelenterazine] to oxyluciferin [coelenteramide] with the concomitant production of blue light [lambda max=469 nm]. (See FIG. 3 ).
[0143] The sulfate derivative of the coelenterate luciferin [lauryl-luciferin] is particularly stable in water, and thus may be used in a coelenterate-like bioluminescent system. In this system, adenosine diphosphate (ADP) and a sulphakinase are used to convert the coelenterazine to the sulphated form. Sulfatase is then used to reconvert the lauryl-luciferin to the native coelenterazine. Thus, the more stable lauryl-luciferin is used in the item to be illuminated and the luciferase combined with the sulfatase are added to the luciferin mixture when illumination is desired.
[0144] The bioluminescent system of Aequorea is particularly suitable for use in the methods herein. The particular amounts and the manner in which the components are provided depend upon the type of neoplasia or specialty tissue to be visualized. This system can be provided in lyophilized form, which will glow upon addition of Ca ++ . It can be encapsulated, linked to microcarriers, such as microbeads, or in as a compositions, such as a solution or suspension, preferably in the presence of sufficient chelating agent to prevent triggering the reaction. The concentration of the aequorin photoprotein will vary and can be determined empirically. Typically concentrations of at least 0.1 mg/l, more preferably at least 1 mg/l and higher, will be selected. In certain embodiments, 1-10 mg luciferin/100 mg of luciferase will be used.
[0145] G. Renilla Systems
[0146] The Renilla system is representative of coelenterate bioluminesence systems. Renilla , also known as sea pansies, are members of the class of coelenterates Anthozoa, which includes other bioluminescent genera, such as Cavarnularia, Ptilosarcus, Stylatula, Acanthoptilum , and Parazoanthus . Bioluminescent members of the Anthozoa genera contain luciferases and luciferins that are similar in structure [see, e.g., Cormier et al. (1973) J. Cell. Physiol. 81:291-298; see, also Ward et al. (1975) Proc. Natl. Acad. Sci. U.S.A. 72:2530-2534]. The luciferases and luciferins from each of these anthozoans crossreact with one another and produce a characteristic blue luminescence.
[0147] Renilla luciferase and the other coelenterate and ctenophore luciferases, such as the aequorin photoprotein, use imidazopyrazine substrates, particularly the substrates generically called coelenterazine [see, Formula I ( FIG. 2 ) above]. Other genera that have luciferases that use a coelenterazine include: squid, such as Chiroteuthis, Eucleoteuthis, Onychoteuthis, Watasenia , cuttlefish, Sepiolina ; shrimp, such as Oplophorus, Acanthophyra, Sergestes , and Gnathophausia ; deep-sea fish, such as Argyropelecus, Yarella, Diaphus, Gonadostomias and Neoscopelus. Renilla luciferase does not, however, have bound oxygen, and thus requires dissolved oxygen in order to produce light in the presence of a suitable luciferin substrate. Since Renilla luciferase acts as a true enzyme, i.e., it does not have to be reconstituted for further use, the resulting luminescence can be long-lasting in the presence of saturating levels of luciferin. Also, Renilla luciferase is relatively stable to heat. Renilla luciferase, DNA encoding Renilla luciferase, and use of the DNA to produce recombinant luciferase, as well as DNA encoding luciferase from other coelenterates, are well known. (See for example Bhaumik, S., X. Z. Lewis, et al. (2004). “Optical imaging of Renilla luciferase, synthetic Renilla luciferase, and firefly luciferase reporter gene expression in living mice.” Journal of Biomedical Optics 9(3): 578-86.; Inouye, S, and O, Shimomura (1997). “The use of Renilla luciferase, Oplophorus luciferase, and apoaequorin as bioluminescent reporter protein in the presence of coelenterazine analogues as substrate.” Biochemical & Biophysical Research Communications 233(2): 349-53.; Loening, A. M., T. D. Fenn, et al. (2007). “Crystal structures of the luciferase and green fluorescent protein from Renilla reniformis.” Journal of Molecular Biology 374(4): 1017-28. Loening, A. M., T. D. Fenn, et al. (2006). “Consensus guided mutagenesis of Renilla luciferase yields enhanced stability and light output.” Protein Engineering, Design & Selection 19(9): 391-400.; Loening, A. M., A. M. Wu, et al. (2007). “Red-shifted Renilla reniformis luciferase variants for imaging in living subjects.” Nature Methods 4(8): 641-3.)
[0148] The DNA encoding Renilla luciferase and host cells containing such DNA provide a convenient means for producing large quantities of the enzyme. When used herein, the Renilla luciferase can be packaged in lyophilized form, encapsulated in a vehicle, either by itself or in combination with the luciferin substrate. Prior to use the mixture is contacted with an aqueous composition, preferably a phosphate buffered saline pH 7-8; dissolved O 2 will activate the reaction. Final concentrations of luciferase in the glowing mixture will be on the order of 0.01 to 1 mg/l or more. Concentrations of luciferin will be at least about 10 −8 M, but preferably are 1 to 100 or more orders of magnitude higher to produce a long lasting bioluminescence.
[0149] In certain embodiments herein, about 1 to 10 mg, or preferably 2-5 mg, more preferably about 3 mg of coelenterazine will be used with about 100 mg of Renilla luciferase. The precise amounts, of course can be determined empirically, and, also will depend to some extent on the ultimate concentration and application. In one example, the addition of about 0.25 ml of a crude extract from the bacteria that express Renilla to 100 ml of a suitable assay buffer and about 0.005 mg of coelenterazine was sufficient to produce a visible and lasting glow
[0150] Lyophilized mixtures, and compositions containing the Renilla luciferase are also provided. The luciferase or mixtures of the luciferase and luciferin may also be encapsulated into a suitable delivery vehicle, such as a liposome, glass particle, capillary tube, drug delivery vehicle, gelatin, time release coating or other such vehicle. The luciferase may also be linked to a substrate, such as biocompatible materials.
[0151] G. Crustacean, Particularly Cyrpidina Systems
[0152] The ostracods, such as Vargula serratta, V. hilgendorfii and V. noctiluca are small marine crustaceans, sometimes called sea fireflies. These sea fireflies are found in the waters off the coast of Japan and emit light by squirting luciferin and luciferase into the water, where the reaction, which produces a bright blue luminous cloud, occurs. The reaction involves only luciferin, luciferase and molecular oxygen, and, thus, is very suitable for application herein.
[0153] The systems, such as the Vargula bioluminescent systems, are particularly preferred herein because the components are stable at room temperature if dried and powdered and will continue to react even if contaminated. Further, the bioluminescent reaction requires only the luciferin/luciferase components in concentrations as low as 1:40 parts per billion to 1:100 parts per billion, water and molecular oxygen to proceed. Importantly an exhausted system can renew by addition of luciferin.
[0154] Vargula luciferase is water soluble and is among those preferred for use in the methods herein. Vargula luciferase is a 555-amino acid polypeptide that has been produced by isolation from Vargula and also using recombinant technology by expressing the DNA in suitable bacterial and mammalian hosts.
[0155] Methods for purification of Vargula [also known as Cypridina ] luciferase are well known. For example, crude extracts containing the active can be readily prepared by homogenizing or crushing the Vargula shrimp. In other embodiments, a preparation of Cypridina hilgendorfii luciferase can be prepared by immersing stored frozen C. hilgendorfii in distilled water containing, 0.5-5.0 M salt, preferably 0.5-2.0 M sodium or potassium chloride, ammonium sulfate, at 0-30° C., preferably 0-10° C., for 1-48 hr, preferably 10-24 hr, for extraction followed by hydrophobic chromatography and then ion exchange or affinity chromatography.
[0156] The luciferin can be isolated from ground freeze-dried Vargula by heating the extract, which destroys the luciferase but leaves the luciferin intact
[0157] Vargula [also known as Cypridina ] luciferase is preferably produced by expression of cloned DNA encoding the luciferase. DNA encoding the luciferase or variants thereof is introduced into E. coli using appropriate vectors and isolated using standard methods.
[0158] Natural Vargula [also known as Cypridina ] luciferase has a substituted imidazopyrazine nucleus. Analogs thereof well known in the prior art and other compounds that react with the luciferin in a light producing reaction also may be used. Other bioluminescent organisms that have luciferases that can react with the Vargula luciferin include, the genera Apogon, Parapriacanthus and Porichthys.
[0159] The luciferin upon reaction with oxygen forms a dioxetanone intermediate [which includes a cyclic peroxide similar to the firefly cyclic peroxide molecule intermediate]. In the final step of the bioluminescent reaction, the peroxide breaks down to form CO 2 and a molecule with the C═O bond in an electronically excited state. The excited state molecule then returns to the ground state and in this process emits a blue to blue-green light.
[0160] The optimum pH for the reaction is about 7. For purposes herein, any pH at which the reaction occurs may be used. The concentrations of reagents are those normally used for analytical reactions or higher [see, e.g., Thompson et al. (1990) Gene 96:257-262]. Typically concentrations of the luciferase between 0.1 and 10 mg/l, preferably 0.5 to 2.5 mg/l will be used. Similar concentrations or higher concentrations of the luciferin may be used.
[0161] H. Other Fluorescent Protein Systems
[0162] Blue light is produced using the Renilla luciferase or the Aequorea photoprotein in the presence of Ca ++ and the coelenterazine luciferin or analog thereof. By means of Dexter-Forster energy transfer, this light can be converted into a light of a different and longer wavelength if a green fluorescent protein (GFP) is added to the reaction. Green fluorescent proteins, which have been purified and also are used by cnidarians as energy-transfer acceptors. GFPs fluoresce in vivo upon receiving energy from a luciferase-oxyluciferein excited-state complex or a Ca ++ -activated photoprotein. This process is known as Bioluminescent Resonant Energy Transfer (BRET) and has been utilized extensively for a wide variety of biological assay systems. In GFP, the chromophore is series of adjacent modified amino acid residues within the polypeptide. The best characterized GFPs are those of Aequorea and Renilla . For example, a green fluorescent protein from Aequorea Victoria contains 238 amino acids, absorbs blue light and emits green light. Thus, inclusion of this protein in a composition containing the aequorin photoprotein charged with coelenterazine and oxygen, can, in the presence of calcium, result in the production of green light. Thus, it is contemplated that GFPs may be included in the bioluminescence generating reactions that employ the aequorin or Renilla luciferases or other suitable luciferase in order to enhance or alter color of the resulting bioluminescence. Many genetically-altered GFPs are well known in the prior art, and these can produce colors from the blue to the red.
[0163] GFPs are activated by blue light to emit green light and thus may be used in the absence of luciferase and in conjunction with an external light source to illuminate neoplasia and specialty tissues, as described herein. Similarly, blue fluorescent proteins (BFPs), such as from Vibrio fischeri, Vibrio harveyi or Photobacterium phosphoreum , may be used in conjunction with an external light source of appropriate wavelength to generate blue light. In particular, GFPs, and/or BFPs or other such fluorescent proteins may be used in the methods described herein using a targeting agent conjugate by illuminating the conjugate with light of an appropriate wavelength to cause the fluorescent proteins to fluoresce.
[0164] Such systems are particularly of interest because no luciferase is needed to activate the photoprotein. These fluorescent proteins may also be used in addition to bioluminescence generating systems to enhance or create an array of different colors.
[0165] I. Phycobiliprotein Systems
[0166] Phycobiliproteins are water soluble fluorescent proteins derived from cyanobacteria. These proteins have been used as fluorescent labels in immunoassays; the proteins have been isolated and DNA encoding them is also available; the proteins are commercially available from, for example, ProZyme, Inc., San Leandro, Calif.
[0167] In these organisms, the Phycobiliproteins are arranged in subcellular structures termed phycobilisomes, and function as accessory pigments that participate in photosynthetic reactions by absorbing visible light and transferring the derived energy to chlorophyll via a direct fluorescence energy transfer mechanism.
[0168] Two classes of phycobiliproteins are known based on their color: phycoerythrins (red) and phycocyanins (blue), which have reported absorption maximal between 490 and 570 nm and between 610 and 665 nm, respectively. Phycoerythrins and phycocyanins are heterogeneous complexes composed of different ratios of alpha and beta monomers to which one or more class of linear tetrapyrrole chromophores are covalently bound. Particular phycobiliproteins may also contain a third subunit which often associated with aggregate proteins.
[0169] All phycobiliproteins contain either phycothrombilin or phycoerythobilin chromophores, and may also contain other bilins phycourobilin, cryptoviolin or the 697 nm bilin. The subunit is covalently bound with phycourobilin which results in the 495-500 nm absorption peak of B- and R-phycoerythrins. Thus, the spectral characteristics of phycobiliproteins may be influenced by the combination of the different chromophores, the subunit composition of the apophycobiliproteins and/or the local environment effecting the tertiary and quaternary structure of the phycobiliproteins.
[0170] As described above for GFPs and BFPs, phycobiliproteins are also activated by visible light of the appropriate wavelength and, thus, may be used in the absence of luciferase and in conjunction with an external light source to illuminate neoplasia and specialty tissues, as described herein. These proteins may be used in combination with other fluorescent proteins and/or bioluminescence generating systems to produce an array of colors or to provide different colors over time. Attachment of phycobiliproteins to solid support matrices is known. Therefore, phycobiliproteins may be coupled to microcarriers coupled to one or more components of the bioluminescent reaction, preferably a luciferase, to convert the wavelength of the light generated from the bioluminescent reaction. Microcarriers coupled to one or more phycobiliproteins may be used in any of the methods provided herein.
[0171] The conversion of blue or green light to light of a longer wavelength, i.e., red or near infra-red, is particularly preferred for the visualization of deep neoplasias or specialty tissues using a laparoscope or computer tomogram imaging system. Thus, when a change in the frequency of emitted light is desired, the phycobiliprotein, or other spectral shifter, such as synthetic fluorochrome, green fluorescent proteins, red fluorescent proteins, and substrates altered chemically or enzymatically to cause shifts in frequency of emission can be included with the bioluminescent generating components.
[0172] J. Membrane Permeant Analogs of Coelenterazine
[0173] The present invention may not be limited to the above embodiments, but may use various bioluminescent substances other than shown in the embodiments.
[0174] This invention specifically includes compositions which are membrane permeant analogs of coelenterazine, the substrate for renilla luciferase, having the following Structure II:
[0000]
[0000] wherein R4 and R5 may independently be alkyl or aralkyl, and R4 may be aryl or optionally substituted aryl, aralkyl or optionally substituted aralkyl, and R5 may be alkyl, optionally substituted alkyl, alkoxy, aralkyl, or optionally substituted aralkyl, aryl, or a heterocycle. Structure II is also shown in FIG. 4 .
[0175] The present invention further includes the related class of membrane permeant coelenterazine analogs which are exemplified by the following Structure III:
[0000]
[0000] wherein p may be an integer ranging from 1 to 20. Structure III is also shown in FIG. 5 .
[0176] The present invention further includes the related class of membrane permeant coelenterazine analogs which are exemplified by the following Structure IV:
[0000]
[0000] wherein R1, R2, and R3 are independently alkyl, optionally substituted alkyl, alkenyl, or aralkyl. Structure IV is also shown in FIG. 6 :
[0177] The present invention further includes the related class of membrane permeant coelenterazine analogs which are exemplified by the following Structure V:
[0000]
[0000] in which r may be an integer from 1 to 20. Structure V is also shown in FIG. 7 .
[0178] The present invention further includes the related class of membrane permeant coelenterazine analogs which are exemplified by the following by the following Structure VI:
[0000]
[0000] in which r may be an integer from 1 to 20 and R6 may be alkyl, aryl, aralkyl, optionally substituted alkyl, optionally substituted aryl, optionally substituted aralkyl, or alkoxyalkyl. Structure VI is also shown in FIG. 8 .
[0179] The steps of the general synthetic schema for preparation of the above identified membrane permeant analogs of coelenterazine is shown in FIGS. 36-39 .
[0180] The procedure for the preparation of substituted glyoxal for coupling with coelenterazine is shown generally in FIGS. 9 , 10 , and 11 and is specifically described in the following Example.
[0181] Glyoxal Synthesis Step 1
[0182] Glyoxal synthesis step 1 is shown in FIG. 12 . In a 100 mL Schlenk tube containing 46% Pd—C aerogel (110 mg, 0.47 mmol) were placed Cul (190 mg, 1 mmol), Ph 3 P (250 mg, 1 mmol), 4-iodoacetophenone (0.79 mmol), i-Pr 2 NH (0.17 mL, 1.2 mmol), deca-1-yne (8 mmol), and previously degassed dimethylformamide (DMF) (0.5 mL) under argon. This was magnetically stirred at 100° C. for a 16-h period. After cooling, the solution was removed and the catalyst was washed with DMF (3×3 mL) and recovered. The combined organic extracts were diluted in Et 2 O (100 mL), washed with brine (3×30 mL), dried (annh. MgSO 4 ), and evaporated at reduced pressure. The residue (a yellow oil) was purified by preparative high pressure column chromatography (silica gel, n-hexane-EtOAc, 99.5:0.5) to give the product, 1-(4-(dec-1-ynyl)phenyl)ethanone as a yellow oil; yield: 96% 1 H NMR (CDCl 3 ): d=7.87 d,(2H), 7.53 (d, 2H), 2.55 (s, 3H), 2.03 (2H), 1.46 (2H), 1.31 (m, 10H), 0.86 (3H) 13C NMR (CDCl 3 ): d=CH3,14.0; CH2 22.6; CH2 31.5,; CH2 29.3; CH2 28.7; CH2 28.4; CH2 28.7; CH2 18.7; C (alkyne) 100.1; C (alkyne) 78.5; CH3 29.3; C (carbonyl) 199.8; C 136.4; CH 128.4; CH 132.2; C 127.1; CH 132.2; CH 128.4
[0183] Glyoxal Synthesis Step 2
[0184] Glyoxal synthesis step 2 is shown in FIG. 13 . The Compound is protected using method of N. H. Andersen and H.-S. Uh, Synth. Commun., 3, 125 (1973); glycol (1.1 mole), oxalic acid (2 mole equivalents) acetonitrile at 25 C for 1 hour. Workup; extraction with ethyl acetate (3×), extract with 1% solution of Girard's reagent P, wash with 8× of water, dry over annhydrous Magnesium sulfate, rotovap (Buchi) to yield oil, flash purify oil through a small column of silica gel. 1 H NMR (CDCl 3 ): d=7.34 d,(2H), 7.13 (d, 2H), 5.27 (1H), 3.85, 3.95 (m, 4H) 3.59 (1H) 2.55 (s, 3H), 2.03 (2H), 1.46 (2H) 1.30 (m, 10H), 0.86 (3H). H), 1.31 (m, 10H), 0.86 (3H).
[0185] Glyoxal Synthesis Step 3
[0186] Glyoxal synthesis step 3 is shown in FIG. 14 . The electrocarboxylation with CO 2 is carried out in a high-pressure stainless-steel undivided cell designed to fit into a modified Paar bomb equipped with electrical feedthroughs. The electrolytic cell is fitted with a nickel sheet (3 cm×4 cm×0.05 cm) as the cathode and an aluminum (or magnesium) plate (3 cm×4 cm) as the anode, Prior to the electrolysis, the two electrodes were cleaned with detergent and diluted HCl, washed with distilled water. n-Bu 4 NBr (10 mmol), dried DMF solvent (100 mL), and 2-(1-(4-(dec-1-ynyl)phenyl)ethyl)-1,3-dioxolane (6.28 gm, 20 mmol) are added to the cell. Carbon dioxide is then charged into the bomb after the cell was sealed. The electrolysis was performed at a suitable constant current until 4 F per mole of starting substrates had been passed through the cell at room temperature. The electrolyte solution was continuously stirred by a magnetic stirrer during the electrolysis. At the end of the electrolysis, the solvent was removed at reduced pressure, and the residue was acidified with dilute HCl and extracted with diethyl ether. The ether phase was washed twice with distilled water. After evaporation of ether, the product was purified by flash chromatography. Yield 80% 1 H NMR (CDCL 3 ): CH 7.26 (aromatic); CH2 3.90 and CH4.90 (1,3-dioxolan); CH3 0.86; CH2 1.37 (14H) CH 1.50 13 C NMR 165.9; 165.1; 147.7; 143.7; 141.0; 137.4; 129.7; 128.5; 126.0; 108.8; 66.8; 38.4; 31.8; 29.7; 27.1; 24.3; 22.5; 14.1 11.5
[0187] Glyoxal Synthesis Step 4
[0188] Glyoxal synthesis step 4 is shown in FIG. 15 . The acid is formed from the anhydride by means of warming in dilute LiOH. The dilithium salt is recrystallized from warm isopropanol-water. The NMR was not taken. In the LC/MS, compound (dilithium salt) gave m/e: 416.24 (100.0%) and some smaller decomposition peaks.
[0189] Glyoxal Synthesis Step 5
[0190] Glyoxal synthesis step 5 is shown in FIG. 16 . The ester is prepared from the acid chloride. The acid chloride is prepared by the procedure of Cvetovich and DiMichele, Organic Process Research & Development 2006, 10, 944-946, from the dilithium salt. A small amount (0.2 mole equivalent) of Cesium carbonate is present as a catalyst. The reaction mixture is added to 1% sodium bicarbonate, extracted 3× with ethyl acetate, and the extracts pooled, dried with magnesium sulfate, and reduced on the rotary evaporator to a thick oil. The material is chromatographed on Silica gel (ethyl acetate-heptane) to give purified ester, yield 71%, TLC, single spot. Mass spectrum: m/e: 684.53 (100.0%) 1 H NMR (CDCL 3 ): 7.26 (m, 3H), 7.08 (m, 3H), 5.27 (1H), 3.9 (m, 4H), 3.90 (m, 4H), 1.96 (m, 2H), 1.56 (m, 4H), 1.37, singlet and multiplet (46H), 0.86 (9H) 13 C NMR: 168.2; 167; 166.0; 147; 141.9; 139.2; 129,7; 126.2; 108.2; 66.8; 65.6; 31.8 29.7; 27.1; 29.4; 25.8; 22.7; 14.1
[0191] Glyoxal Synthesis Step 6
[0192] Glyoxal synthesis step 6 is shown in FIG. 17 . Deprotection of the glyoxal is achieved with pyridinium tosylate in acetone at 25° C. in a quantitative manner.
[0193] Glyoxal Synthesis Step 7
[0194] Glyoxal synthesis step 7 is shown in FIG. 18 .
[0195] K. Use of Bioluminescence Generating Systems on Test Subjects
[0196] Instillation of a bioluminescent solution into the bile duct, intestinal anastomosis, or ureter during surgery allows excellent instantaneous visualization to the surgeon, potentially preventing damage to these structures. These techniques may also facilitate recognition of leaks or injuries, greatly expediting the surgical procedure. This visualization may be performed using a conventional endoscope or in some methods a modified cooled CCD or CMOS camera specifically adapted for these procedure. These methods are not limited to the above examples, but rather can be applied to any anatomic tube, duct, lumen, vessel, chamber or hollow structure.
[0197] One embodiment of the invention includes the viewing of bioluminescent illumination with a red light background in order that background anatomy with visible light can be viewed at the same time as the bioluminescent image. In terms of human vision, this is optimal if a green signal, generated by the bioluminescent system, and a red signal, generated by a lamp or an LED, are used (Nathans J (1999)). The evolution and physiology of human color vision: insights from molecular genetic studies of visual pigments. Neuron: 299-312. This is accomplished with the aid of a conventional color endoscope camera which has two narrow band interference filters. Endoscopes equipped with interference filters are well known in the prior art for the protection of the surgeon to filter out light from a YAG laser when using this laser for cutting through the endoscope (U.S. Pat. No. 4,916,534, Endoscope, Apr. 10, 1990). Endoscopes with rotating interference filters have been used to remove infrared light from the illuminating lamp (U.S. Pat. No. 5,993,037, Light Source Device for Endoscopes, Nov. 30, 1999). Endoscopes used for fluorescent studies, such as cystoscopes in the bladder, have been equipped with interference filters to isolate the fluorescence signal (U.S. Pat. No. 5,984,861 Endofluorescence Imaging Module For An Endoscope, Nov. 16, 1999).
[0198] As to the requisite interference filters, the construction of such filters is well known in the prior art in the visible regions of the electromagnetic spectrum (U.S. Pat. No. 2,890,624, Interference Color Filter With Blue Absorbing Layers Jun. 16, 1959) and infrared (U.S. Pat. No. 4,832,448, Interference Filters May 23, 1989). A dichroic mirror could alternatively be employed in order to reduce the total amount of undesired light admitted in to the system (U.S. Pat. No. 4,047,805, Ripple-Free Dichroic Mirrors, Sep. 13, 1977). Specific bands could also be eliminated if desired (U.S. Pat. No. 5,400,174 Optical Notch Or Minus Filter Mar. 21, 1995) although broadband filters are to be most preferred. The filters could be located at the viewer's end, such as in the glasses of the surgeon (U.S. Pat. No. 6,369,964 Optical Filters For Reducing Eye Strain, During Surgery Apr. 9, 2002) but this is not a highly preferred method because the resolution of the system should be higher if light filtering is done prior to conversion to an electronic signal by the camera. In summary, it is seen that the use of various wide and narrow band interference and dichroic filters is a well known method in the Prior Art to separate a red signal (illuminating the interior of the anatomical structure) from the blue-green signal provided by the bioluminescent composition.
[0199] As to the required source of red light, it could be obtained from a conventional high pressure xenon arc lamp by means of conventional interference filters (U.S. Pat. No. 6,364,829 Autofluorescence Imaging System For Endoscopy Apr. 2, 2002) but is probably most conveniently obtained by the use of a light emitting diode. Recent work in this area has provided high-output narrow band devices which do not have temperature sensitivity or wavelength limitations, an issue with some older devices. For example, see U.S. Pat. No. 6,829,271, Light-Emitting Semiconductor Device Producing Red Wavelength Optical Radiation, Dec. 7, 2004; U.S. Pat. No. 7,071,490 Group Iii Nitride Led With Silicon Carbide Substrate Jul. 4, 2006). These devices are small and can readily be incorporated into the endoscopic probe which enters the patient. The advantage which this presents is that the fiber-optical assembly is not needed to carry the incoming visible or infrared light signal. Indeed, in one modification of the endoscope which is useful in the present context both the camera and the red light source could be located on a trocar-like probe which would enter a cavity within an organ of the patient, and no fiber optical whatsoever would be required. An advantage of a conventional fiber optic-based endoscope would be that a very low light level image-intensified, cooled CCD camera could be employed. For example, see U.S. Pat. No. 7,129,464 Low-Photon Flux Image-Intensified Electronic Camera Oct. 31, 2006.
[0200] However, our bioluminescent studies in animals in accordance with the present application as described in the specification have provided study results of sufficient brightness that use of a cooled CCD camera has not been necessary, nor has an image intensifier been needed. Indeed, it is a major advantage of the methods and procedures described within the present application that simple commercial video and still cameras of consumer-grade quality are more than sufficient to record the bioluminescent signal, and that generally it is as bright as to be visible with the use of an unmodified, off-the-shelf endoscope. Wavelengths other than the red could be used, provided that the CCD camera had adequate sensitivity in the desired wavelength region. Low light level CCD cameras sensitive in the infrared region are well known in the prior are (for example see U.S. Pat. No. 7,016,518, Vehicle license plate imaging and reading system for day and night, Mar. 21, 2006.) Image intensifiers of Generation III and IV are also commercially available which are extremely sensitive in the near-infrared region of the electromagnetic spectrum.
[0201] The membrane permeant analogs of coelenterazine concentrate in hydrophobic regions of various organs, in particular including the central nervous system. The blood-brain barrier (BBB) is an endothelial barrier present in capillaries that course through the brain. A very complex tight-junctional epithelium is integral to this barrier. The BBB significantly impedes entry from blood to brain of virtually all molecules, except those that are small and lipophilic. Certain small molecules and rather surprisingly some very large molecules can readily cross the blood brain barrier in an efficient manner. Except for small hydrophobic molecules which can bind to albumin they do so by active transport. Amino acids which are of course required in the brain are moved across the barrier by a series of specific transporters (Hawkins, R. A., R. L. O'Kane, et al. (2006). “Structure of the blood-brain barrier and its role in the transport of amino acids.” Journal of Nutrition 136(1 Suppl): 218S-26S.). Most large molecules are moved across the BB by receptor-mediated transport. The best known of these is the transferrin receptor but evidence indicates that other growth factors and cytokines such as ferritin (Fisher, J., K. Devraj, et al. (2007). “Ferritin: a novel mechanism for delivery of iron to the brain and other organs.” American Journal of Physiology—Cell Physiology 293(2): C641-9) and TGF-beta can cross the BBB (McLennan, I. S., M. W. Weible, 2nd, et al. (2005). “Transport of transforming growth factor-beta 2 across the blood-brain barrier.” Neuropharmacology 48(2): 274-82). One of the more important transporters is P-glycoprotein, also present in relatively high concentrations on brain capillaries. (Sanderson, L., A. Khan, et al. (2007). “Distribution of suramin, an antitrypanosomal drug, across the blood-brain and blood-cerebrospinal fluid interfaces in wild-type and P-glycoprotein transporter-deficient mice.” Antimicrobial Agents & Chemotherapy 51(9): 3136-46.) That is, it generally transports back into the blood a variety of lipophilic molecules that enter the brain and is in maintaining therapeutic concentrations of drugs in the brain (Parepally, J. M., H. Mandula, et al. (2006). “Brain uptake of nonsteroidal anti-inflammatory drugs: ibuprofen, flurbiprofen, and indomethacin.” Pharmaceutical Research 23(5): 873-81). Various therapeutic strategies have been devised to couple drugs to peptides and even proteins which carry them across the BBB by carrier-mediated transport (de Boer, A. G. and P. J. Gaillard (2007). “Strategies to improve drug delivery across the blood-brain barrier.” Clinical Pharmacokinetics 46(7): 553-76.). The important point is that very hydrophobic, non-charged small molecules which bind to albumin will be generally transported efficiently across the blood brain barrier provided that they are not back-transported by the P-glycoprotein receptor. (Pardridge W. M., and Mietus, L. J. (1979) Transport of Steroid Hormones through the Rat Blood-Brain Barrier J. Clin. Invest. 64:145). In the present study, we prepared hydrophobic analogues of coelenterazine which bind to albumin and are efficiently transported across the blood-brain barrier. Such analogues can bind efficiently to the tissues of the lymphatics, making the sentinel node detection possible.
[0202] In fact we have found that sentinel node analysis may be performed utilizing coelenterazine and membrane permeant analogs of coelenterazine. We have found that coelenterazine and membrane permeant analogs of coelenterazine can be used for the bioluminescent analysis of lymphatic connection to the sentinel node of a tumor. To do this, the enzyme luciferase, typically but not limited to that from Renilla reniformis , is injected into the lymphatics which surround the tumor in the manner that technetium colloid or blue dye is administered. Then, upon biopsy of the sentinel node, the biopsy specimen is treated with coelenterazine or a membrane permeant analog of coelenterazine. Bioluminescence may be detected using a camera, or a luminometer, or by visual inspection.
[0203] Use of bioluminescence systems in connection with sentinel node analysis will be enhanced by mixing one of the components of the bioluminescence system with sugars or other molecules that are absorbed by cancer cells at a more rapid rate than surrounding tissues.
[0204] Clinical tests using bioluminescence systems as described in this application are described in the following examples.
EXAMPLE 1
[0205] A rat was equipped with bilateral jugular cannulas. To one was applied a solution of coelenterazine (50 mM) in Hank's balanced salt solution and to the opposite jugular cannula was administered Renilla luciferase, 5 mg/ml in Hank's balanced slat solution. An image was obtained and was pseudocoloured with Scion Image according to the light level obtained by a Princeton Instruments camera and is shown at FIG. 19 .
EXAMPLE 2
[0206] A rat was equipped with bilateral jugular cannulas. To one was applied a solution of coelenterazine (50 mM) in Hank's balanced salt solution and to the opposite jugular cannula was administered Renilla luciferase, 5 mg/ml in Hank's balanced slat solution. An image was obtained and was pseudocoloured with Scion Image according to the light level obtained by a Princeton Instruments camera and is shown at FIG. 20 . FIG. 20 illustrates patchy contrast regions in the liver:
EXAMPLE 3
[0207] A rat was equipped with bilateral jugular cannulas. To one was applied a solution of coelenterazine (50 mM) in Hank's balanced salt solution and to the opposite jugular cannula was administered Renilla luciferase, 5 mg/ml in Hank's balanced slat solution. An image was obtained and was pseudocoloured with Scion Image according to the light level obtained by a Princeton Instruments camera and is shown at FIG. 21 . FIG. 21 perfusion of bioluminescence in the whole animal:
EXAMPLE 4
[0208] A duodenal loop in the rat was cannulated and the bioluminescent generating mixture was applied thereto. An image was obtained and was pseudocoloured with Scion Image according to the light level obtained by a Princeton Instruments camera and is shown at FIG. 22 .
EXAMPLE 5
[0209] Two separate cannulas were applied to the duodenum of the rat, and luciferase was administered through one and luciferin through the other under the conditions of example 1. An image was obtained and was pseudocoloured with Scion Image according to the light level obtained by a Princeton Instruments camera and is shown at FIG. 23 .
EXAMPLE 6
[0210] Swine studies. All animal study protocols were approved by the appropriate IACUC, either at the University of Arizona in Tucson, or at the High Quality Research facility located in Ft. Collins, Colo. For these studies, one live pig, approximately 30 kg (anesthetized, non-survival, Arizona site) and one fresh cadaver pig, approximately 30 kg (heparinized, euthanized, Colorado site) were used. A standard open laparotomy operative approach was done to allow use of more than one camera at a time. The color cooled CCD camera used was a Spot R3 supplied by Diagnostic Instruments Inc., Sterling Heights, Mich. This camera is connected by a firewire connection to laptop running Windows XP. The camera is cooled electronically, with its own power source and fan. The camera is controlled and settings adjusted with a Beta Version of the Spot Camera software. Focus is adjusted at the lens for the focal length chosen, between 1 and 2 feet for the open recordings. The videocamera used was a Sony (Sony DCR-SR200) model, which is a hand held camera, mounted on a tripod for the experiments. The image in real time was viewed on the cameras LCD panel or using a small television set. The camera is controlled and settings adjusted on the LCD touch screen. Focus for low light recording is best done in manual mode on the touch screen for the focal length chosen, between 1 and 2 feet for the open recordings.
EXAMPLE 6A
[0211] Swine bioluminescent cholangiography was done by direct gallbladder puncture and infusion 40 ccs of bioluminescent media using an 18 gauge angiocatheter. Some retraction on the gallbladder in the same method as for a cholecystectomy was done, specifically lifting and moving the gallbladder cephalad to better expose the neck of the gallbladder—cystic duct junctions. The picture was also converted to monochrome to allow comparison to standard radiologic cholangiogram techniques.
[0212] The standard visble light view of a gallbladder (bile ducts not visualized) is shown at FIG. 24 . A color bioluminescent cholangiogram is shown at FIG. 25 . A monochome bioluminescent cholangiogram is shown at FIG. 26 . An inverted monochome bioluminescent cholangiogram is shown at FIG. 27 .
EXAMPLE 6B
[0213] Swine bioluminescent small intestine anastomosis integrity testing was done by direct puncture and infusion of 40 ccs of bioluminescent media using an 18 gauge angiocatheter into the lumen of side to side, stapled small intestine anastomosis. The color cooled CCD camera used was a Spot R3 supplied by Diagnostic Instruments Inc. The standard view of bowel anastomosis is shown at FIG. 28 . A color bioluminescent view of bowel anastomosis is shown at FIG. 29 .
EXAMPLE 6C
[0214] Swine bioluminescent angiography was done was done by direct puncture and infusion of 40 cc of bioluminescent media using an 18 gauge angiocatheter into the pulmonary vasculature, coronary vasculature and small bowel mesentery vasculature, images were from the Sony videocamera. A standard view of the lung right upper lobe is shown at FIG. 30 . A color bioluminescent view of the lung right upper lobe is shown at FIG. 31 . A standard view of the heart is shown at FIG. 32 . A color bioluminescent view of the coronary artery of the heart is shown at FIG. 33 . A standard view of the small intestine is shown at FIG. 34 . A color bioluminescent view of the mesentery small intestine is shown at FIG. 35 .
[0215] The foregoing examples establish the value of the present invention in illuminating and highlighting delicate structures. | Bioluminescent endoscopy methods and compounds, wherein an anatomical object is examined by means of filling, perfusing, intubating, injecting, or otherwise administering a solution containing a bioluminescent substance or a mixture of luciferin and luciferase which produces bioluminescence, wherein a color or monochrome image of the object is constituted using the images and information based on bioluminescent emitted by the bioluminescent substance. Procedures are demonstrated which allow bioluminescent solutions to be perfused into certain tissue regions, such as but not limited to the common biliary duct, genitourinary tract, gastro-intestinal tract, cardiovascular system and lymphatic system wherein said structures may be conveniently visualized during surgery to avoid damage to these structures. Such images may also be combined with visual light images. Methods of detection of cancer cells using bioluminescence are provided. Preferred embodiments disclosed include membrane permeant coelenterazine analogs. | 6 |
BACKGROUND OF THE INVENTION
The reaction of amines with phosgene to produce isocyanates is well known. The reaction may be represented by the following general reaction: ##STR1## In the course of the reaction the intermediate carbamyl chloride is formed which has a tendency to react under normal reaction conditions to produce urea and tars which detract substantially from the yield of the desired isocyanate. To avoid the formation of these side products several improvements in the phosgene preparation of isocyanates have been proposed.
One prior art method calls for a two-stage process, the first stage entails the formation of a slurry of intermediates at temperatures ranging from 0° C. to room temperature and subsequently reacting the intermediate products with phosgene at temperatures high enough to convert the intermediate to the isocyanate, usually in the range of 160° to 200° C. This procedure presents processing difficulties due to the release of large amounts of phosgene when the temperature is elevated in the course of the reaction.
Another prior art method is that of U.S. Pat. No. 2,908,703 wherein efforts to minimize by-product formation are by means of a two-stage procedure involving a first stage reaction at a temperature of from about 60° C. to about 90° C. and a second stage wherein intermediate product from the first stage are further reacted.
Still another method attempted is that of U.S. Pat. No. 3,226,410 wherein the patentees describe a continuous process for producing diisocyanates aimed at minimizing backmixing by reacting the phosgene with a dilute stream of the amine carried in an inert organic diluent under superatmospheric pressure in a controlled turbulent flow. None of the known prior art methods have sufficiently reduced the undesirable by-product formation. There is thus a need for a suitable method to increase the yield by minimizing by-products in the manufacture of diisocyanates.
SUMMARY OF THE INVENTION
In accordance with the invention a novel plug flow reactor and process is provided to eliminate backmixing at the feed mixing zone and facilitate the production of diisocyanates with a minimum of undesirable by-products. With the method and arrangement of the invention plugging is essentially eliminated in the reactor mixing zone.
In accordance with the invention, the pluggage in the reactor mixing zone identified as being primarily carbamyl chloride, the intermediate product in the isocyanate reaction is essentially eliminated by regulating the wall temperature of the reactor mixing zone. By thus controlling the temperature, timely and essentially complete conversion of the carbamyl chloride to the desired diisocyanate product takes place before the carbamyl chloride is able to deposit on the wall of the reactor resulting in pluggage of the reactor.
Thus the present invention includes a method of continuously preparing aromatic isocyanates by reacting phosgene in a reactor with an aromatic primary amine under conditions in which an intermediate carbamyl chloride is formed, regulating the reactor wall temperature by supplying sufficient heat to the reactor wall to counteract the cooling effect of additional amounts of phosgene reactant on said intermediate and, by said supplied heat, sustaining the reactor wall at a temperature at which the carbamyl chloride decomposes to aromatic isocyanate and above the reaction temperature prevailing during the formation of said carbamyl chloride, thereby preventing solidification of carbamyl chloride at the reactor wall and producing the desired aromatic isocyanate from the carbamyl chloride.
Regulation of the reaction of the carbamyl chloride in accordance with the invention is effected by controlling the wall temperature and thereby the temperature at which the carbamyl chloride is exposed in the reactor. Preferably a steam jacket is employed for this purpose.
Based on these heat transfer calculations and the fact that carbamyl chloride decomposes to the diisocyanate at temperature of about 90° to 140° C. heating of the reactor wall has been found to prevent pluggage of the reaction zone and undesirable by-product formation while only practical considerations impose an upper temperature limit, generally temperatures between about 90° C. and about 200° C. may be employed.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a flow diagram illustrating a preferred scheme for production of diisocyanate utilizing the improved reactor arrangement and process of the invention.
FIG. 2 is a vertical schematic cross-sectional illustration of a reactor of the kind employed in the process of the invention wherein the isocyanate is formed from the phosgene and aromatic amine.
FIG. 3 is a flow diagram similar to FIG. 1 illustrating an alternate scheme in accordance with the invention.
DETAILED DESCRIPTION OF THE INVENTION
In the description which follows toluenediamine (TDA) will be employed as a typical aromatic amine in describing the invention. However, it will be apparent that various other aromatic amines may also be employed while still retaining the advantages of the invention.
According to the present invention phosgene and an inert organic solvent solution of a primary aromatic amine are reacted together, initially at a temperature between about 60° C. and about 90° C. and subsequently by means of the heat of reaction and secondary backmix reactors. The intermediate reaction mixture is subjected to an elevated temperature sufficiently high to convert the intermediate product to the isocyanate before it can be exposed to reduced temperatures which generate undesirable by-products from the intermediate carbamyl chloride. In the process, aromatic isocyanates are prepared by reacting phosgene with an aromatic primary amine under conditions in which an intermediate carbamyl chloride is formed. Sufficient heat is supplied to the reaction to counteract the cooling effect of the phosgene. The reactor wall temperature is sustained above the temperature prevailing during the subsequent reaction between the carbamyl chloride and phosgene which produces the desired isocyanate.
In a representative embodiment of this invention, a dilute solution of the aromatic amine in an inert organic solvent, such as dichlorobenzene, is passed into the first reactor. Concomitant with the addition of amine solution to the first reactor, phosgene liquid from any convenient source is also admitted to the reactor through a separate entry point. The mass in the reaction vessel is preferably well agitated and sufficient heat is supplied via the exothermic heat of reaction of the amine with phosgene to maintain the preferred temperature for phosgenation.
Preferably, the solution of the amine and the phosgene are introduced at such rates that there is at least a 50% stoichiometric excess of phosgene over that theoretically required to react with the amine.
The process of the invention is preferably carried out continuously and is described by reference to the drawing wherein primed reference numbers are applied in FIG. 3 corresponding, where applicable, to similar components in FIG. 1 bearing the same reference numbers without prime designation.
In the drawing, 24 is a feed tank for the liquid phosgene, provided with the feed line 17 which feeds reactor 10 with the phosgene feed. In FIG. 3, 25 is a feed tank for a solution of phosgene and solvent with a feed line 25' which mixes with the liquid phosgene from line 17' and then fed via line 28' to reactor 10'. 23 and 23' are feed tanks for the amine and 22 and 22' are the solvent feed tanks. The amine fed from line 15 or 15' mixes with the solvent of line 14 or 14' is fed to reactor 10 or 10' via line 16 or 16'. The amine solvent mixture of line 16 or 16' contacts either the phosgene liquid from line 17 or the phosgene and phosgene solvent mixture from line 25' and 17' in the mixing zone 29 of reactor 10. In order to assure good mixing in reactor 10 without backmixing, reactor 10 is sized such that the velocity of stream 28' or 17 in the reactor annular space 30 is lower than the velocity of stream 16 or 16' in the feed tube 31. A velocity ratio of 2.6 to 1 assures good mixing while minimizing backmixing. A heating jacket 11 is provided to maintain the reactor wall temperature above 90° C. to avoid pluggage of the reaction zone. In the heating jacket steam as the heating medium is chosen for convenience, but any suitable heating method can be used such as hot oil in the jacket or heat tracing, steam tracing or electrical tracing, for example. The reaction mass containing a mixture of solvent, intermediate product and isocyanate product is fed through lines 26 or 26' continuously to two secondary backmixed agitated reactors 12, 27 or 12', 27' (FIGS. 1 and 3 respectively) maintained at a temperature of 110° C. to 155° C. to complete the reaction to the desired isocyanate. Excess phosgene and by-product hydrochloric acid are removed from reactors 12, 27 or 12', 27' as a gas, the majority of the phosgene is condensed in condenser 18 or 18' and sent from tank 20 or 20' to the phosgene feed tank 24 or 24' for reuse. The gas stream exits through tank 20 or 20' via line 19 or 19' for further processing to recover the remaining phosgene for reuse and HCl by-product. The reaction mass from reactor 27 or 27' is sent to product purification via line 32 or 32'.
Various aromatic amine primary may be converted to the corresponding isocyanate by this process. The amine may be a monoamine, a diamine or some other polyamine. Examples of aromatic amines which may be used in the practice of this invention are aniline, the isomeric toluidines, the isomeric xylidines, o-, m-, and p-alkylanilines, o-, m-, amd p-chloroanilines, the isomeric dichloroanilines, the isomeric phenylenediamines, the isomeric diaminotoluenes, the isomeric diaminoxylenes, various diaminoalkyl benzenes, alpha- and beta naphthylamines, the isomeric diaminonaphthalenes, the isomeric bisaminophenylmethanes, the isomeric trisaminophenylmethanes, the dianisidines the diaminodiphenyls and mixtures of these amines. The amine should be free of groups which would interfere with the reaction between the amino group and phosgene or with the isocyanate radical, that contain active hydrogen atoms. Such groups are, for example, --OH, --COOH, --SH, etc. The most preferred diamine is toluenediamine.
The initial temperatures of phosgenation employed in this invention range from about 60° C. to about 90° C. The preferred temperatures in this range are from 65° to 80° C.
30 pounds per square inch gage pressure is normally employed as a matter of convenience, though higher or lower pressure may be used.
The solvents employed in this process are those which are inert to the reactants and products. Although aliphatic and aromatic hydrocarbons which are inert to the reactants and products, are satisfactory solvents, the preferred solvents are the chlorinated hydrocarbons. Representative members of this class are monochlorobenzene, dichlorobenzene, carbon tetrachloride, the corresponding chlorinated toluenes and xylenes and trichloroethylene. The most preferred solvent is dichlorobenzene. It is desirable and preferable to choose a solvent that boils lower than the isocyanate product.
The amine may be introduced into the reaction vessel in solution in the chlorinated hydrocarbon solvent. Concentrations of the amine may be varied from about 2 to 20% by weight of the solution. The reaction will proceed at lower concentrations; however, lower concentrations result in uneconomically low volume productivities. Higher concentrations of the amine lead to formation of undesirable side products, i.e., urea, substituted ureas, polyureas and tar compounds The preferred range of the amine solution is 5 to 10% by weight of amine.
The concentration of phosgene in the reaction solution is regulated by the temperature being employed for the reaction. Preferably, an essentially saturated solution of phosgene in the solvent should be maintained at all times during the reaction. Low concentrations of phosgene result in decreased efficiencies, due to formation of side products. The use of greater amounts of phosgene does not adversely affect the efficiency of the operation. However, it will be apparent that precautions must be taken to handle the excess phosgene and, thus, large excesses of phosgene are to be avoided.
The advantages and mode of carrying out the process of this invention are further illustrated by the following representative examples:
EXAMPLE I
Referring to FIGS. 1 and 2, 100 pounds per hour of toulenediamine are mixed with 900 pounds per hour of dichlorobenzene at 60° C. and sent to reactor 10. Simultaneously, 365 pounds per hour of phosgene at 0° C. is pumped to reactor 10. Reactor 10 is so sized that a velocity ratio of 2.6 to 1 is maintained between the toluenediamine, dichlorobenzene mixture and the phosgene entering the reaction zone 29.
The reaction proceeds adiabatically with the reaction mass exiting the reactor at a temperature of 110° C. via stream 26. Steam is added to the jacket at point 33 to maintain the wall temperature of reactor 10 at 90° C. The reactor 10 is run at a pressure of 30 psig.
The reaction to the diisocyanate is completed in reactor 12 and 27. Reactor 12 being maintained at 110° C. and reactor 27 being maintained at 145° C. Phosgene and by-product HCl along with trace amounts of product isocyanate are taken overhead in stream 13. Stream 13 consists of 182.6 pounds per hour phosgene and 116.6 pounds per hour HCl. The phosgene is recovered from the HCl by condensation and 182.6 pounds per hour are sent to tank 20. 116.6 pounds per hour of HCl is recovered as aqueous HCl in standard equipment. 1065.8 pounds per hour of reaction products are removed via line 32. This reaction product consists of 3.1 pounds per hour HCl, 20.3 pounds per hour phosgene, 900 pounds per hour dichlorobenzene, 130.5 pounds per hour toluene diisocyanate and 11.9 pounds of reaction by-product. The product toluene diisocyanate is purified by fractional distillation. The yield of toluene diisocyanate is approximately 91% based on the amine.
EXAMPLE II
Referring to FIGS. 2 and 3, 100 pounds per hour of toluenediamine are mixed with 540 pounds per hour of dichlorobenzene at 60° C. and sent to reactor 10'. Simultaneously, 301 pounds per hour of phosgene is mixed with a solution containing 360 pounds per hour dichlorobenzene and 64 pounds per hour phosgene and is sent to reactor 10' via line 28. The mixture is at 0° C. Reactor 10' is so sized such that a velocity ratio of 2.6 to 1 is maintained between the toluenediamine, dichlorobenzene mixture and the phosgene, dichlorobenzene mixture entering the reaction zone 29.
The reaction proceeds adiabatically with the reaction mass exiting the reactor at a temperature of 110° C. via stream 26. Steam is added to the jacket at point 33 to maintain the wall temperature of reactor 10 at 90° C. The reactor 10' is run at a pressure of 30 psig.
The reaction to the diisocyanate is completed in reactor 12' and 27'. Reactor 12' being maintained at 110° C. and reactor 27' being maintained at 145° C. Phosgene and by-product HCl along with trace amounts of product isocyanate are taken overhead in stream 13'. Stream 13' consists of 182.6 pounds per hour phosgene and 116.6 pounds per hour HCl. The phogene is recovered from the HCl by condensation and 182.6 pounds per hour are sent to tank 20'. 116.6 pounds per hour of HCl is recovered as aqueous HCl in standard equipment. 1065.8 pounds per hour of reaction products are removed via line 32'. This reaction product consists of 3.1 pounds per hour HCl, 20.3 pounds per hour phosgene, 900 pounds per hour dichlorobenzene, 130.5 pounds per hour toulene diisocyanate and 11.9 pounds of reaction by-product. The product toluene diisocyanate is purified by fractional distillation. The yield of toluene diisocyanate is approximately the same as Example I based on the amine.
It will be apparent that various changes may be incorporated in the foregoing procedure without departing from the scope of the invention and that unless specifically limited in the appended claims the details supplied in the description as shown in the drawing are to be interpreted as illustrative and not limiting. | The reaction of aromatic amines with phosgene takes place in the mixing zone of a plug flow reactor to form both the product isocyanate as well as the intermediate carbamyl chloride. The aromatic amine dissolved in an inert diluent is fed to the center portion of the plug flow reactor while the phosgene is fed to the annular space. The reactor is designed so as to eliminate back-mixing at the feed zone and thus to avoid reaction of any isocyanate formed with the incoming aromatic amine which produces in turn undesirable by-products such as urea and tar. Cold phosgene that is fed into the annular space cools the wall sufficiently to inhibit the reaction to TDI. By heating the wall such as with the installation of a heating jacket to counteract the cooling effect of phosgene, the wall of the reactor is maintained above 90° C. and thus any solid carbamyl chloride that migrates to the wall is reacted to the isocyanate, eliminating pluggage of the reactor from solids build-up. | 2 |
TECHNICAL FIELD
[0001] The present invention relates to a communication apparatus which has achieved an improvement in the ease of operations thereof.
BACKGROUND ART
[0002] In recent years, such an operation of photographing an object by using a mobile communication terminal equipped with a camera unit and transmitting an e-mail attached with the image data having been acquired through the photography has been generally performed. This operation is usually performed in accordance with the following procedure.
[0003] That is, first, the user starts the camera unit included in the mobile communication terminal. The camera unit scans an object to acquire the image data related thereto, and further, displays the acquired image data on a display unit. The user performs an acquisition by pushing a shutter button thereof with watching the display unit. In response to the shutter button being pushed down, the image data being displayed on the display unit is stored into a memory portion. Next, the user performs an operation of terminating an imaging mode, and further, starts an e-mail function. The user creates a new e-mail, and further, designates the stored image data as an attachment file of the e-mail. Further, the user input a destination address and an e-mail body, and then, the user executes a mail transmission operation.
[0004] By performing such operations as described above, the user can acquire the image of the object by using a camera unit, and can transmit the e-mail to which the acquired image data is attached. However, in order to transmit an e-mail with which the image data related to an object is attached, the user needs many operations. Therefore, there is a disadvantage in that the operability is insufficient for users.
[0005] For example, Japanese Patent Application Laid-Open No. 2004-153453, Japanese Patent Application Laid-Open No. 2004-289879 and Japanese Patent Application Laid-Open No. 2005-100191 disclose solutions of the above described disadvantage. Japanese Patent Application Laid-Open No. 2004-153453 discloses a folding-type mobile termination apparatus which is configured to, when, in a folded condition, made into an unfolded condition under the state where a selected image is displayed on a display area provided on the back thereof, automatically start an e-mail function. The mobile terminal apparatus displays a screen for creating a new e-mail on the display area, and further, automatically attaches the image data related to the selected image to the e-mail.
[0006] Japanese Patent Application Laid-Open No. 2004-289879 discloses a mobile communication terminal which is configured to, when an e-mail transmission operation is performed during an imaging mode in which a still image being acquired by a camera is displayed on a display unit, start an e-mail transmission mode. When, under the state where the e-mail transmission mode is started, the user inputs information necessary for an e-mail transmission, and further, creates a e-mail body, the mobile communication terminal attaches the encoded data corresponding to the still image being displayed on the display unit to the e-mail body, and further, transmits the e-mail.
[0007] Japanese Patent Application Laid-Open No. 2005-100191 discloses a mobile communication terminal which is configured to, in a transmission process mode for an e-mail with which the image is attached, when an operation of a key, which is allocated in advance, is performed, start a camera function, and further, store the image data. The mobile communication terminal attaches the stored image data to an e-mail, and further, transmits the e-mail to a destination which is associated with the above-described key in advance.
SUMMARY OF INVENTION
[0008] However, although an apparatus described in each of the above-described Japanese Patent Application Laid-Open No. 2004-153453 and Japanese Patent Application Laid-Open No. 2004-289879 are capable of performing a start of an e-mail function and an attachment of the image data automatically in an imaging mode, with respect to a destination of the e-mail, user operations are needed. Therefore, for the apparatus disclosed in each of the above-described patent gazettes, there is a disadvantage in that operability is still insufficient.
[0009] According to the apparatus described in the above-described patent document 3, first, the user starts an e-mail transmission function, and then, starts a camera. When the user pushes a shutter key, the apparatus attaches the image data, which has been acquired through imaging and has been stored by the camera, to an e-mail, and further, transmits the e-mail. Accordingly, when an object the user desires to acquire the image thereof exists in front of the user, the user needs to go through a procedure of, first, starting the e-mail transmission function, and subsequently, starting the camera. Therefore, for the apparatus disclosed in the above-described patent gazette, there is a disadvantage in that operability is still insufficient.
[0010] The present invention has been made in view of the above-described disadvantage, and a main object thereof is to provide a communication apparatus, an e-mail creation method, an imaging method, a program storage medium and an imaging program storage medium which has achieved a further improvement in the operability required in transmitting an e-mail attached the image data.
Solution to Problem
[0011] A first communication apparatus according to an aspect of the present invention includes imaging means for imaging an object to acquire image data related to the object; storage means for storing registration information which is associated at least one predetermined action and at least one destination address; and control means for, in response to one of the predetermined action being performed during an operation of the imaging means, controlling the imaging means so that the storage means stores the image data acquired by the imaging means and creating an e-mail to which the destination address is set and with which the image data which is stored in the storage means is attached, the destination address being associated with the predetermined action and being stored in the registration information.
[0012] A first e-mail creation method according to another aspect of the present invention includes storing registration information which is associated at least one predetermined action and at least one destination address, into storage means; controlling, in response to one of the predetermined action being performed during an operation of imaging means for imaging an object to acquire image data related to the object, the imaging means so that the storage means stores the image data acquired by the imaging means and creating an e-mail to which the destination address is set and with which the image data which is stored in the storage means is attached, the destination address being associated with the predetermined action and being stored in the registration information.
[0013] A first imaging method according to another aspect of the present invention includes controlling, in response to an key which instructs to store the image data being pushed down during an operation of imaging means for imaging an object to acquire image data related to the object, the imaging means so that storage means stores the image data acquired by the imaging means and displaying the image data acquired by the imaging means while the key is pushed down.
[0014] In addition, the foregoing object can be also achieved by a computer program which enables a computer to realize the communication apparatus, the e-mail creation method and the imaging method including the individual components described above, as well as a storage medium which includes the computer program stored thereon, and which is readable by the computer.
Advantageous Effects of Invention
[0015] According to some aspects of the invention, an effect in which the operability required in transmitting an e-mail attached with the image data is further improved can be obtained.
BRIEF DESCRIPTION OF DRAWINGS
[0016] FIG. 1 is a block diagram showing a configuration of a mobile information terminal according to a first exemplary embodiment of the present invention.
[0017] FIG. 2 is a diagram showing a hardware configuration of a mobile information terminal according to a first exemplary embodiment of the present invention.
[0018] FIG. 3 is a flowchart showing operations of registering a specific key, performed by a user.
[0019] FIG. 4 is a diagram showing specific key registration information stored in a storage unit of a mobile information terminal according to a first exemplary embodiment of the present invention.
[0020] FIG. 5 is a flowchart showing operations of a control unit of a mobile information terminal according to a first exemplary embodiment of the present invention.
[0021] FIG. 6 is a flowchart showing operations of a control unit of a mobile information terminal according to a second exemplary embodiment of the present invention.
[0022] FIG. 7 is a diagram showing specific key registration information stored in a storage unit of a mobile information terminal according to a third exemplary embodiment of the present invention.
[0023] FIG. 8 is a diagram showing that specific key registration information includes pieces of automatic transmission on/off information in addition to pieces of key and destination address information.
[0024] FIG. 9 is a diagram showing that specific key registration information includes pieces of image information in addition to pieces of key and destination address information.
[0025] FIG. 10 is a diagram showing that specific key registration information includes pieces of stamp image data in addition to pieces of key and destination address information.
[0026] FIG. 11 is a block diagram showing a configuration of a mobile information terminal according to a fourth exemplary embodiment of the present invention.
DESCRIPTION OF EXEMPLARY EMBODIMENTS
First Exemplary Embodiment
[0027] Next, exemplary embodiments of the present invention will be described in detail with reference to the drawings. By way of examples, in each of which a communication apparatus according to the present invention is applied to a mobile communication terminal, the following exemplary embodiments will be described.
[0028] FIG. 1 is a block diagram showing a configuration of a mobile communication terminal 100 according to a first exemplary embodiment of the present invention. As shown in FIG. 1 , the mobile communication terminal 100 includes a control unit 101 , a radio communication unit 102 , an operation unit 103 , a display unit 104 , a camera unit 105 , a storage unit 106 , a voice processing unit 107 , a microphone 108 and a speaker 109 .
[0029] The control unit 101 of the mobile communication terminal 100 shown in FIG. 1 has a hardware configuration exemplified in FIG. 2 in the case where it is realized by a computer. The configuration shown in FIG. 2 includes a central processing unit (CPU) 70 , a storage medium 71 , such as a memory, and a program 72 included in the storage medium 71 . The CPU 70 of the mobile communication terminal 100 performs controls of the overall operation of the mobile communication terminal 100 by executing various software programs (computer programs). In this exemplary embodiment and other exemplary embodiments described below, the CPU 70 performs controls of operations performed by individual modules (individual units), described below, included in the mobile communication terminal 100 , appropriately referring to the storage medium 71 , such as a memory.
[0030] More specifically, the CPU 70 performs controls of operations performed by hardware elements, such as the radio communication unit 102 , the operation unit 103 and the camera unit 105 , by executing a software program which executes the functions of the control unit 101 included in the mobile communication terminal 100 , appropriately referring to the storage medium 71 , such as a memory.
[0031] The control unit 101 performs controls of individual units of the mobile communication terminal 100 . The radio communication unit 102 transmits and receives information by radio to/from radio base station apparatuses (not illustrated) via an antenna. The operation unit 103 includes a numeric keypad, a direction key, a decision key, a side key and the like, and receives various information input from a user to the mobile communication terminal 100 . The display unit 104 displays images, graphics, characters, symbols and the like. The camera unit 105 images an object to require image data related to the object. Here, the imaging means acquiring image data related to the object, and further, displaying the acquired image data on the display unit 104 . The storage unit 106 stores therein telephone directory information, transmitting/receiving mail information, application program information, acquired image data, various setting information and the like. The voice processing unit 107 performs processing on voice signals having been input and output via the microphone 108 , which is a telephone transmitter, and the speaker 109 , which is a telephone receiver.
[0032] In response to one of the specific keys being pushed down by a user during an operation of the camera unit 105 , the mobile information terminal 100 is capable of storing the image data which is acquired by the camera unit 105 , that is, which is displayed on the display unit 104 , into the storage unit 106 , and further, creating an e-mail attached with the stored image data easily. The camera unit 105 stores the image data which is acquired thereby into the storage unit 106 if a decision key, a side key or the like is pushed other than the specific keys.
[0033] Here, the specific keys will be described. The specific keys are, for example, individual keys of a numeric keypad, and each of the specific keys instructs the control unit 101 to store the image data acquired by the camera unit 105 , to create an e-mail, to attach the image data, and to set an e-mail address which is associated with the specific key. The specific keys are each associated with at least one intended e-mail address in advance.
[0034] FIG. 3 is a flowchart showing operations for associating specific keys with e-mail addresses. FIG. 4 is a diagram showing association information of specific keys with e-mail addresses, that is, specific key registration information (registration information) 10 created by the user. The specific key registration information 10 includes specific keys 11 and destination addresses 12 . Here, individual keys of the numeric keypad of the operation unit 103 are supposed to the specific keys. The association of specific keys with e-mail addresses will be described with reference to FIGS. 3 and 4 .
[0035] The user starts a specific key registration function by operating the operation unit 103 (step ST 201 ). The control unit 101 displays the individual keys of the keypad “1”, “2” . . . “0” on the display unit 104 , and further, displays an input screen for inputting e-mail addresses to be associated with the individual keys (step ST 202 ). The user inputs e-mail addresses the user desires to associate with the individual keys of the numeric keypad (step ST 203 ). For example, “aaa@bbb.com” is input as an e-mail address to be associated with the key “1” of the keypad. At this time, the user may directly input e-mail addresses, or may select them from an address book.
[0036] The control unit 103 stores the specific key registration information 10 , which associates the specific keys with the e-mail addresses, into the storage unit 106 (step ST 204 ). By performing such operations as described above, the control unit 103 creates the specific key registration information 10 , such as shown in FIG. 4 .
[0037] FIG. 5 is a flowchart showing operations of the mobile communication terminal 100 . The operations will be described with reference to FIG. 5 . Note that, here, the storage unit 106 stores therein the specific key registration information 10 shown in FIG. 4 .
[0038] In response to input of an instruction for starting the camera unit 105 by user operation of the operation unit 103 , the control unit 101 starts the camera unit 105 . The control unit 101 determines whether the camera unit 105 is in an imaging mode or not(step ST 302 ), in which the imaging mode the image data acquired by the camera unit 105 is displayed on the display unit 104 , and if the camera unit 105 is in the imaging mode, receives an operation of pushing a key from the user. The user pushes one of photographing keys with watching the image data displayed on the display unit 104 . Here, the photographing keys include the decision key or the side key, and the specific keys. The decision key or the side key has a function as the photographing key for instructing a usual photography. The specific keys each instructs to attach the stored image data through a photographing to the e-mail and to transmit thereof. In case where the user desires to perform the usual photography, the user pushes the decision key or the side key which has the function as the photographing key. In case where the user desires to attach the image data which is stored through the photography to the e-mail and transmit it, the user pushes one of the specific keys.
[0039] In response to detection of one of the photographing keys being pushed (step ST 303 ), the control unit 101 determines whether the photographing key corresponds to any one of the specific keys, or not (step ST 304 ). If the photographing key does not correspond to any one of the specific keys, that is, if the photographing key corresponds to the decision key or the side key, the push of the key indicates an instruction for execution of the usual photography. Therefore, in response to the photographing key being pushed down, the control unit 101 controls the camera unit 105 so that the storage unit 106 stores the image data acquired by the camera unit 105 . In response to the instruction from the control unit 101 , the camera unit 105 stores the image data acquired thereby into the storage unit 106 (step ST 305 ). Subsequently, the control unit 101 returns the process to step ST 302 .
[0040] In contrast, if the pushed photographing key in step ST 304 corresponds to any one of the specific keys, the control unit 101 identifies the key, and further, searches the specific key registration information 10 stored in the storage unit 106 in order to determine whether any destination address associated with the key is registered, or not (step ST 306 ). If any destination address is not registered (“No” in step ST 307 ), the control unit 101 indicates the fact on the display unit 104 (step ST 308 ), and then, returns the process to step ST 302 . At this time, the camera unit 105 does not store the image data acquired thereby. In contrast, if any destination address associated with the above-described key is registered (“Yes” in step ST 307 ), the control unit 101 retrieves the destination address (step ST 309 ), and further, controls the camera unit 105 so that the storage unit 106 stores the image data acquired by the camera unit 105 . In response to the instruction from the control unit 101 , the camera unit 105 stores the acquired image data acquired thereby into the storage unit 106 (step ST 310 ).
[0041] Further, the control unit 101 starts a mailer, and further, changes to a new e-mail creation mode (step ST 311 ). The control unit 101 sets the destination address which is retrieved from the specific key registration information 10 as a destination of a new e-mail (step ST 312 ). The control unit 101 attaches the image data which is stored in step ST 310 to the mail (step ST 313 ).
[0042] Subsequently, the user inputs a title and a body to the new e-mail to which the destination address is set and the image data is attached in such a way as described above (step ST 314 ). Further, in response to a transmission button being pushed down by the user (step ST 315 ), the control unit 101 transmits the e-mail (step ST 316 ). In response to an instruction for terminating the imaging mode, the control unit 101 terminates the process. If not receiving the instruction, the control unit 101 returns the process to step ST 302 (step ST 317 ).
[0043] Owing to such operations described above, the user can perform storing the acquired image data, starting the new e-mail creation mode, attaching the image data, and setting the destination address, only by pushing one of the specific keys following starting the camera unit 105 .
[0044] Here, the control unit 101 may have a destination-address registration reception function. That is, if, in step ST 307 , any destination address is not registered in the specific key registration information 10 , the control unit 101 may indicate the fact on the display unit 104 , and further, may change to a mode in which the registration of any destination address is prompted. In this mode, the user may directly input the e-mail address with which the user desires to associate the pushed specific key, or may select it from an address book. In response to an input of a destination address, the control unit 101 associates the destination address with the pushed specific key, and further, registers the destination address into the specific key registration information 10 in the storage unit 106 . Moreover, the control unit 101 may indicate help information regarding the specific key registration function before changing to the mode in which the registration of destination addresses is prompted. In this way, the control unit 101 can indicate the specific key registration function to users who do not know that function.
[0045] The control unit 101 may have a preview function. That is, when the user pushes and holds the photographing key in step ST 303 , the control unit 101 may continue to display the image data which is stored by the camera unit 105 on the display unit 104 while the photographing key is pushed. When the user releases the photographing key, the control unit 101 may transfer to the process in step ST 304 . As described above, while the user pushes and holds one of the photographing keys, the control unit 101 continues such a preview, thereby making it unnecessary for the user to separately perform any reproduction operation for confirming the stored image data. Therefore, the ease of operations is further improved. At this time, if the user does not desire to store the image data, the control unit 101 may delete the image data in response to, for example, a clear button being pushed down by the user.
[0046] Further, as the specific keys, hardware keys, such as individual keys of the keypad, may be allocated in such a way as described above, or software keys may be allocated. For example, the display unit 104 may be constituted as a touch panel, and further, the control unit 101 may indicate numeric keys, which function as the specific keys, on the display unit 104 . The user enables to photograph by touching one of the numeric keys with watching the image data displayed on the display unit 104 . Further, the control unit 101 may display icons instead of the numeric keys. For example, the control unit 101 may also use pictures of transmission recipients as icons corresponding to the respective specific keys. In this case, even if the user does not remember numeric characters of respective numeric keys which the user registers so as to correspond to e-mail addresses of transmission recipients, the user can identify the e-mail addresses of transmission recipients at a glance. Further, in the case where the control unit 101 displays the software keys on the display unit 104 as the specific keys, when a folding-type or sliding-type mobile communication terminal is in a folded condition, the user thereof can push one of the specific keys without troubling to change it into a unfolded state. Accordingly, the ease of operations is further improved.
[0047] Further, the image data described above may be the still image data or the moving image data. In the case of the moving image, for example, in step ST 303 of FIG. 5 , the camera unit 105 may start a moving-image taking operation in response to one of the photographing keys being pushed down by the user, and may terminate the moving-image taking operation in response to a release of the photographing key by the user.
[0048] As described above, according to the first exemplary embodiment, the user perform associations of the destination addresses with the specific keys and registers them in advance, and the control unit 101 controls the camera unit 105 so that the storage unit 106 stores the image data acquired by the camera unit 105 in the imaging mode in response to one of the specific keys being pushed down. Moreover, in the imaging mode, in response to the specific key being pushed down, the control unit 101 starts a mailer, and further, changes to the new e-mail creation mode. Furthermore, the control unit 101 sets the destination addresses which is associated with the specific key as a destination of the new e-mail, and further, attaches the stored image data to the created e-mail. Owing to this configuration, only by pushing a key once in the imaging mode, the user can perform storing the image data, starting the new e-mail creation mode, setting the destination address, and attaching the image data, and thus, an effect in which the operability required in transmitting an e-mail attached with the image data is further improved can be obtained.
Second Exemplary Embodiment
[0049] In a second exemplary embodiment, a method in which the image data acquired by camera unit is stored in response to voice input will be described.
[0050] FIG. 6 is a flowchart showing operations performed by the mobile information terminal 100 according to the second exemplary embodiment. The operations will be described with reference to FIG. 6 . Note that, in this embodiment, the storage unit 106 stores therein the specific key registration information 10 shown in FIG. 4 .
[0051] In response to input an instruction for starting the camera unit 105 by a user operation of the operation unit 103 , the control unit 101 starts the camera unit 105 . The control unit 101 determines whether the camera unit 105 is in the imaging mode or not (step ST 302 ), and if it is in the imaging mode, the control unit 101 starts the microphone 108 (step ST 402 ). The image data which is being acquired by the camera unit 105 is displayed on the display unit 104 . The user vocalizes a name representing one of the specific keys, such as “one” or “two” with watching the image data displayed on the display unit 104 (step ST 403 ). In response to the voice being input, the microphone 108 notifies the voice processing unit 107 of the voice information (step ST 404 ). The voice processing unit 107 recognizes the notified voice information, and further, notifies the control unit 101 of the result thereof (step ST 405 ).
[0052] The control unit 101 determines whether the voice recognition is succeed or not and if not succeeded (“No” in step ST 406 ), the control unit 101 displays the fact on the display unit 104 (step ST 407 ), and then, returns the process to step ST 403 . If succeeded in the voice recognition (“Yes” in step ST 406 ), the control unit 101 searches the specific key registration information 10 in the storage unit 106 and determines whether the destination address associated with the specific key which is indicated by the recognized voice is registered or not(step ST 408 ). If the above-described destination address is not registered (“No” in step ST 409 ), the control unit 101 displays the fact on the display unit 104 (step ST 407 ), and then, returns the process to step ST 403 . Then, the camera unit 105 does not store the image data being acquired thereby. In contrast, if the above-described destination address is registered (“Yes” in step ST 409 ), the control unit 101 retrieves the destination address (step ST 411 ), and further, controls the camera unit 105 so that the storage unit 106 stores the image data acquired by the camera unit 105 . In response to the instruction from the control unit 101 , the camera unit 105 stores the image data acquired thereby into the storage unit 106 (step ST 412 ).
[0053] Hereinafter, since operations in steps ST 413 to ST 419 are similar to those in steps ST 311 to ST 317 shown in FIG. 4 in the first exemplary embodiment, descriptions thereof will be omitted. As described above, by vocalizing the name one of the specific keys, the user can issue an instruction for storing the image data acquired by the camera unit 105 , creating a new e-mail, attaching the stored image data, and setting an e-mail address associated with the specific key into the e-mail.
[0054] Here, in the specific key registration information 10 shown in FIG. 4 , instead of allocating individual keys of a keypad such as “1” and “2” as the specific keys, the names of transmission recipients such as “farther” and “mother” may be allocated. In this case, since all the user requested to do is just to vocalize the name of the transmission recipient, the user can create a new e-mail to be transmitted to the recipient even if the user does not remember the specific key which is associated with the e-mail address of the transmission recipient. Therefore, in the mobile information terminal 100 according to the second exemplary embodiment, operability is improved further.
[0055] As described above, according to the second exemplary embodiment, the voice processing unit 107 recognizes the input voice and the control unit 101 sets the destination address associated with the specific keys which is indicated by the recognized voice into the new e-mail. Owing to this configuration, the user does not need to push any specific key, and thus, an effect in which the operability is further improved can be obtained.
Third Exemplary Embodiment
[0056] In a third exemplary embodiment, a modified example of the specific key registration information 10 having been described in the first exemplary embodiment, will be described.
[0057] FIG. 7 is a diagram showing specific key registration information 20 stored in the storage unit 106 of the mobile information terminal 100 according to the third exemplary embodiment. As shown in FIG. 7 , the specific key registration information 20 includes specific keys 21 , destination addresses 22 , titles 23 and bodies 24 . The specific key 21 and the destination address 22 are similar to those having been described in the first exemplary embodiment. The title 23 indicates the content of a title which is automatically added to an e-mail to be transmitted to the corresponding destination address 22 . The body 24 similarly indicates the content of a body.
[0058] In the case where the specific key registration information 20 shown in FIG. 7 is stored in the storage unit 106 , the control unit 101 retrieves the title 23 and the body 24 in addition to the destination address 22 from the specific key registration information 20 in step ST 309 of FIG. 5 . The control unit 101 sets the title 23 and the body 24 into the new e-mail in addition to the retrieved destination address 22 in step ST 312 .
[0059] As described above, by allowing the user to perform registration of the title 23 and the body 24 in addition to the destination address 22 into the specific key registration information 20 in advance, the title and the body is also set into the new e-mail. Therefore, in the mobile terminal 100 according to the third exemplary embodiment, the ease of operations is improved further.
[0060] FIG. 8 is a diagram showing a case in which the specific key registration information 20 shown in FIG. 7 further includes automatic transmission on/off setting 25 . The automatic transmission on/off setting 25 is set to “ON” or “OFF”. In the case where “ON” is set, in response to the specific key 21 being pushed, the e-mail is automatically transmitted to the corresponding destination address 22 . In the case where “OFF” is set, the automatic transmission is not performed.
[0061] In the case where the specific key registration information 30 shown in FIG. 8 is stored in the storage unit 106 , the control unit 101 retrieves the automatic transmission on/off setting 25 in addition to the destination address 22 , the title 23 and the body 24 from the specific key registration information 20 in step ST 309 of FIG. 5 . In step ST 312 , the control unit 101 sets the title 23 and the body 24 into the new e-mail in addition to the retrieved destination address 22 . In the case where the automatic transmission setting 25 is set to “ON”, the control unit 101 performs e-mail transmission process of step ST 316 without determining the presence or absence of the push of the e-mail transmission button in step ST 315 . In the case where the automatic transmission setting 25 is set to “OFF”, the control unit 101 does not perform the automatic transmission, but performs operations similar to those of the first exemplary embodiment. As described above, by allowing the user to perform registration regarding whether the automatic transmission is to be performed or not in advance, an operation of pushing the transmission key is not needed, and thus, the ease of operations is improved further. Such a setting of the automatic transmission is particularly useful, for example, in case where the acquired image data is transmitted to a digital photo frame.
[0062] Plurality of sentences may be registered into any one of the bodies 24 of the specific key registration information 20 . In case where the control unit 101 retrieves a plurality of sentences in the body 24 from the specific key registration information 20 , the control unit 101 may set any one of them into the new e-mail at random, or may cyclically select any one of them to set into. Being registered a plurality of sentences as described above is particularly useful in case where, for example, the user frequently posts the image data to a blog. That is, the user can post the body which is selected from among a plurality of bodies at random, which is not the same body each time, together with the image data in posting the image data. Similarly, a plurality of titles may also be registered.
[0063] FIG. 9 is a diagram showing specific key registration information 30 including specific keys 21 , destination addresses 22 and pieces of image information 31 . The image information 31 each include, for example, a resolution 32 and a file size 33 . A user sets the resolution 32 and the file size 33 in advance so that they are compatible with the display function of a receiving terminal of a corresponding transmission recipient.
[0064] In the case where the specific key registration information 30 shown in FIG. 9 is stored in the storage unit 106 , the control unit 101 retrieves the image information 31 in addition to the destination address 22 from the specific key registration information 20 in step ST 309 of FIG. 5 . Then, in step ST 313 , after modifying the image data to be compatible with the retrieved image information 31 , the control unit 10 attaches the modified image data to the new e-mail. In this way, the user can transmit the image data which is compatible with the display function of the receiving terminal of the transmission recipient.
[0065] FIG. 10 is a diagram showing specific key registration information 40 including the keys 21 , the destination addresses 22 and pieces of stamp image data 41 . As the stamp image data 41 , a file name of arbitrary image data is allocated. For example, the image data for signatures may be allocated.
[0066] In the case where the specific key registration information 40 shown in FIG. 10 is stored in the storage unit 106 , the control unit 101 retrieves the stamp image data 41 in addition to the destination Address 22 from the specific key registration information 20 in step ST 309 of FIG. 5 . The control unit 101 , in step ST 313 , performs process (stamping process) for superimposing the retrieved stamp image data 41 on the stored image data, and then, attaches the image data resulting from the stamping process into a new e-mail. In this way, the user can perform stamping process to the stored image data using arbitrary image data.
[0067] In addition, any combination of the specific key registration information shown in FIGS. 7 to 10 may be used.
[0068] As described above, according to the third exemplary embodiment, since the control unit 101 automatically sets one of the pre-registered titles and bodies into the new e-mail, an effect in which the operability is further improved can be obtained. Further, since the control unit 101 controls a transmission on the basis of the automatic transmission on/off setting for the new e-mail, the user can automatically perform a transmission thereof without instructing the transmission, whereby an effect in which the operability is further improved can be obtained. Moreover, since the control unit 101 modifies the image data on the basis of the pre-registered resolution and file size regarding the image data to be attached to the new e-mail, an effect in which the user can transmit the image data in accordance with the display function of the receiving terminal of a transmission recipient can be obtained. Furthermore, since the control unit 101 performs stamping process to the image data which is stored by the camera unit 105 using arbitrary stamp image data which is registered in advance, an effect in which the user can transmit the image data which is performed the stamping process can be obtained.
Fourth Exemplary Embodiment
[0069] FIG. 11 is a block diagram showing a configuration of a communication apparatus 50 according to a fourth exemplary embodiment of the present invention. As shown in FIG. 11 , the communication apparatus 50 includes an imaging unit 51 , a storage unit 52 and a control unit 53 .
[0070] The imaging unit 51 images an object to acquire image data related to the object. The storage unit 52 stores registration information which is associated at least one predetermined action and at least one destination address. The control unit 53 controls, in response to one of the predetermined action being performed during an operation of the imaging unit 51 , the imaging unit 51 so that the storage unit 52 stores the image data acquired by the imaging unit 51 and creates an e-mail to which the destination address is set and with which the image data which is stored in the storage unit 52 is attached, the destination address being associated with the predetermined action and being stored in the registration information.
[0071] The communication apparatus 50 corresponds to the mobile information terminal 100 according to any one of the above-described first to third exemplary embodiments. The imaging unit 51 similarly corresponds to the camera unit 105 . The storage unit 52 corresponds to the storage unit 106 . The control unit 53 similarly corresponds to the control unit 101 .
[0072] As described above, according to the fourth exemplary embodiment, an effect in which the operability required in transmitting an e-mail attached the image data is further improved can be obtained.
[0073] In addition, the present invention having been described by using the above-described individual exemplary embodiments as examples thereof is realized by supplying the above-described mobile information terminal 100 with a computer program which can realize the functions shown by the flowcharts (shown in FIGS. 3 , 5 and 6 ) having been referred to during the description thereof, and afterward, causing the CPU 70 of the relevant terminal to retrieve and execute the computer program.
[0074] Further, the computer program having been supplied into the terminal may be stored in a storage device (a storage medium), such as the memory 71 or a hard disk device which is readable and writable. Moreover, in such a case, the present invention is constituted by cords representing the computer program, or a storage medium for storing the computer program.
[0075] The present invention has been described with reference to the exemplary embodiments hereinbefore, but the present invention is not limited to the above-described exemplary embodiments. Various changes, which can be understood by those skilled in the art, can be made on the configuration and the details of the present invention within the scope of the present invention.
[0076] This application insists on the priority based on the Japanese application Japanese Patent Application No. 2009-285886 proposed on Dec. 17, 2009 and takes everything of the disclosure here.
INDUSTRIAL APPLICABILITY
[0077] The present invention can be applied to communication apparatuses, such as a mobile phone, a digital camera, a personal handy-phone system (PHS) and a personal digital assistant (PDA).
REFERENCE SIGNS LIST
[0000]
100 mobile communication terminal
101 control unit
102 radio communication unit
103 operation unit
104 display unit
105 camera unit
106 storage unit
107 voice processing unit
108 microphone
109 speaker | Disclosed is a communication device wherein, in order to improve operability when sending electronic mail to which image data has been attached, the communication device is provided with an image capture means for capturing image data of a subject; a storage means for storing registered information associating a predetermined action with a destination address; and a control means that, in response to a predetermined action being performed during operation of the image capture means, controls the image capture means so that the storage means records image data that is being captured by the image capture means, and additionally set a destination address recorded in the registered information associated with the predetermined action as a destination, and creates an electronic mail message to which the recorded image data has been attached. | 7 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims benefit of U.S. Provisional Patent Application No. 60/339,799, “Toy Car Wash Play Set”, filed Oct. 31, 2001, the subject matter of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] The invention relates to toy play sets for use with conventional, unpowered, {fraction (1/64)} scale toy vehicles (e.g., Hot Wheels® and Matchbox® toy vehicles) to enhance the play value of such vehicles.
BRIEF SUMMARY OF THE INVENTION
[0003] According to a first preferred embodiment of the invention, a toy car wash play set comprising a toy vehicle car wash station, including a conveyer belt for transporting a toy vehicle from a first position to a second position, scrubbing rollers for simulating scrubbing rollers used in car washes for full-scale vehicles, and a bubble producing apparatus for simulating soap suds generated by car washes for full-scale vehicles is disclosed. The conveyer belt and the bubble producing apparatus are motorized. The toy car wash play set further comprises a base section, the car wash station being elevated with respect to the base section by structural members connecting the base section to the car wash station. A manually operated elevator for raising a toy vehicle from the base section to the car wash station is provided, along with a rinse station which may be rotated under the action of a manual actuator. The toy car wash may further comprise a drying station which includes a fan which may be rotated under the action of a manual actuator and a rotating table in the base section rotatable under the action of a manual actuator. The motorized bubble producing apparatus further comprises a rotating wheel driven by an electric motor, wherein the rotating wheel has at least one aperture through the rotating wheel, and wherein the rotating wheel is partially immersed in a reservoir of bubble-producing solution, so that the aperture is covered by the bubble-producing solution as the rotating wheel rotates through the bubble-producing solution in the reservoir. The bubble producing apparatus further comprising a fan driven by the electric motor, wherein the fan blows air through the bubble-producing solution covered aperture, thus producing bubbles.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0004] 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 is shown in the drawings embodiments which are presently preferred. It should be understood, however, that the invention is not limited to the precise arrangements and instrumentalities shown.
[0005] In the drawings:
[0006] [0006]FIG. 1 is a front perspective view of a first embodiment of a toy car wash play set in accordance with the present invention;
[0007] [0007]FIG. 2 is a left rear perspective view of the play set of FIG. 1;
[0008] [0008]FIG. 3 is a right rear perspective view of the play set of FIG. 1;
[0009] [0009]FIG. 4 is a top plan view of a second embodiment of a toy car wash play set in accordance with the present invention, the second embodiment being a second generation play set derived from the play set of FIG. 1;
[0010] [0010]FIG. 5 is an exploded perspective view of the major assemblies and connective components of the play set of FIG. 4;
[0011] [0011]FIG. 6 is an exploded perspective view of the components of a twin spiral elevator unit of FIG. 4;
[0012] [0012]FIG. 7 is an exploded perspective view of the components of a wash conveyer/bubble unit of FIG. 4;
[0013] [0013]FIG. 7A is an exploded perspective view of the motor drive of FIG. 7;
[0014] [0014]FIG. 7B is an exploded perspective view of the components of a conveyer/vehicle washer of FIG. 7;
[0015] [0015]FIG. 8 is an exploded perspective view of the components of a rinse unit of FIG. 4;
[0016] [0016]FIG. 9 is an exploded perspective view of the components of a fan dry unit of FIG. 4; and
[0017] [0017]FIG. 10 is an exploded perspective view of the components of a turntable unit of FIG. 4.
[0018] [0018]FIG. 11 is a side elevational view of the conveyer/bubble maker subassembly of FIG. 4 with washer rollers removed;
[0019] [0019]FIG. 12 is a bottom plan view of the conveyer of FIG. 11 with the bottom cover removed; and
[0020] [0020]FIG. 13 is a rear side perspective view of the conveyer of FIG. 12 showing a portion of the gear drive.
DETAILED DESCRIPTION OF THE INVENTION
[0021] Shown in FIGS. 1 - 3 is a first embodiment, assembled, toy car wash play set in accordance with a preferred embodiment of the present invention indicated generally at 10 . The major components of the play set include an elevator 12 with entrance ramp 21 leading to an elevated car wash/conveyer/bubble maker indicated generally at 14 leading to a car rinse station indicated generally at 16 . Ramp section 22 connects the exit of the elevator 12 with the entrance of the car wash conveyer/bubble maker 14 . Ramp section 23 connects the exit of the conveyer with the car rinse station 16 . The car rinse station 16 is connected by yet another ramp section 25 to yet another ramp section 26 , which extends through an elevated base 59 supporting the car wash conveyer/bubble maker 14 and to a “dryer” station indicated generally at 18 . The ramp section 25 is supported by a pier 24 . The discharge end of ramp section 26 connects to a central ramp 27 of a discharge station indicated generally at 20 which has a ramp 28 leading to the elevator 12 and an opposing exit ramp 29 .
[0022] [0022]FIGS. 4 and 5 illustrate a second generation play set indicated generally at 10 ′ derived from the play set 10 of FIGS. 1 through 3 with many components identical. Play set 10 ′ components include an elevator base assembly indicated generally at 30 supporting and operatively coupled to an elevator assembly indicated generally at 40 , which together form the elevator 12 . A conveyer/bubble maker assembly indicated generally at 50 with base indicated generally at 59 form the elevated car wash/conveyer bubble maker 14 . A slightly modified rinse station 16 ′ includes a modified rinse unit base indicated generally at 60 ′ with rinse tub 65 with ladle 66 . A modified dryer station 18 ′ is formed by a modified base indicated generally at 70 ′ with a modified fan assembly 75 ′. A modified discharge station is indicated generally at 20 ′. Also shown are the same ramp sections and supports 21 - 29 .
[0023] Turning now to FIG. 6, the elevator base assembly 30 and elevator assembly 40 are each shown in exploded view. Elevator base assembly 30 includes an entrance ramp 21 coupled to the base member 149 by suitable means such as plug in connectors 168 . Base member 149 includes a first recess 149 a receiving a crank 159 . The crank 159 is rotatably coupled to a gear 169 which engages with two other spur gears 179 beneath the base unit 149 by a bottom cover 199 .
[0024] The elevator 40 includes a spiral base plate 117 received in a recess 149 b of the main base member 149 , a support 127 , the bottom of which is also received in recess 149 b , and a roof 137 mounted to the top of the support 127 . Supported for rotation between the base plate 117 and the bottom of support 127 are drive gears 147 and idler gears 157 . The support 127 includes a pair of top and bottom journals 128 , 129 , respectively, which are configured to receive each of a pair of complementary spirals or screws 138 a , 138 b , one left-hand wound and the other right hand wound. Spiral 138 a is formed by half shells 148 , 158 keyed with a pair of identical spiral mount members 188 at the top and bottom. The second spiral 138 b is formed by half spirals 168 , 178 keyed with a pair of the mounts 188 at the top and bottom. The bottom mounts 188 are keyed to engage gears 147 and the spirals 138 a , 138 b so that the spirals 138 a , 138 b rotate in opposite directions. The right spiral 138 b is rotatably coupled through upper mount 188 to a cover plate 108 , which supports a simulated spotlight 128 for rotation on the roof 137 . Spiral 138 a is similarly coupled through cover plate 118 to a simulated radar antenna 138 for rotation on the roof 137 . Spotlight 128 and radar antenna 138 rotate with the spirals 138 a , 138 b , which are driven to rotate in opposite directions by crank 159 and one of the idler spur gears 179 engaging the left drive gear 147 in base 149 . Right gear 147 is coupled to left gear 147 through idler gears 157 .
[0025] [0025]FIG. 7 indicates the components of the conveyer/bubble maker 14 with base 59 . Referring to FIGS. 4 and 5, in addition to the base 59 , the conveyer/bubble maker 14 includes a driven assembly 50 that includes a conveyer/vehicle washer indicated generally at 51 , a bubble maker indicated at 53 , a light bar indicated generally 54 and a sign 55 . Referring to FIG. 7B, the conveyer/vehicle washer 51 includes a base member 511 and frame member 512 capturing between them a plurality of conveyer rollers 513 as well as drive roller components 514 a and 514 b , which receive at their respective ends drive gears 516 which are coupled together with shaft 517 . The rollers 513 and drum components 514 a and 514 b are rotatably captured between the frame member 512 and base member 511 and rotatably support a continuous conveyer belt 520 . A horizontal roller support 521 and horizontal roller pivot 522 supports horizontal wash roller 523 . Vertical wash rollers 524 are supported on vertical rollers shafts 525 which are keyed into vertical roller mounts 526 , which are crown gears mounted between base and frame members 511 , 512 to engage roller gears 516 . Roller gears 516 are driven by spur gears 528 and 529 . Spur gear 529 has a shaft end 529 a which is keyed to engage a drive socket 585 seen on the right side of FIG. 7 and in FIG. 7A.
[0026] The bubble maker 53 includes a main housing formed by a front housing shell 530 and a rear housing shell 531 . A bubble maker disk 532 is mounted for rotation on the front of the front housing 530 and supported for partial immersion in a bubble tub 533 . The housing 530 / 531 contains and receives a motor drive indicated generally at 56 . The rear housing 531 also contains the battery supply which is retained by means of a door 534 . Various connectors indicated generally 535 are provided in the rear housing 531 to couple the individual batteries of the battery power supply to the motor drive 56 and LED's 543 . A switch housing cover 536 is also removably attached to one side of the rear housing 531 and pivotally supports a switch handle 537 and operating an on/off switch 538 . The sign 55 is captured between the front and rear housings 530 , 531 as is the light bar 54 (FIG. 5) formed by elongated shell halves 541 , 542 . The shell halves 541 , 542 support at their distal ends LED's 543 and LED covers 544 . The motor drive 56 includes a battery operated electric motor 561 and a motor drive housing 562 receiving the motor 561 .
[0027] [0027]FIG. 7A depicts the components of the motor drive 56 . The front housing half 562 b has on the left side a protruding wall 563 defining a fan chamber 564 . A fan 565 is received in the chamber 564 and captured by fan cover 566 . The fan cover 566 has an outlet 567 which is aligned with the openings 532 a through the bubble disk 532 as the disk is rotated (FIG. 7). Attached to the rear housing 562 a are a cam 568 , a movable switch contact 569 and a stationary switch contact 570 . Captured between the housing halves 562 a and 562 b are a series of gears and clutches, which include a motor pinion 571 fixed to the drive shaft 561 a of the motor 561 . Engaged with the motor pinion 571 are three compound gears 572 a , 572 b and 572 c which are mounted for free rotation on jack shafts 573 a , 573 b and 573 c and provide speed reduction. Two clutched output drives are provided, one to drive the bubble disk 532 to rotate and the other to drive the conveyer/vehicle washer 51 to rotate the conveyor belt 520 and the vertical and horizontal rollers 523 , 524 . The drive to the conveyer/vehicle washer 51 is provided by a compound gear 578 mounted for rotation on shaft 579 . The smaller gear of compound gear 578 is engaged by the larger gear portion of third gear 572 c in the direct drive train. The larger gear portion of compound gear 578 engages a geared clutch member 580 , which is biased by spring 581 against a second clutch member 582 , keyed to shaft 583 . Also keyed to shaft 583 is a socket connection 585 , which is exposed on the front housing shell 562 b for engagement with the conveyer drive. Engaged with the larger gear portion of the second compound gear 572 b is a geared clutch member 588 of a bubble wheeled clutch. Member 588 is biased against a second clutch member 589 by spring 590 . Clutch member 589 is keyed to a shaft 591 extending through an opening 564 c on the front housing shell 562 b which drives bubble wheel 532 (FIG. 7).
[0028] FIGS. 8 - 13 depict components of the car wash play set 10 ′ in various states of disassembly. FIG. 11 shows the conveyor/bubble maker assembly 50 with the conveyer/vehicle washer 51 and bubble tank 533 removed. The bubble wheel 532 has been reinstalled on its drive shaft 591 . The blower outlet opening 567 is shown in its alignment with one of the bubble making holes 532 a of the wheel 532 . Also shown in the lower right hand corner is the socket drive 585 which provides power to the conveyer/vehicle washer 51 .
[0029] [0029]FIG. 12 is a bottom plan view of the conveyer/vehicle washer 51 , with the base member 511 removed to show the various gear members 516 , 526 , 528 and 529 . The outer end 529 a of gear 529 protrudes from the rear side of the frame 512 and is shaped to key into socket 585 on the front housing 530 (FIG. 11). FIG. 13 is a rear side perspective view showing the three gears 516 , 528 and 529 engaged.
[0030] [0030]FIG. 8 depicts the rinse tub 65 , ladle 66 and the base 61 of the rinse unit 16 ′ together with various drive components of the rinse unit 16 ′. The rinse unit 16 ′ components include a lower cover 62 which is attached to the bottom side of base 61 and retains a floater gear 612 mounted to rotate on an axle 614 , a bell crank 616 having a toothed face 618 meshing with the teeth of gear 612 , a torsional spring 620 and a handle 622 secured to the outer end of bell crank 616 so as to protrude outwardly from the base 61 through a slot 61 c . The bell crank 616 is mounted between the base 61 and lower cover 62 to be pivoted back and forth using the handle 622 to rotate the floater gear 612 . The floater gear 612 is positioned for engagement with a rinse tub gear 630 , which is located within the base 61 but coupled to a rinse tub mount 632 which is located in a central well 61 a at the center of a larger well 61 b on the upper surface of the base 61 . The rinse tub mount 632 has its own multisided central recess 632 a which is configured to receive and key with the same multiple sides on a rinse tub collar 639 , which is nonrotatably attached to the bottom of rinse tub 65 . Collar 639 keys the tub 65 to the tub mount 632 in recess 61 a . The tub 65 is removably mounted to the base 61 in recess 61 b and rotated clockwise by cyclic movement of handle 622 . The ladle 66 is received in the bottom of tub 65 . The ladle 66 cushions the impact of toy vehicles dropping into the tub 65 from ramp section 23 and can be used to lift vehicles from the tub 65 and deposit the lifted vehicles on ramp section 25 leading to the dryer station 18 ′. The modified rinse station 16 ′ differs from the original in the location and movement of the rinse tub actuator.
[0031] [0031]FIG. 9 depicts the major components of the “dryer” station 18 ′ including base unit 70 ′ and fan assembly 75 ′. Base unit 70 ′ includes a base housing 71 and a fan actuator including a drive housing 72 (FIG. 5) formed by front and rear housing halves 720 , 722 that contains a rack handle 73 supporting a rack 732 for up and down movement within the housing 72 . Rack 732 is engaged with and drives a compound acceleration gear 734 which in turn drives a floater gear 735 rotating on axle 736 . The handle 73 is biased upwardly by torsion spring 738 . An upper portion of the floater gear 735 is exposed in the upper corner of the housing 72 (FIG. 5). The fan assembly 75 ′ includes a front stationary drum 752 , a rear drum cover 754 and a “fan” member 756 mounted on a plurality of bearings 758 to rotate on the drum 752 . The exposed upper edge of floater gear 735 is engaged with a gear integrally molded with the rear of the fan 756 for clockwise rotation of the fan 756 (when viewed from the front) as the handle 73 is pushed down and released. The dryer station 18 ′ differs from the original dryer station 18 of FIGS. 1 - 3 in the configuration of “fan” 75 and the location and construction of the fan actuator.
[0032] [0032]FIG. 10 depicts the components of modified discharge station 20 ′ including a base 80 with a central recessed opening 80 a receiving a circular turntable member 82 . The circumferential outer edge of the turntable 82 bears a plurality of gear teeth 82 a which are engaged with a gear 83 supported for rotation inside the base 80 and coupled to a handle 84 in the form of a fire hydrant received in an opening 80 b in the front right area of the top of the base 80 . Rotation of the handle/fire hydrant 84 causes rotation of the gear 83 and turntable 82 . An opening 80 c in the upper left corner of the base 80 as seen in FIG. 10 receives a sub-base 86 of a gate/gate house actuator 85 . Sub base 86 has a central post 862 supporting a compression coil spring 87 which in turn supports a gate/house base 88 for sliding movement up and down post 862 . Base 88 in turn, supports a gate house 89 . The gate portion 882 of base 88 is depressed into a slot 80 d in the base 80 by pressing down on the house 89 . The modified discharge station 20 ′ differs from the original 20 in FIGS. 1 - 3 in that the handle of the original discharge station 20 turntable was located originally behind rather than in the front of exit ramp 29 .
[0033] Operation of either version of the play set 10 , 10 ′ is substantially the same. The child can drive a toy vehicle up the ramp 21 onto the elevator base member 149 and manually place the toy vehicle between spirals 138 a , 138 b of the elevator assembly 40 . The spirals are rotated by rotation of the crank 159 . Rotation of the crank 159 clockwise rotates the left spiral 138 a counterclockwise and the right spiral 138 b clockwise when viewed from above. The spirals 138 a , 138 b drag the toy vehicle loaded into the bottom of the elevator 40 to the rear of the elevator 40 where the vehicle impacts the back 127 a of the support 127 (FIG. 3). The spirals 138 a , 138 b continue to drag the vehicle into the elevator 40 pressing it against the back of the support 127 as the spirals 138 a , 138 b rotate beneath the vehicle and elevate the vehicle as they turn. Eventually, the vehicle passes through opening 127 b in the top center rear of the spiral support 127 . The vehicle is pushed by the spirals 138 a , 138 b onto the ramp section 22 which deposits the vehicle in the left end of the conveyer/vehicle washer 51 of the car wash/conveyor/bubble maker station 14 (FIG. 3).
[0034] The conveyer/vehicle washer 51 and bubble maker 53 are the only electrically powered components of either play set. The conveyer/vehicle washer 51 and bubble maker 53 , are driven by the motor drive 56 , the operation of which is controlled by on/off switch 537 . The motor drive 56 provides a rotational output in the form of shaft 591 which rotates bubble maker disk 532 through a soapy water or other bubble forming solution in bubble tub 533 and past blower outlet 567 in front housing cover 566 . The motor drive 56 further directly drives centrifugal fan 565 through front gear housing 562 b causing the fan 565 to blow air through the outlet 567 aligned with the openings 532 a and past which openings 532 a in the bubble disk 532 must pass. The conveyer 520 is driven by the power takeoff through socket 585 . LED 543 in the light bar 54 are caused to flash on and off by rotation of LED cam 568 on shaft 583 . The conveyer 520 carries the toy vehicle beneath the overhead roller 523 and through the vertical rollers 524 to ramp section 23 , which directs the toy vehicle by gravity into the rinse tub 65 (FIGS. 1 - 3 ).
[0035] The rinse tub 65 is also rotated clockwise (viewed from above) by movement and release of the bell crank handle 622 . The floater gear 612 only engages the tub gear 630 while the handle 622 is being moved against spring 620 . The rinse tub 65 may have a solid wall but could have a hollow wall construction which permits the addition of a liquid such as water within the wall, which can be made transparent, to give the impression that the vehicle within the tub is actually immersed in a rinse liquid. The vehicle is manually lifted from the tub 65 using the ladle 66 and is deposited on the ramp section 25 , which leads to ramp section 26 passing through elevated base 59 and through the fan assembly of dryer station 18 or 18 ′. The “fan” of original fan unit 18 is caused to rotate by depressing and releasing a cylinder at the right front corner of the dryer station 18 in FIG. 1 while the fan member 756 in FIG. 9 is caused to rotate by depressing and releasing rack handle 73 at the right rear of dryer station 18 ′. Again, floater gear 735 only engages fan 756 while handle 73 is being depressed. The vehicle on ramp 26 is stopped at the forward end of the ramp by gate portion 882 , which can be depressed by depressing the gate/house 89 . The vehicle drops from the ramp section 26 across the central ramp 27 to the turntable 82 . Turntable 82 can be rotated by handle 84 to direct the vehicle to ramp 28 leading to the elevator 12 or to the exit ramp 29 .
[0036] 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. | A toy car wash play set including a toy vehicle car wash station, including a conveyer belt for transporting a toy vehicle from a first position to a second position, scrubbing rollers for simulating scrubbing rollers used in car washes for full-scale vehicles, and a bubble producing apparatus for simulating soap suds generated by car washes for full-scale vehicles. The conveyer belt and the bubble producing apparatus are motorized. The toy car wash play set further comprises a base section, the car wash station being elevated with respect to the base section. A manually operated elevator for raising a toy vehicle from the base section to the car wash station is provided, along with a rinse station which may be rotated under the action of a manual actuator. The toy car wash may further comprise a drying station which includes a fan which may be rotated under the action of a manual actuator and a rotating table in the base section rotatable under the action of a manual actuator. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of U.S. Provisional Application Ser. No. 60/215,447, filed on Jun. 30, 2000.
TECHNICAL FIELD
The present invention relates generally to database systems. More particularly, the present invention relates to a system and method for storing and accessing data in data cells.
BACKGROUND OF THE INVENTION
Current database technology generally relies on one of three main types: relational databases, object-oriented databases, or a combination of relational and object-oriented databases. Relational databases divide the world into tables, with columns defining data fields and rows defining data records. Relational databases then use relationships and set theory to model and manage real-world data. Object-oriented databases model the world in objects, in which data is encapsulated into objects and associated with methods and procedures. Object-relational databases are a combination of the previous two types.
All of these database constructs are primarily concerned with organizing data into predefined formats and structures. In order to represent the data, an object or a table must be defined with known data characteristics. For instance, before data can be stored in an object, the object must be defined to allow certain types of data, and the object must be pre-associated with relevant procedures. Alternatively, in the relational database construct, a table must be defined before any data can be stored in the table, with each column being defined to allow only certain amounts and types of data.
Unfortunately, this pre-defining of data is always done without a perfect knowledge of the real-world data being modeled. As a result, once the database is actually implemented, changes often must be made to the table definitions or objects so as to more accurately reflect the real-world data. These changes will typically require that the database be reconstructed according to the new definitions. In addition, even after an optimum definition of the real-word data is created, the existing database constructs are not flexible enough to handle unique situations that do not fit the optimum definition. Once this definition is created, along with the related data formats, relationships, and methods, the created structure cannot be easily modified to allow the representation of the unusual case.
What is needed is a database construct that is not as rigid as the existing models of relational and object-oriented databases. This preferred model would not require a pre-definition of the data, but would rather allow data to be entered as it is encountered. Associations between data elements could be developed on-the-fly, and new data could be added to the system even if the pre-existing model did not expect such data to exist.
SUMMARY OF THE INVENTION
The present invention meets the needs and overcomes the associated limitations of the prior art by storing data in cells. A data cell contains only a single element of data. By storing all data in these cells, data can be dynamically structured according to changing needs. In addition, the information stored in the cell is easily accessible, meaning that data extrapolation is quick and easy. Additional references to a particular data value will always use the one data value that has been dynamically normalized by the present invention. Finally, meta data that defines data structures and types are stored in data cells, which allows the data collection to be self-defining.
The data cell of the present invention includes four elements: an Entity Instance Identifier (identified in this application through the letter “O”), an Entity Type Identifier (“E”), an Attribute Type Identifier (“A”), and an Attribute Value (“V”). For instance, the existence of an employee who is named “Johnson” would be represented by a single cell. The Entity Type Identifier would be an “Employee.” The Entity Instance Identifier is an identifier, such as the number “1,” that allows the employee to be uniquely identified. The Attribute Type Identifier would be the “Employee Name,” and the Attribute Value would be “Johnson.” The data cell would look like the following:
O
E
A
V
1
Employee
Employee Name
Johnson
Groups of cells with identical O and E values constitute a cell set, and contain information about a specific instance of an entity. Every cell contains a unique combination of O, E, A, and V, meaning that each cell is unique within any particular information universe.
Relationships between cells and cell sets are created through the use of “linking” or “synapse” cells. Synapse cells are created through a process of transmutation. In transmutation, two cell sets are associated with each other through the creation of two synapse cells. The first synapse cell has the O and E values of the first cell set, and has an A and V value equal to the E and O value, respectively, of the second cell set. The second synapse cell has the O and E values of the second cell set, and has as its A and V values the E and O value, respectively, of the first cell set.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a prior art database table showing a sample representation of employee data in a relational database system.
FIG. 2 is a prior art database table showing a sample representation of project data in a relational database system.
FIG. 3 is a prior art database table showing a sample representation of relationship data in a relational database system.
FIG. 4 is a schematic illustration of a cell of the present invention showing the four components of a data cell.
FIG. 5 shows an example data cell.
FIG. 6 is a cell listing of present invention data cells containing the data stored in the tables shown in FIGS. 1 and 2 .
FIG. 7 is a cell listing showing three cells that can be added to the cell set list.
FIG. 8 is a schematic drawing showing the first stage of transmutation to create a synapse cell linking an employee cell set with a project cell set.
FIG. 9 is a schematic drawing showing the second stage of transmutation to create a second synapse cell linking a project cell set with an employee cell set.
FIG. 10 is a cell listing showing a portion of the data cells shown in FIG. 6 along with the synapse cells setting forth the relationships found in FIG. 3 .
DETAILED DESCRIPTION OF THE INVENTION
1. Prior Art
FIGS. 1 through 3 show three relational tables as would be used in the prior art. The first table 10 shown in FIG. 1 contains employees. There are four columns in this table 10 , namely employee name 12 , social security number 14 , address 16 , and salary 18 . These columns 12 , 14 , 16 , and 18 define the different types of data that can be contained in table 10 . Table 10 also contains three rows 20 of data. Each row 20 contains information about a different employee in the table 10 . Data values for a relational data table such as table 10 are determined by finding the field that exists at the cross section between a particular row 20 and a particular column 12 , 14 , 16 , or 18 .
Similarly, the second table 40 shown in FIG. 2 contains information about projects that employees might work on for their employer. The projects table 40 shown in FIG. 2 contains only two columns, namely a project name column 42 and a project size column 44 . The projects table 40 contains information about three projects, and therefore the table contains exactly three rows 46 .
It is often important in databases to model the fact that some data is associated with other data. In the example of employees and projects, as shown in FIGS. 1 and 2 , the database should show that certain employees work on certain projects. If only one employee can be assigned to a project, it would be possible to associate an employee with a project simply by adding an employee column to the project table 40 . Similarly, if each employee were assigned only to a single project, a project column in the employee table 10 would serve to make the association.
However, in the real world, it is likely that each project will have more than one employee assigned to it, and it is likely that each employee will be assigned to more than one project. To handle the possibility of these types of many-to-many relationships, it is necessary to utilize a third table 60 , such as that shown in FIG. 3 . This third table 60 contains only two columns, namely project name 62 and employee name 64 . The project name column 62 contains the same type of information as the project name column 42 in table 40 . Likewise, employee name column 64 contains the same information as employee name column 12 of table 10 . Each row 66 represents a relationship between a row 20 in table 10 (i.e., an employee) and a row 46 in table 40 (i.e., a project). Thus, table 60 shows that the Red project has two employees working on it, namely Johnson and Anderson, while the Yellow and Green projects have only a single employee assigned to them, namely Rodriguez.
Very often, relational databases utilize key fields to aid in data access. The data in a key field must be unique for the entire table. Thus, a key field for the employee table 10 might be the social security number column, since the U.S. government strives to ensure that each social security number is unique to one individual. In project table 40 , it might be wise to create a project number column that is subject to a uniqueness constraint to ensure that no two rows 46 contain the same project number. The key fields are then pre-indexed, which allows fast access to data in a table when the key field is known. These key fields can then be used to create efficient relationships in a table such as table 60 .
2. Data Cells
The present invention differs from traditional relational and object-oriented databases in that all data is stored in data cells 100 . In its most generic sense, a data cell 100 is a data construct that contains a single attribute value. In comparison to a relational database table, a single data cell would contain the value of a field found at a single column and row intersection. The data cell 100 of the present invention differs from an intersection in a data table in that the data cell 100 is not stored within a table or an object construct. Because there is no external construct to associate one cell 100 with another, each data cell 100 of the present invention must be self-identifying. In other words, the data cell 100 must contain not only the value of interest, but it also must contain enough information to identify the attribute to which the value relates, and to associate the attribute with a particular instance of an entity.
As shown in FIG. 4 , the preferred embodiment of a data cell 100 utilizes four fields: an Entity Instance Identifier 102 , an Entity Type Identifier 104 , an Attribute Type Identifier 106 , and an Attribute Value 108 . These four fields 102 , 104 , 106 , and 108 are also identified by the one letter titles “O,” “E,” “A,” and “V,” respectively.
The O field 102 is the Entity Instance Identifier, and serves to uniquely identify the entity that is associated with the data cell 100 . The E field 104 is the Entity Type Identifier, which identifies the type of entity associated with the cell 100 . The O field 102 and the E field 104 together uniquely identify an entity in an information universe. An information or data universe is defined as the complete collection of data cells 100 that exist together. All cells 100 with the same O field 102 and E field 104 within an information universe are considered part of the same cell set 101 . All cells 100 within a cell set 101 are used to store data and relationships about the particular entity instance identified by the combination of the O and E fields 102 , 104 .
The A or Attribute Type Identifier field 106 indicates the type of information found in the cell 100 . Finally, the V or Attribute Value field 108 contains the actual real-world information that is found in the cell 100 . The data in V 108 can be of any type, including a character string, a number, a picture, a short movie clip, a voice print, an external pointer, an executable, or any other type of data.
Each cell 100 contains one unit or element of information, such as the fact that a particular employee makes $ 50 , 000 per year. The data cell 100 that contains this information might look like that shown in FIG. 5 . The O field 102 contains the phrase “Object ID,” which indicates that the O field 102 contains some type of identifier to uniquely identify the employee that has this salary. In the preferred embodiment, the object identifiers in the O field 102 are integers. The E field 104 of FIG. 5 indicates that the type of entity that this cell 100 applies to is an employee. The A field 106 shows that this cell 100 describes the salary attribute. Finally, the V field 108 contains the actual, real-world data for the cell 100 , namely the $ 50 , 000 salary.
FIG. 6 shows the data found in FIGS. 1 and 2 in the form of data cells 100 of the current invention. For each employee in table 10 , the four columns 12 , 14 , 16 , and 18 of data are embodied in four separate data cells 100 . The data for the employee named Johnson are found in the first four data cells 100 in FIG. 6 . Since these first four data cells 100 all contain the same O and E values, these cells 100 form a cell set 101 . More specifically, the O field 102 and E field 104 indicate that this first cell set 101 contains information about instance number “1” of an entity of type “Employee.” The A fields 106 of these four cells 100 represent the four attributes for which data has been stored, namely Employee Name, Social Security, Address, and Salary. The V fields 108 holds the actual values for these attributes.
An examination of FIGS. 1 , 2 , and 6 reveals that all of the information stored in tables 10 and 40 has been replicated in individual data cells 100 of FIG. 6 . In FIG. 1 , the employee Anderson has no salary value in column 18 . Thus, the second cell set 101 in FIG. 6 contains only three cells 100 , since no cell 100 is needed to represent that fact that no information is known about Anderson's salary. This differs from relational database table of FIG. 1 , where each column 12 , 14 , 16 , and 18 must exist for all employee rows 20 , even in cases where no value exists and the field simply sits empty.
Moreover, this flexibility makes it possible to have additional cells 100 for some cell sets 101 that do not exist in other cell sets 101 . FIG. 7 shows three possible additional cells 100 that relate to the employee named “Johnson.” With the flexibility of the cell-based data structure of the present invention, it is possible to add cells 100 such as those shown in FIG. 7 on the fly. There is no need to restructure the database to allow such new information, as would be required if new information were to be tracked in a prior art relational or object oriented database.
3. Transmutation
As shown in FIG. 3 , an association between the employee named Johnson and the project named Red is created in a relational database by creating a row 66 in a relationship table 60 . An association between cells 100 and/or cell sets 101 can also be created in the cell-based data structure of the present invention. This is accomplished through the use of special types of cells known as synapse cells 110 .
Synapse cells 110 are created through a process known as transmutation, which is illustrated in FIGS. 8 and 9 . FIG. 8 shows two conventional cells 100 , the first belonging to the cell set 101 relating to the employee named Johnson, and the second belonging to the cell set 101 relating to the Red project. The synapse cell 110 that establishes an association between these two cell sets 101 is created by making a new synapse cell 110 based upon the values of cells 100 from the two cell sets 101 . The new synapse cell is given the same O 102 and E 104 values of the first cell set 101 , in this case the values “1” and “Employee.” The A 106 and the V 108 values of the synapse cell 110 are taken from the E 104 and the O 102 values, respectively, of the second cell 100 . This “transmutation” of the existing cells 100 into a new synapse cell 110 is represented in FIG. 8 by four arrows.
The association of the two cell sets 101 is not complete, however, with the creation of a single synapse cell 110 . This is because every association created in the present invention is preferably a two-way association, and therefore requires the creation of a second synapse cell, as shown in FIG. 9 . This second synapse cell 110 is created using the same O 102 and E 104 values as that of the second cell 100 . The A 106 and the V 108 values of this second synapse cell 110 are taken from the E 104 and the O 102 values, respectively, of the first cell 100 being associated. The transmutation into the second synapse cell 110 is shown by the arrows in FIG. 9 .
When the two synapse cells 110 shown in FIGS. 8 and 9 have been created, then the association between the cell sets 101 has been completed. FIG. 10 shows the cell listing of FIG. 6 , with the first and last cells 100 of FIG. 6 surrounding vertical ellipses that represent all of the other cells 100 of FIG. 6 . In addition to the cells 100 of FIG. 6 , the cell listing of FIG. 10 includes the synapse cells 110 that are needed to represent the relationships shown in table 60 of FIG. 3 . It is clear that each synapse cell 110 has a partner synapse cell 110 that shows the same association in the opposite direction. Thus, eight synapse cells are used to represent the four relationships shown in table 60 of FIG. 3 .
The synapse cells 110 are generally treated the same as other cells 100 that exist in a data universe. Occasionally, it is useful to be able to know whether a particular cell 100 contains actual data, or is a synapse cell 110 . In the present invention, this is accomplished by associating a value, bitmap, or other flagging device with each cell 100 in the data universe. By examining this value, it would be possible for a database management system to immediately determine whether the cell 100 is a synapse cell 110 or contains real-world data.
The terms synapse and cell are used in this description to allude to the similarity between the present invention and the way that the human brain is believed to store memories. When the brain encounters new data, the data is stored in the brain's memory cells. The brain does not pre-define the data into tables or objects, but rather simply accepts all data “on-the-fly” and puts it together later.
Research has shown that the synapses in the brain hook cells together. Where synapse pathways are more frequently traversed in the brain, those pathways become thicker or are connected with more synapses. As a result, these connections become stronger. At the same time, other connections can be formed in the brain that can be loose or incorrect. Yet these memory errors to not corrupt the database of the brain. Rather, the brain is constantly checking associations for validity, and correcting those associations as needed.
This is similar to the present invention. Data is encountered and placed into data cells 100 . There is no need to predefine tables or objects before a new source of data is encountered. New cells 100 are simply created as needed. Synapse cells 101 can be formed between those data cells 100 on the fly. The associations that are represented by these synapse cells 101 can be strong or week, and be broken as needed without altering the structure of the database.
4. Conclusion
The above description provides an illustrative version of the present invention. It should be clear that many modifications to the invention may be made without departing from its scope. For instance, it would be possible to include only some of the elements of the present invention without exceeding the essence of the present invention. Therefore, the scope of the present invention is to be limited only by the following claims. | A method and system is presented for storing data in data cells containing only a single element of data. Each data cell includes four components: an Entity Instance identifier (“O”), an Entity Type identifier (“E”) an Attribute Type identifier (“A”), and an Attribute Value (“V”). Groups of cells with identical O and E values constitute a cell set. Every cell contains a unique combination of O, E, A, and V. Relationships between cell sets are established by creating two synapse cells. The first synapse cell has O and E values of the first cell and has A and V values equal to the E and O value, respectively, of the second cell. The second synapse cell, has O and E values of the second cell, and has as its A and V values the E and O value, respectively, of the first cell set. | 8 |
FIELD OF THE INVENTION
[0001] This invention relates to a set of brackets for constructing a wooden gate.
BACKGROUND OF THE INVENTION
[0002] Corner gate brackets can be used to frame right angle joints between structural members of a gate at each of four corners. Such gate brackets are meant to provide a reliable guide for the positioning of the structural members to assist the do-it-yourself handy man. In addition, corner gate brackets are meant to minimize or eliminate the distortion of the gate structure over time.
[0003] Gate brackets are typically made of metal so as to resist bending and to ensure a rigid structure. Typically, a gate bracket comprises elongate flat metal members arranged in perpendicular relationship so as to guide the formation of a right angle between the pieces of structural lumber which are made to abut the elongate members. An example of such a system is disclosed in Boroviak, U.S. Pat. No. 6,896,244.
[0004] Parallel elongate flat metal members may be provided in a spaced relationship for bracketing structural lumber on two opposed sides and to provide a perpendicular arrangement of such elongate members. Such a system is disclosed in Cosgrove, U.S. Design Patent No. D410,835. In Cosgrove, each pair of parallel elongate flat metal members form a U-shape and the two U-shaped pairs are welded together to form the overall bracket.
[0005] To provide structural rigidity for gate brackets, typically either a brace member is provided, as in Boroviak, or relatively thick metal members are provided, as in Cosgrove. In Boroviak, the diagonal brace member is welded to each of the perpendicular elongate metal members, which are in turn welded together at the intersection.
[0006] It is an object of the present invention to provide a structural gate bracket that serves to effectively frame a right angle between structural pieces, such as 2×4 pieces of lumber, while maintaining the structural relationship of the joint, over time, and at the same time not providing undue weight to the gate bracket, avoiding overly thick metal elements or excessive welding.
[0007] This and other objects of the invention will be better understood with reference to the detailed description of the invention which follows.
SUMMARY OF THE INVENTION
[0008] According to the invention, there is provided a web extending in a plane. A first pair of perpendicular elongate portions are provided normal to the plane of the web, preferably along two edges of the web. A second pair of perpendicular elongate portions are provided normal to the plane of the web in spaced parallel relationship to the first pair.
[0009] In another aspect of the invention, each pair of elongate portions comprises flanges of said web.
[0010] In a further aspect, an opening is provided in said web member between the first and second pairs of elongate portions.
[0011] In a further aspect, the opening extends between a first pair of parallel first and second members and between a second pair of parallel first and second members thereby defining a substantially L-shaped opening.
[0012] In another aspect, the invention comprises a web extending in perpendicular directions in a plane, said web including a first flange extending normal to said plane parallel to a first one of said directions, a second flange extending normal to said plane parallel to a second one of said directions in an end-to-end perpendicular, abutting relationship to said first flange. The web has an outer perimeter, an opening extending in generally perpendicular directions within said perimeter, a third flange normal to said plane along an edge of said opening and in spaced relationship to said first flange and a fourth flange normal to said plane along an edge of said opening and in spaced relationship to said second flange.
[0013] In another aspect, the invention comprises a method of forming a gate bracket comprising:
providing a web extending generally in perpendicular directions within a plane and having an opening within the perimeter thereof, said opening extending generally in said perpendicular directions; bending one edge of said web to provide a first flange normal to said plane; bending a second edge of said web to provide a second flange normal to said plane and abutting said first flange in a perpendicular relationship; bending a portion of said web that is adjacent to an edge of said opening to form a third flange normal to said plane; bending a portion of said web that is adjacent to an edge of said opening to provide a fourth flange normal to said plane and in perpendicular abutting relationship to said third flange.
[0019] The foregoing was intended as a broad summary only and of only some of the aspects of the invention. It was not intended to define the limits or requirements of the invention. Other aspects of the invention will be appreciated by reference to the detailed description of the invention and to the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] The invention will be described by reference to the detailed description of the invention and to the drawings thereof in which:
[0021] FIG. 1 is a front perspective view of a first embodiment of the invention;
[0022] FIG. 2 is a rear perspective view of the first embodiment of the invention;
[0023] FIG. 3 is a plan view of the first embodiment;
[0024] FIG. 4 is a plan view of a web member, prior to bending, according to the method of the first embodiment;
[0025] FIG. 5 is a front perspective view of a web member of FIG. 4 after the bending of the first and second flanges according to the method of the first embodiment;
[0026] FIG. 6 is a rear perspective view of a second embodiment of the invention; and
[0027] FIG. 7 is a front perspective view of a third embodiment of the invention;
[0028] FIG. 8 is a front perspective view of a fourth embodiment of the invention; and
[0029] FIG. 9 is a plan view of the fourth embodiment of the invention, prior to bending.
DETAILED DESCRIPTION OF THE INVENTION
[0030] Throughout the following description specific details are set out to provide a more thorough understanding of the invention. However, the invention may be practiced without these particulars. In other instances, well known elements have not been shown or described in detail to avoid unnecessarily obscuring the present invention. Accordingly, the description and drawings are to be regarded in an illustrative, rather than a restrictive, sense.
[0031] Referring to FIGS. 1 , 2 and 3 the gate bracket of the first embodiment 10 includes a web 12 extending within a plane generally along two perpendicular directions 14 and 16 in a generally L-shaped configuration.
[0032] Web 12 has a generally L-shaped opening 18 that extends in perpendicular directions parallel to directions 14 and 16 . Opening 18 is spaced inwardly from the perimeter 20 of the web 12 .
[0033] A first flange 22 extends normal to the plane of the web 12 along a perimetral edge 24 of web 12 , parallel to direction 14 . A second flange 26 extends normal to the plane of the web 12 along a perimetral edge 28 of web 12 , parallel to direction 16 . First 22 and second 26 flanges are in abutting perpendicular relationship to one another.
[0034] A third flange 30 extends normal to the plane of the web 12 along an edge 32 of opening 18 . Third flange 30 extends parallel to first flange 22 and in spaced relationship therewith.
[0035] A fourth flange 34 extends normal to the plane of the web 12 along an edge 36 of opening 18 . Third 30 and fourth 34 flanges are in abutting perpendicular relationship to one another.
[0036] The spacing between first 22 and third 30 flanges is selected so as to correspond to the dimensions of structural pieces (such as lumber, plastic or metal), to be used in the gate system, as is the spacing between second 26 and fourth 34 flanges.
[0037] One end of each of the third and fourth flanges may optionally be further bent away from opening 18 as at 38 , 40 in order to provide additional structure rigidity to the flanges.
[0038] A hinge 42 may be provided on selected brackets according to whether the bracket will be used on the hinge side of the gate to be constructed.
[0039] One advantage of the first embodiment of the invention is that the entire structure, save for the attachment of a hinge, may be formed from a single flat sheet of materials, as will be described by reference to FIGS. 4 and 5 .
[0040] There is first provided a web 12 as shown in FIG. 4 that extends generally in two perpendicular directions 14 and 16 . Web 12 is cut at 17 , 19 , 21 and 23 , with cut 19 being parallel to direction 14 and cut 21 being parallel to direction 16 . Each cut 17 , 19 , 21 , 23 is spaced inwardly from the edges of web 12 . A gap 15 is provided at the juncture cut lines 19 and 21 .
[0041] An elongated rectangular portion 30 is bent from the plane of the web so as to be normal to it and an elongated rectangular portion 34 is bent from the plane of the web so as to be normal to it to form flanges 30 and 34 .
[0042] Short end portions 29 , 31 of flanges 30 , 34 may then be bent along lines 33 , 35 so as to be normal to flanges 30 , 34 to provide structural rigidity to flanges 30 , 34 .
[0043] An elongated rectangular portion 22 along edge 25 of web 12 is bent so as to form a flange 22 that is normal to the plane of the web 12 . An elongated rectangular portion 26 along edge 27 of web 12 is bent so as to form a flange 26 that is normal to the plane of the web 12 . Once bent, flanges 22 and 26 are in abutting perpendicular relationship and flanges 30 , 34 are in abutting perpendicular relationship, as seen in FIGS. 1 and 2 .
[0044] As shown in a second embodiment 60 illustrated in FIG. 6 , the shape of the web 12 may be altered in area 68 , for example to increase rigidity, and the hinge 42 may not be provided on selected brackets.
[0045] As shown in the third embodiment 70 shown in FIG. 7 , alternate embodiments of the invention do not require web 12 to extend into area 68 beyond flanges 30 and 40 . Optional piece 76 could be welded between flanges 30 and 40 to assist with the structural integrity of the bracket.
[0046] A fourth embodiment 80 is shown in FIG. 8 in which a straight edge 86 can brace the portion between perpendicular structural members on a corner. Flanges 82 and 84 can be attached to the outside edges of structural members while flanges 88 and 90 can be attached to the inside edges. Flange 82 together with flange 88 and flange 84 together with flange 90 can firmly hold the structural members (such as 2×4 lumber pieces) of the corner of a gate in place. When folded in position, flanges 88 and 90 leave openings 92 and 94 in embodiment 80 . The edge along 86 can be reinforced by folding the edge over itself, as shown in FIGS. 8 and 9 . Further, a hole 96 may be provided, for example to reduce the overall material used and the weight of the embodiment. For versions of embodiment 80 used on the side of the gate to which a hinge should be attached, a hinge may be attached to one of flanges 82 and 84 , and preferably to flange 84 . As shown in FIG. 9 with reference to planar layout 98 , embodiment 80 can be made from a flat piece of unitary material, such as sheet metal.
[0047] In a method of assembly of a gate or door, four brackets as described above, may be used in the construction of a gate. Two brackets placed on adjacent corners may have hinges, whereas the two other brackets may not have hinges. Structural pieces, such as lumber, plastic or metal members may be used in the assembly of the gate. Typically four structural pieces of lumber (or equivalent) will be used to create a gate frame in a square or rectangular formation. Gate face structural members, such as 2×4 pieces of lumber, can then be secured to the gate frame to complete the gate. As understood in the art, the face structural members could be attached to one side of the gate frame, on both sides, or having face structural members in an alternating pattern with structural members secured to opposing sides of the gate frame.
[0048] Many other variations or additional features can be practiced in accordance with this invention. For example, a structural brace 66 could be added between flanges 30 and 34 . The structural brace would help maintain the structural integrity of the corner of the gate. The structural brace could be placed at any suitable angle, such as 45 degrees from each of flanges 30 and 34 .
[0049] Portions 64 of web 12 could be punched out, cut out, or otherwise removed from the structure without departing from the scope of the invention. Cutting out portions 64 of web 12 could be of any desired shape and location and would reduce the amount of material, such as metal, and reduce the weight of the gate bracket.
[0050] In certain embodiments, reinforcing lines 62 could be used to add structural integrity to the metal. Reinforcing lines 62 could be depressions formed on one side of the metal, with a corresponding protrusion on the opposite side of the metal. To maximize effectiveness of the reinforcing lines 62 , the lines may be linear. Reinforcing lines 62 could be added to web 12 or flanges 30 and 31 .
[0051] It will be appreciated by those skilled in the art that the first and second embodiments have been described above in some detail but that certain modifications may be practiced without departing from the principles of the invention. | A gate bracket is formed of a planar web in which two rectangular portions along two edges of the web are bent to define a first pair of perpendicular flanges, and two other rectangular portions are bent from an inner portion of the web to form a second pair of perpendicular flanges. The flanges of the first pair are spaced from the flanges of the second pair by a distance corresponding to the dimensions of the structural members used to construct the gate. The invention provides a rigid bracket of simpler and lighter construction than prior art brackets. | 8 |
BACKGROUND OF THE INVENTION
The present invention relates generally to an automatic body-part cleansing apparatus for cleansing the body surface of fecal matter and urine while the user is positioned to utilize a toilet, and more particularly an automatic cleansing apparatus for such an application which apparatus includes means for systematically spraying cleansing and rinsing fluids and subsequently blowing warm air onto the appropriate body surface.
The nature of the human excretory process presents a fundamental situation that virtually all humans must deal with--that of cleansing the body surface of waste material after its elimination from the body. While many humans resort to the use of toilet tissue to deal with the situation, others, such as physically impaired persons, have difficulty utilizing toilet tissue for this purpose without substantial assistance from another individual. Many individuals who are able to perform the cleansing function with toilet tissue would also prefer not to for reasons such as personal hygiene and personal preference. Alternatives to cleansing with toilet tissues have thus been sought.
Therefore, even for a fully capacitated individual, as the natural excretory process are usually performed while seated on a toilet, cleansing of an individual's crotch area while the individual is positioned in ordinary relation with the toilet seat is a desirable function, particularly after the individual has utilized the toilet for defecation. Beyond the use of toilet tissue for achieving this function, the prior art has utilized a variety of apparatuses. However, as will be partially discussed herein, the teachings of the prior art have limitations and the present invention provides solutions for overcoming many of those limitations.
For an incapacitated individual such as a quadrapalegic, the cleansing of private body parts, the flushing of a toilet and even the utilization of a toilet (including particularly the containment of urine within the toilet bowl by a male) may be difficult if not impossible. Such incapacitation is not confined to specific age groups and, thus, even a person in the prime of his life may require assistance from another person to accomplish these simple but extremely private functions. As a result, emotional and psychological struggles are commonly encountered by such incapacitated persons. These containments, cleansing and flushing tasks are extremely personal and can be embarrassing, to say the least, for a person who must rely on another to perform such tasks. Practically, such assistance also creates difficult situations for other individuals who live with and must accordingly assist incapacitated individuals. These problems often cause emotional and psychological turmoil to an incapacitated individual since such a person often feels to blame for the inconvenience of others around him. The emotional strain of such feelings of guilt and embarrassment ingrain and heighten the unavoidable feelings of inadequacy and often materialize into other physical ailments such as constipation.
Perhaps the most common type of the alternatives to toilet tissue is that which employs a means for spraying liquid onto body parts of a toilet user. This type of apparatus is evidenced in the following U.S. Patents: Epstein, U.S. Pat. No. 4,441,219; Ando, U.S. Pat. No. 4,389,738; and Brannon, U.S. Pat. No. 1,957,625.
However, the apparatuses of these patents which utilize the spraying of liquid onto the body parts are limited in their effectiveness due to the spaced relationship between the nozzle for such spraying and the target body parts. Due to the obvious necessity of positioning such nozzles at locations where they would not likely be in contact with the human excretions during the excretory process, previous apparatuses have resorted to positioning such nozzles at locations near the perimeter of the toilet bowl. This positioning limits the cleansing effectiveness of the nozzles since it would be optimized at positions immediately adjacent the target body surfaces. Although Sollerud, U.S. Pat. No. Re28,405, discloses a handheld apparatus with nozzles positionable immediately adjacent a patient's flesh for hygenically washing the patient, nozzles similarly positionable are not known in the prior art of record to be incorporated with an automatic cleansing apparatus which is connectable to a toilet.
Additionally, means for controlling such apparatus are advantageous. Previous apparatuses including that of Epstein and that of Ando, have employed means for cleansing private body parts which are controlled by operating switches or buttons, while Pulvari, U.S. Pat. No. 4,141,091, has addressed the control problem associated with actuating the flushing of excretions from a toilet bowl by employing means which does so in correspondence with approach and departure of a user of the apparatus.
The prior art represented by the apparatus of Brannon and that of Ando teaches means for cleansing parts of the human body by streaming warm water and air from stationary ports onto the body; however, since the human body varies from individual to individual with each individual having parts of their body positioned at slightly different locations with respect to the toilet, the streaming of solutions from stationary ports can be inaccurately directed such that the spray might miss the appropriate body parts of some individuals. Thus, it is another object of the present invention to provide a means for cleansing the perianal regions of human bodies regardless of natural variations between individuals of the positioning of the anus with respect to on the seat of a toilet when such individuals are seated on a toilet.
Additionally, it is an object of the present invention to provide a seat for a mountable toilet apparatus which seals fluids within the space of the toilet bowl beneath an individual using the toilet.
Furthermore, it is also an object of the present invention to provide an automatic cleansing apparatus which is operable by incapacitated individuals and which is mountable in a comfortable, compact form on a common toilet.
Other objects, features and advantages of the invention will become evident in light of the following detailed description considered in conjunction with the referenced drawings of a preferred exemplary automated cleansing apparatus adaptable to a commode according to the present invention.
SUMMARY OF THE INVENTION
The present invention provides an automatic apparatus mountable on a common toilet, for directing fluids onto the crotch of the body of a person utilizing the apparatus. This fluid direction is primarily for enabling cleansing of the user's crotch area after defecation but may also be employed for other advantages such as for enabling a douche, enabling an enema, applying medications, or other purposes that are enabled by the direction of fluid onto the user's crotch area while the user is seated on a toilet. Uniquely, the present invention accomplishes these body caring functions by providing means for directing fluid onto the user's crotch area, which directing means are pivoted to within close proximity of the user's crotch. Controlling mechanisms may control this fluid direction to automatically cleanse, rinse and dry the user's body parts while the user is seated on a seat specifically adapted for sealing fluid from passing upward beyond the user's crotch area.
For the purposes of this application, crotch or crotch area is taken to include the perianal region and external genitalia of both sexes and, in the female, the periurethral region.
By pivoting nozzles for directing cleansing, rinsing and drying fluids onto the user's body parts, the present invention improves the advantages of such fluid spraying by minimizing the distance between the nozzles and the body parts. The nozzles may be positioned away from view, beneath the seat of the apparatus of the present invention, until the user desires to cleanse the body parts. This out-of-sight positioning not only minimizes anxieties and embarrassment to the user, which are common when a handicapped user is confronted with viewing special adaptions (such as the pivoting nozzles) that are necessary for dealing with his handicap, but this positioning also minimizes the likelihood that the nozzles would come in contact with excretions during users' excretory processes. Then, when the cleansing function of the present invention is desired, the controls may be operated to control the pivoting of the nozzles to positions directly beneath the user's crotch area.
Means including special motors and springs are also included in the preferred embodiment of the present invention for biasing the nozzles in the out-of-sight positions beneath the seat. The motors which pivot the nozzles beneath the user's crotch area are such that the rotation of such motors will only stop in positions corresponding to the out-of-sight positions of the nozzles beneath the seat, regardless of when the empowering electricity of such motors is disconnected during the rotation of such motors.
The movement of the nozzles with respect to the user's private body parts also enhances the cleansing action of fluid sprayed from the nozzles when the apparatus is utilized for cleansing purposes. This enhanced cleansing action is the result of the surge-like application of the fluids onto the user's private body parts, which surge-like application is accompanied by enhanced dislodging of foreign particles on the user's surface.
Although the specific locations of user's relevant body parts with respect to the toilet seat varies from user to user, these are usually variations along the center of lateral symetry of the seat since the human body is laterally symetrical while the shape of a toilet seat tends to align the line of symetry of the user's body along with the line of symetry of the toilet seat. Further, as nozzles of the embodiments of the present invention are pivoted beneath the user's crotch area through a path which has only a slight arc and which is thus approximately linear, the relevant body parts of almost all potential users would be located at positions beneath which the nozzles of the present invention pivot. This arc of the nozzles' path remains slight since the cleansing and rinsing nozzles are pivoted about a vertical axis laterally outside the perimeter of the toilet. Since the radius of curvature of the nozzles paths are accordingly larger than a similar path would be if the nozzles were pivoted about an axis within the perimeter of the toilet, the arcs of the paths of the rinsing and cleansing nozzles are only slight. The location of the pivotal axis of the rinsing and cleansing nozzles laterally to the side of an ordinarily positioned user enables the slightly curved paths of the rinsing and cleansing nozzles to approximate a straight path directly beneath the the user's body and in the same plane as the body's axis of symetry. On the other hand, experience has shown that the proximity of a nozzle for blow-drying the user's body parts is not as crucial as the proximity of the rinsing and cleansing nozzles. A nozzle for blowing heated air onto the user's body surface, thus, is pivoted beneath the user's crotch area about a vertical axis to the rear of the seat on which the user is ordinarily positioned.
A control box controls the operation of the preferred embodiment of the present invention. This control box systematically controls the flow of cleansing, rinsing and blow-drying fluids through the respective cleansing, rinsing and blow-drying nozzles while also controlling the pivotal movements of these nozzles to provide a maximally effective cleansing operation of an apparatus of the present invention. This operation also includes controlling a means for actuating the flushing of the excretion receiving chamber of the toilet in order to flush the excretions and previously utilized cleansing and rinsing fluids from the excretion receiving chamber. This maximally effective operation is ideal and sequentially includes: the generation of a warm water source; the testing of the temperature of the generated warm water source by spraying a portion of spray of the warm water onto a sensitive (but not critically sensitive) part of the user's body; cleansing the user's body by spraying a cleansing fluid from a cleansing nozzle that pivots beneath the user's crotch area; rinsing the cleansing fluid from the user's body surface by spraying a rinsing fluid upwardly onto the user's body from a rinsing nozzle pivoting beneath the user's crotch area; actuating the flushing of the excretion receiving chamber of the toilet; drying the body surface by compressing, heating, and blowing heated air upwardly across the user's crotch area from a blower nozzle while pivoting the blower nozzle beneath the user's crotch area; and ceasing this ideal operation when it is complete. This ideal operation is controlled by the control box with the aid of the user or another person depressing buttons on the control box, and, in an alternative embodiment, by a timer which sequentially controls the individual operations in the ideal operation according to predetermined sequential durations.
In another embodiment, the controls are operated by movement of the user's back. The user's back can operate means which close electrical switches in order to sequentially actuate valves and other electrical components, which valves and other components in turn control the flow of liquids through the embodiment's nozzles. Pivoting of the nozzles beneath the user's crotch area can also be controlled by the user's back through manual controls which translate pivoting movement of the user's back into pivoting movement of the nozzles. Users who do not have the use of their arms can thus control that embodiment's operation. Several other alternative means for performing the functions of the specific components of the preferred embodiment of the present invention further enable manually controlled operation of this alternative embodiment of the present invention. These alternative means include a modified seat as provided with a plurality of blower ports, integrally formed with the seat, for blowing warm air across the user's crotch area; a pressure sensitive switch, incorporated into the seat, for actuating the generation of warm water source when the user is seated on the seat; an electrical connection that is controllable by the user's back to rotate a rotating electrical contact into differing positions, which differing positions enable the closing of differing electrical circuits, which rotating electrical connections may be substituted for other types of electrical switches; and a lever mechanism, manually controlled by the user's back, which disconnects the circuit for generating the warm water source and also which actuates the flushing of the excretion receiving chamber of the toilet.
Additionally, although the prior art has included the spraying of a liquid onto the user's crotch area, the Applicant has improved the cleansing effect of such liquid spraying. By sequentially spraying two liquids--a first, cleansing fluid which is a mixture of warm water and soap, and a second, rinsing fluid which is warm water--the present invention improves the cleansing action enjoyed by the spraying of fluids on the user's private body parts.
The apparatus of the present invention is preferably embodied in a housing that is comfortable and suitable for supporting and containing the apparatus, as well as for supporting the body of the user. This housing includes a seat, which seat itself is advantageous. To begin with, the seat provides a fluid seal for sealing fluids in a space substantially beneath the body of the user. This fluid seal enables thorough cleansing of the user's crotch area since adequate fluids may be sprayed onto the user's crotch area without also spraying onto other parts of the user's body. This fluid seal is also effective for sealing foul gasses associated with the human excretion process within the sealed space until (and after) flushing. A particularly unique aspect of this fluid sealing seat is the inclusion of a cup in the frontal portion of the seat that is positioned and has features for aiding in the containment of urine excreted by a male when such male cannot or chooses not to manually control the direction in which urine is excreted from his penis. Additionally, while heated air is communicated through the seat, the present invention is also provided with means for warming the seat in order to enhance the comfort of use of the apparatus of the present invention.
These and other advantages of the present invention will become evident to those skilled in this art upon a reading of the following detailed description of the invention, which should be taken in conjunction with the accompanying drawings and appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cut-away left side elevation view of the apparatus of the present invention with the housing of the apparatus of the present invention shown cross-sectionally.
FIG. 2 is a birds-eye perspective view of the apparatus of the present invention as mounted on a common toilet.
FIG. 3 is a cross-sectional view taken along line 3--3 shown in FIG. 1.
FIG. 4 is a schematic diagram of the electrical circuitry of the present invention.
FIG. 5 is a cut-away left side elevation view of the apparatus of an alternative embodiment of the present invention.
FIG. 6 is a birds-eye perspective view from the rear side of the apparatus of an alternative embodiment of the present invention.
FIG. 7 shows a right side elevation view of the rotating electrical connection of the apparatus of an alternative embodiment of the present invention.
FIG. 8 is a close up, front elevation view showing the rotating electrical connection of FIG. 7 in relation to other components of the apparatus of an alternative embodiment of the present invention.
FIG. 9 is a top view of the control box of the apparatus of the present invention oriented with the rearward direction being toward the top of FIG. 9.
FIG. 10 is a right side elevation view of part of the control box shown in FIG. 9.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the accompanying FIGS. 1 through 4, the elements of an automatic cleansing apparatus adaptable to a commode are shown. It should, of course, be understood that the figures and the following description serve merely to present a clear understanding of the underlying technical details and principles, and that various types of nozzles, controls, retracting means, and other devices could be equally well utilized. The embodiment described is merely for the purpose of illustration.
Referring to FIG. 2, the present invention is shown in operative relation to a standard toilet 100 having a waste receiving chamber 109 which is flushed by operating a flush handle 110. Flush handle 110 is operatively connected through holding tank 101 to standard means (not shown) for flushing chamber 109. Such standard toilet 100 is also provided with bolts 102 and 111 that are normally utilized for connecting a lid (not shown) upon the standard toilet 100, although the connecting of the embodiment of the present invention requires the removal of such a lid.
With the lid of toilet 100 removed, housing 10 is mountable on standard toilet 100 by securing housing 10 to toilet 100 with bolt 102 through bore 11 (shown in FIG. 1). Housing 10 rests on floor surface 112 and contains and supports most of the embodiment of the present invention. Housing 10 has a box-like shape which is formed by front planar member 12, top planar member 13, right side planar member 14 (shown in FIG. 1) and left side planar member 15 which members 12, 13, 14 and 15 are integrally formed together. Housing 10 has openings at its rear side 15 and at the side adjacent floor 112. An access hole 17 is provided in top planar member 13 for access to the excretion receiving chamber 109 from above top planar member 13. Seat 20 is integrally formed with top planar member 13 and surrounds access 17.
Seat 20 is a seat having a shape basically similar to seats of standard toilets for supporting the body of a person (not shown) who is using the apparatus of the present invention in an ordinary position over access 17, which position of the body is a convenient and comfortable position for enabling the excretion of bodily wastes through access 17. This ordinary position of the body over access 17 is a position which is a typical one in relation to a standard toilet 100 for utilizing standard toilet 100. More particularly, this ordinary position of the body over access 17 is typically characterized as similar to a sitting position with the body's buttocks resting centrally from left to right on seat 20 with the body's back facing holding tank 101.
More particularly, seat 20 is also provided with cleavage seal 21, crotch seal 22, slots 23 and 32, rise 31 and cup 30 (shown in FIG. 1 in hidden lines). Cleavage seal 21 is integrally formed with seat 20 and comprises a ridge-shaped protrusion from the rear of seat 20, which ridge-shaped protrusion has an elongated dimension positioned lengthwise in a substantially vertical position. Cleavage seal 21 has an appropriate shape for conforming to the body of a person seated in an ordinary position on seat 20 with cleavage seal 21 conforming to the rear and upper portion of the person's buttocks cleavage (not shown).
Rise 31 encloses cup 30. Cup 30 communicates with the excretion receiving chamber 109 of toilet 100 even when a person is positioned on seat 20 in an ordinary position with each of the person's legs extending forward to the right and left side of rise 31. Rise 31 is integrally formed with seat 20. Rise 31 is further provided with slot 23 and 32 having elongated dimensions positioned substantially horizontally lengthwise from front 12 to rear 16. Slots 23 and 32 penetrate into seat 20, but slots 23 and 32 do not communicate with cup 30. Pubic seal 22 is slideably engaged with slots 23 and 32 for sliding from front to rear and vice versa. The shape of pubic seal 22 is such that pubic seal 22 seals off a space including excretion receiving chamber of toilet 100 when pubic seal 22 is positioned in its rearmost position within slots 32 and 23 when a person is seated on seat 20 in a normal position. Pubic seal 22 has a shape defined in part by protruding edges 113. Edges 113 form to the upper legs and upper pubic region of the body of a person who is seated on seat 20 in an ordinary position when pubic seal 22 is in its rearmost position within slots 23 and 32.
Thus, when an individual is seated in an ordinary position on seat 20, a substantially sealed space is formed beneath the body of the individual. The substantially sealed space, which comprises excretion receiving chamber 109 is substantially sealingly enclosed by toilet 100, the body of the individual O-ring 26, contoured panel 25, pubic seal 22, cleavage seal 21, rise 31 and the other parts of seat 20. The sealed characteristic of this sealed space is incorporated in the apparatus of the present invention for containing fluids, including humanly excreted fluids as well as fluids for cleansing the body, which might other wise escape.
Referring now to FIG. 1, contoured panel 25, which is rigidly connected to upper planar member 13, rests upon the rim 103 of toilet 100 for additional support of top planar member 13. O-ring like seals 26 are positioned between contoured panel 25 and rim 103 for providing a seal therebetween, which seal retards the flow of liquid or gasses between contoured panel 25 and rim 103. Seal 26 is mounted to contoured panel 25. Contoured panel 25 also encloses a space 27 between contoured panel 25 and upper planar member 13. Space 27 communicates with compressed air source 40 and blower port 45 through ports 28 and 29 respectively. Spacers 24 are rigidly and sealingly connected between upper planar member 13 and contoured panel 25 at bores 11 with bores 11 passing through spacers 24. Spacers 24, thus, prevent gasses from escaping space 27 through bore 11.
A warm water source 62 is provided for the apparatus of the present invention by mixing valve 69. Cold water line 71 and hot water line 72 are sealingly connected with valve 69. When valve 69 is actuated, cold water line 71 enables fluid communication between a pressurized cold water source (not shown) and warm water supply 62. Also, when valve 69 is actuated, hot water line 72 enables fluid communication from a pressurized hot water supply to warm water source 62. The actuation of valve 69 enables the mixing of pressurized cold water received through line 71 with pressurized hot water received through line 72, and this mixing produces a warm water source 62 within valve 69.
Valves 50 and 64 are each actuable by electrical means to provide fluid communication from warm water source 62 to the fluid passages within lines 51 and 70 respectively. Bifurcated fluid conduit 65 enables this fluid communication between warm water source 62 and each of the passages with lines 51 and 70. Valves 50 and 64 are identical with respect to each other and each of valves 50 and 64 have inlets and outlets, each of which inlets receive fluids supplied by warm water source 62. The outlets of valves 50 and 64 communicate with warm water supply 62 only when valves 50 and 64, respectively, are actuated. First bifurcated end 66 of bifurcated fluid conduit 65 is sealingly connected to the inlet of valve 50. Second bifurcated end 67 of bifurcated fluid conduit 65 is sealingly connected to valve 64 at the inlet of valve 64. Source end 68 of bifurcated conduit 65 is sealingly connected to valve 69 for enabling fluid communication with warm water source 62.
A cleansing solution supply system comprises cleansing valve 50, line 51, line mingling cap 52, soap container 53, soap source 54, soap draw line 57, coaxial line 55, and cleansing nozzle 56. Line mingling cap 52 has water inlet 58 and outlet 49 and is threadably engaged with soap container 53. Soap container 53 contains soap source 54. The lower end 60 of soap draw line 57 is submerged within soap source 54. Line 51 is connected between line mingling cap 52 and cleansing valve 50 for enabling communication between water inlet 58 of line mingling cap 52 and a warm water supply 62 provided through cleansing valve 50. Inlet 58 is further in fluid communication with cap outlet 59 for providing communication of warm water from warm water source 62 to outlet 59. Cap outlet 59 is also in fluid communication with soap source 54 through soap draw line 57. Line mingling cap 52 mingles soap draw line 57 with the water communication between inlet 58 and outlet 59 while line mingling cap 52 maintains the integrity of soap draw line 57. This mingling by line mingling cap 52 is such that a coaxial flow is enabled through outlet 59 when valve 50 is actuated to enable fluid communication between warm water source 62 and water inlet 58. This coaxial flow through outlet 59, while valve 50 is thus actuated, is, in part, comprised of a stream of water flowing from water inlet 58, which stream of water is, at outlet 59, a stream surrounding soap draw line 57. The coaxial flow through outlet 59 also comprises a stream of soap enclosed by soap draw line 57 and drawn from soap source 54 through soap draw line 57. Coaxial line 55 is connected to line mingling cap 52 at outlet 59.
Additionally, coaxial line 55 contains a coaxial flow which maintains the definition of the coaxial flow through outlet 59. Coaxial line 55 has an outer line (not numbered) and an inner line (not shown), each outer and inner line being approximately coaxial with respect to the other. Coaxial line 55 is flexible. There is a fluid passage in between the outer line and the inner line of coaxial line 55. The connection between coaxial line 55 and line mingling cap 52 at outlet 59 is such that the inner line of coaxial line 55 is connected to soap draw line 57 in a manner that provides fluid communication of the liquid within soap draw line 57 to that within the inner line of coaxial line 55. The connection between coaxial line 55 and line mingling cap 52 at outlet 59 also enables fluid communication from water inlet 58 to the fluid passage between the outer line and inner line of coaxial line 55.
Coaxial line 55 is formed to and connected in substantially fixed relation with arm 63. Coaxial line 55 has a nozzle 56 wherein the soap stream within the inner line of coaxial line 55 communicates and mixes with the water stream in the fluid passage between the outer and inner lines of coaxial line 55. In operation with water valve 50 actuated to enable fluid communication between water inlet 58 and warm water source 62, warm water flows between the outer line and the inner line of coaxial line 55 and upon flowing into nozzle 56, this warm water enabled by the actuation of valve 50 draws the liquid soap from the inner line of coaxial line 55, and the warm water in nozzle 56 mixes with the soap drawn into nozzle 56 for providing a soap-water mixture within nozzle 56. This soap-water mixture within nozzle 56 is dispensed upwardly from nozzle 56 through port 57. The soap to water ratio of the soap-water mixture dispensed from nozzle 56 is determined by the characteristics of nozzle 56, which characteristics determine the pressure that draws soap from the inner line of coaxial line 55.
The temperature of the soap drawn from the inner line of coaxial line 55 is affected by the temperature of the water flowing between the inner and outer lines of coaxial line 55. Due to communication of heat through the inner line, the temperature of the soap in the inner line approaches the temperature of the water between the inner line and the outer line. Thus, when the water flowing through coaxial line 55 has a temperature warmer than that of the soap drawn through coaxial line 55, the soap drawn through coaxial line 55 is warmed by the water drawn through coaxial line 55.
A rinsing solution supply system includes valve 64, line 70, pivotal line connection 77, rigid line 78, and rinsing nozzle 75 each of which 64, 70 77, 78 and 75 contains a passage for communicating fluidly with the outlet of rinsing valve 64. Line 70 is sealingly connected to valve 64 for enabling fluid communication from the outlet of valve 64 to the fluid passage enclosed by line 70. Line 70 is also sealingly connected to pivotal line connection 77. Pivotal line connection 77 is connected to rigid line 78 in a manner that enables fluid communication between the passage within line 70 and the passage within rigid line 78. Pivotal line connection 77 has an upper portion 114 and a lower portion 115. The upper portion 114 is pivotally connected to the lower portion 115. Rigid line 78 has a vertical section 81 and an arm section 63. The vertical section 81 is rigidly connected to the upper portion of pivotal line connection 77. Line 70 is rigidly connected to the lower portion of pivotal line connection 77. The lower portion 115 of pivotal line connection 77 is rigidly connected to the left planar member 15 of housing 10. The pivoting of the upper portion 114 of pivotal line connection 77 pivots about a vertical axis, which vertical axis runs centrally in relation to the vertical section 81 of rigid line 78. Rigid line 78 encloses a fluid passage through its total length for enabling fluid communication between the passage within line 70 and the passage space enclosed by rinsing nozzle 75. Rinsing nozzle 75 is rigidly connected to the armature 63 of rigid line 78 in a manner that, likewise, enables fluid communication between the passage space enclosed by rinsing nozzle 75 and the fluid passage through rigid line 78. The passage space within rinsing nozzle 75 communicates with the excretion receiving chamber of toilet 100 through orifice 82.
Thus, when valve 64 is actuated, fluid communication is enabled between warm water source 62 and orifice 82. While this communication is sealed and since the water supplied to warm water source 62 is pressurized, a stream of pressurized water is thus streamed through orifice 82 when valve 60 is actuated in addition to valve 64. Orifice 82 is positioned in relation to nozzle 75 in order to spray the stream of water through orifice 82 in an upward direction.
The S-like shape of rigid line 78 (shown in FIG. 1) enables the positioning of rigid line 78, along with coaxial line 55, over the rim 103 (pertinent portions of which have been cut away in FIG. 1) of toilet 100 and partially within the excretion receiving chamber of toilet 100. This positioning of rigid line 78 is also apparent in FIG. 3. Coaxial line 55 is connected to and positioned in substantially fixed relation with the arm 63 of rigid line 78, which connection is enabled by brackets 83 through 85. Upper pivotal brackets 80 and cam-like lever 76 enable the positioning of coaxial line 55 in substantially fixed relation with the vertical section 81 of rigid line 78 by rigidly connecting the lines 55 and 78 in bracket-like manner. Nozzles 56 and 75 are positioned to spray fluid through port 57 and orifice 82, respectively, upwardly in a substantially vertical direction.
Motor 86 provides means for pivoting nozzles 56 and 75 about the vertical axis of vertical section 81. Crank arm 89 of motor 86 is rigidly connected to shaft 90, while shaft 90 is positioned with the axis of shaft 90 being perpendicular to the plane of FIG. 1, which plane of FIG. 1 is parallel to the right and left planar members 14 and 15. Pin 88 is pivotally connected to crank arm 89, and pin 88 pivots with respect to crank arm 89 about an axis perpendicular to the plane of FIG. 1. Pin 88 has a bore therethrough through which rod 91 is slideably engaged. Detent 92 is rigidly connected to rod 91. Motor 86 is electrically operated to rotate shaft 90, and crank arm 89 thus rotates about the axis of shaft 90 during such electrical operation of motor 86 in a cam-like fashion. The rotation of crank arm 89 further rotates pin 88 over electrical contact 93. Electrical contact 93 is rigidly mounted to housing 10 and is annularly shaped except for a small gap region. Electrical contact 93 is electrically connected to an electrical power source. Pin 88 is electrically connected to the power terminal of motor 86. Pin 88 is in direct electrical communication with contact 93 when pin 88 is rotated about shaft 90 over electrical contact 93. There is no electrical connection between pin 88 and contact 93 when pin 88 is rotated over the gap region.
The electrical mechanism (not shown) of motor 86 that effects the rotating operation of motor 86 includes means for consistently stopping the rotation of crank arm 89 in substantially the same orientation with respect to each other stopping of the rotation of crank arm 89. The electrical mechanism of motor 86 includes a switch which is remotely operated by control box 150. When this switch of the electrical mechanisms of motor 86 is actuated, the electricity in powering the rotating operation of motor 86 ceases when and only when pin 88 is in a position that disables electrical communication between pin 88 and electrical contact 93. This disabling position of crank arm 89 with respect to the axis of shaft 90 is always substantially that shown in FIG. 1. Rod 91 is ordinarily biased, as described further in this description, in a direction along its length away from pin 88 and toward cam-like lever 76.
Referring briefly to FIG. 3, pivotal drive motor 87 is virtually identical to pivotal drive motor 86 (shown in FIG. 1). The preceding description of motor 86 and of the operation of motor 86 is, therefore, descriptive of motor 87 and its operation as well, but motor 87 is slidably engaged with rod 94 rather than rod 91 and rod 94 has detent 95 rather than detent 92.
Rod 91 has eyelet 120 integrally formed therewith at the longitudinal end of rod 91 opposite detent 92. Eyelet 120 is pivotally connected to pin 121. Pin 121 is engaged through a vertical bore in cam-like lever 76. Test rod 122 also has an eyelet 123 integrally formed therewith at a first end of test rod 122, which eyelet 123 is pivotally connected to pin 121. Rod 122 is rigidly connected to shaft 124 of solenoid 125. Solenoid 125 is rigidly mounted to housing 10 and coils 126 are rigidly connected to and form an integral part of solenoid 125. A first longitudinal end of extension spring 127 is rigidly connected to shaft 124 of solenoid 125 at the end of shaft 124 opposite test rod 122. The second longitudinal end of spring 127, which second longitudinal end is opposite the first longitudinal end, is rig idly connected to housing 10 at spring connection 128. Spring 127 is a helical extension spring which biases shaft 124 of solenoid 125 toward spring connection 128. Solenoid 125 is electrically actuated. During actuation of solenoid 125, shaft 124 is biased away from spring connection 128. Solenoid 125 is of an ordinary type for effecting such actuation through use of electricity. Thus, upon actuation of solenoid 125, test rod 122 is biased in a position away from spring connection 128. When solenoid 125 is not actuated, spring 127, thus, biases test rod 122 in a position toward spring connection 128.
Upper pivotal bracket 80 and lower pivotal bracket 79 are mounted to the left planar member of housing 10. Vertical section 81 of rigid line 78 is pivotally engaged with pivotal bracket 79 and 80 to enable the pivoting of vertical section 81 about the vertical axis of vertical section 81. Cam 76 is rigidly connected to rigid line 78, and cam-like lever 76 is, therefore, able to pivot about the vertical axis of vertical section 81. Likewise, the armature 63 of rigid line 78 pivots about the vertical axis of vertical section 81.
As test rod 122 is biased in a position toward spring connection 128, rod 91 is also biased by extension spring 127 toward spring connection 128. Another extension spring (not shown) is also connected between arm 63 and housing 10 for further improving the spring bias of test rod 122 in a position toward spring connection 128 while likewise biasing armature 63 in the position 310 (shown in FIG. 3). During operation of motor 86, motor 86 translates rod 92 substantially along the length of rod 91 in an oscillatory manner while the detent end of rod 91 is rotated about shaft 90. Such motion of rod 91 drives a pivoting motion of cam-like lever 76 about the vertical axis of vertical section 81, and arm 63 is likewise pivoted about the vertical axis of vertical section 81. The force of motor 86 which is responsible for this pivoting of arm 63 is transferred by the force of crank arm 89 against detent 92 of rod 91. The limits of this pivoting of arm 63 are determined by the characteristics of motor 86.
Similarly, upon actuation of solenoid 125, test rod 122 pivots cam-like lever 76 about the vertical axis of vertical section 81. Solenoid 125 has limits during actuation of solenoid 125 which restrict the movement of shaft 124. These limits of solenoid 125 are incorporated in a manner which limits the pivoting of rinsing nozzle 75. These pivotal limits of rinsing nozzle 75 by solenoid 125 allow rinsing nozzle 75 to pivot from the position shown in FIG. 1 to a position substantially below the lip 129 of contoured panel 125 to a test position 312 (shown in FIG. 3). Test position 312 is a position such that only a portion of a spray through orifice 82 would be sprayed upward beyond lip 129 while other portions of spray 82 are deflected by lip 129 into recess 297 (shown in FIG. 3).
Note that upon actuation of solenoid 125, rod 91 will also translate away from spring connection 128; however, since rod 91 is slideably engaged through pin 88, the actuation of solenoid 125 is not accompanied by movement of pin 88, but rather rod 91 slides in relation to pin 88. On the other hand, the rotating operation of motor 86 does cause the movement of shaft 124 with respect to coils 126. Also note that in an alternative embodiment (not shown) orifice 82 and port 57 are replaced by rotating nozzles for improving the spray onto the crotch area of the user of the alternative embodiment. Such rotating nozzles are rotated with respect to arm 63 about nozzles 75 and 76 respectively. The rotating of such rotating nozzles is driven by the hydraulic force of the fluids flowing from nozzles 75 and 56, respectively.
Referring again to the preferred embodiment of the present invention, a user of the apparatus of the present invention ideally positions the body of the user on seat 20 in an ordinary position. When the user is seated thus, pubic seal 22 may be manually positioned in a position furthest from front planar member 12. Accordingly, a substantial seal is formed around the crotch area of the body of the individual for containing fluids that accompany the operation of the apparatus of the present invention within excretion receiving chamber 109. This seal is effected as the shape of pubic seal 22 enables pubic seal 22 to form a seal with the legs and upper pubic area of the user so that the crotch area of the user is contained in a space communicating with excretion receiving chamber 109. Cleavage seal 21, furthermore, similarly seals fluids within a space communicating with excretion receiving chamber 109 by forming a seal with the buttocks cleavage of the user above the crotch area of the user's body.
A heated air supply system in the preferred embodiment of the present invention includes compressor 40, air supply line 131, blower nozzle 132, and sealed space 27. These components 40, 131, 27, and 132 comprise a system which supplies compressed air from compressor 40 through blower port 45 of blower nozzle 132. Blower port 45 is in sealed communication with compressor 40 for enabling pressurized air to exit the system through blower port 45. Furthermore, air supply line 131 includes heating element 130 for heating the air which flows through air supply line 131. Heating element 130 is a standard air heating element similar to those incorporated for heating air in blow dryers that are used for drying hair. Heating element 130 is integrally formed with air supply line 131 along the course of air supply line 131. A first end of air supply line 131 is connected to compressor 40 at compressor outlet 133 (shown in hidden lines), and air supply line 131 is connected at a second end of line 131 to contoured panel 25 at port 28 for enabling communication between port 28 and the air compressed by compressor 40. As space 27 is a sealed space between contoured panel 25 and top planar member 13, compressed air supplied through port 28 is communicated to port 29 as well as blower port 45. Blower nozzle 132 is pivotally and sealingly connected to contoured panel 25 at port 29 for enabling the communication between port 29 and blower port 45. Blower nozzle 132 encloses an air conduit in sealed communication with port 29. The shape of blower nozzle 132 enables the blowing of the compressed, heated air through blower port 45 in an approximately upward direction.
Referring now to FIG. 3, lever 96 is rigidly connected to blower nozzle 132. Rod 94 is pivotally connected to lever 96 with pin 117. One end of extension spring 116 is also rigidly connected to lever 96 near pin 117; and a second end of extension spring 116 is rigidly connected to contoured panel 25 at spring connection 118. Blower nozzle 132 pivots with respect to contoured panel about a vertical axis through the center of port 29.
Accordingly, the operation of motor 87 cause pivoting of blower port 45 beneath access 17 about the vertical axis through the center of port 29. Motor 87 is mounted to top planar member 13. Similar to the aforementioned operation of motor 86 with respect to rod 92, the operation of motor 87 conveys a pivoting force to detent 95 of rod 94, which pivoting force causes translation of rod 94 approximately toward and away from spring connection 118 in a direction approximately colinear with the length of rod 94. Spring 116 biases lever 96 toward spring connection 118, but the operation of motor 87 transfers an oscillating force through rod 94 to lever 96, which oscillating force opposes and favors, in an oscillating manner, the spring bias of spring 116. Accordingly, during operation of motor 87, lever 96 oscillates approximately away from and toward spring connection 118, and blower port 45 accordingly pivots beneath access 17.
This pivoting of blower port 45 beneath access 17 has pivoting limits which are determined by various interrelated characteristics of motor 87, rod 94, lever 96 and blower nozzle 132. These limits of the pivoting of blower port 45 are represented by the inoperative position 300 of blower port 45, and a second position 301 (shown in hidden line). A blower detent means (not shown, but represented schematically as component 600 in FIG. 4) is also included for stopping lower port 45 from returning to the inoperative position 300 while motor 87 is operating. This blower detent means effectively causes blower port 45 to pivot between the second position 301 and an operating limit position 302 (shown in hidden lines) during operation of motor 87. This blower detent means comprises a small solenoid mounted to contoured panel 25 in recess 295 between rim 103 and contoured panel 25. When the solenoid of the blower detent means is actuated, the pivoting of blower port 45 is effectively limited at operating limit 302 by the solenoid of the blower detent means stopping lever 96 from returning to the position (shown in FIG. 3) that is closest spring connection 118. Note that although the motion of lever 96 is, thus, limited by the solenoid of the blower detent means, and the translating motion of rod 94 is accordingly limited as well, the operation of motor 87 is not affected since rod 94 is slideably engaged through the pin of motor 87. During the operation of the apparatus of the present invention, when the solenoid of the blower detent means is deactuated, the pivoting of blower port 45 includes pivoting blower port 45 to the inoperative position 300. The solenoid of the blower detent means is actuated whenever the user of the apparatus of the present invention causes the transmission of an electrical signal to operate motor 87; however, virtually identically to aforementioned motor 86, motor 87 includes means for returning the rotating arm of motor 87 to the position shown in FIG. 3 when motor 87 is not otherwise caused to operate. Thus, when the electrical signal caused by the user for operating motor 87 is ceased, the solenoid of the blower detent means is deactivated and blower port 45 is enabled to return to the inoperative position 300 as the rotating arm of motor 87 returns to the position shown in FIG. 3.
Similarly, during the rotating operation of motor 86 (shown in FIG. 1), nozzles 56 and 75 are pivoted about the vertical axis of vertical section 81 (shown in FIG. 1) within the excretion receiving chamber 109 beneath access 17 and contoured panel 25. This pivoting of nozzles 56 and 75 is between a first position 310 and a second position 311 (shown in hidden lines). When motor 86 is not operating and solenoid 125 is not actuated, nozzles 56 and 75 remain in the first position 310 beneath recess 297 of contoured panel 25. When motor 86 is not operating and solenoid 125 is actuated, nozzles 56 and 75 are in a test position 312 (shown in hidden lines). When motor 86 is operating and solenoid 125 is not actuated, nozzles 56 and 75 pivot between the first position 310 and the second position 311. When motor 86 is operational and solenoid 125 is also actuated, nozzles 56 and 75 pivot between the test position 312 and the second position 311.
As previously indicated, contoured panel 25 includes recesses 295 and 297 and has a sealed break 296. Recesses 295 and 297 are formed integrally with contoured panel 25. Recess 295 is for enabling the motion of rod 94 between rim 103 and contoured panel 25 and is also for containing the electrically effected detent means (not shown) between rim 103 and contoured panel 25. Recess 297 is for reflecting spray from nozzles 56 and 75 in a manner that reflects such spray toward the excretion receiving chamber 109 of toilet 100. The break 296 in contoured panel 25 is for enabling the pivoting movement of armature 63 and coaxial line 55. Although recesses 295 and 297 protrude slightly into the space 27 (shown in FIG. 1) that is enclosed by contoured panel 25, recesses 295 and 297 do not substantially impair the essential flow of heated air within space 27. Break 296 is a discontinuity in contoured panel 25, and space 27 does not span break 296, but rather space 27 is sealed by the edges of contoured panel 25 being sealingly connected to top planar member 13, which edges of contoured panel 25 are immediately adjacent break 296. In an alternative embodiment (not shown), break 296 is a recess, shaped similar to break 296 rather than a sealed break in order to enhance the flow of heated air within space 27 (shown in FIG. 1).
Referring briefly to FIG. 2, means including looped cable 281 is incorporated in the apparatus of the present invention to operate the flush handle 110 for effecting the flushing of excretion receiving chamber 109. As also shown in FIG. 1, this flushing means further comprises solenoid 280, sleeve-like rod 282 and stop 283. Solenoid 280 is mounted on right planar member 14. The lower end 278 of looped cable 281 is rigidly connected to the shaft 284 of solenoid 280. Upon electrical actuation of solenoid 280, the shaft 284 of solenoid 280 is translated downward from the position shown in FIG. 1, towards floor 112. Sleeve-like rod 282 is rigidly connected to the top planar member 13 in a substantially vertical position. Looped cable 281 has a loop 279 at the upper end 279 of looped cable 281. Looped cable 281 communicates through sleeve-like rod 282 and looped cable 281 is able to translate in vertical directions within sleeve-like rod 282. Stop 283 is rigidly connected near the upper end of looped cable 281. Stop 283 limits the downward motion of looped cable 281 since stop 283 cannot pass beneath the upper end 284 of sleeve-like rod 282. Loop 279 is connectable to the flush handle 110 (shown in FIG. 2) of a standard toilet 100. In the operation of the flush operating means, solenoid 280 is actuated, looped cable 281 is translated downwardly by solenoid 280 as limited by stop 283, and flush handle 110 is accordingly actuated for flushing the excretion receiving tank 109.
Each of the electro-mechanical devices--including compressor 40, solenoids 125 and 280, motors 86 and 87, and the solenoid of the blower detent means (not shown), as well as valves 50, 64 and 69--are electrically operated and are controlled in their operation by control box 150. Heating element 130 is also electrically operated and controlled by control box 150. Control box 150 has buttons 151 through 158, which buttons control electrical switches (shown schematically in FIG. 4) that are enclosed by control box 150. Buttons 151 through 158 are standard buttons for controlling such switches.
Each of buttons 151 through 158 are spring biased in a disengaged, upward position, which upward positions are those positions shown in FIG. 1. When each of buttons 151 through 158 are depressed in their position with respect to box 150, each of buttons 151 through 158, respectively, close specific electrical switches as will be discussed further in detail. Button 155 has an overhanging portion 159 extending over button 156. Overhanging portion 159 is rigidly mounted to the top of button 155. Overhanging portion 159 is positioned for simultaneously depressing button 156 when button 155 is depressed.
Detaining means (not shown) is also included within control box 150 for detaining each of buttons 152 through 158 in their depressed position after the respective button 152 through 158 has been depressed. In contrast button 151 returns to its upwardly biased position after being depressed. The aforementioned detaining means within control box 150 also includes means for releasing buttons 152 through 158 from their detained positions when another of buttons 152 through 158 is depressed. Thus, when any of buttons 152 through 158 is depressed, it subsequently remains in the respective depressed position until it is released as another of buttons 152 through 158 is depressed. Since the depression of button 155 is simultaneously accompanied by the depression of button 156, neither of buttons 155 and 156 are detained by the detaining means when button 155 is depressed but button 156 is detained if depressed separately from button 155. This detaining means within control box 150 is of the type commonly available with electrical control buttons. The detaining means is mounted to control box 150 on the inside of control box 150, and the detaining means is connected to each of buttons 152 through 158 in a manner that fully enables the operation of the detaining means as described in relation to buttons 152 through 158.
Referring now to FIG. 4, the electric circuitry of the present invention is shown schematically. Note that each of the lines, such as line 149, represent electrically conductive wiring for enabling direct electrical communication between the designated electrical components 69, 125, 64, 50, 86, 280, 40, 130, 87, the solenoid of the blower detent means, and switches 161 through 168, as well as the AC power supply 190. Note also that components 69, 125, 64, 50, 86, 280, 40, 130, 87 and the solenoid of the blower detent means are operated and actuated, appropriately, by enabling electrical communication of the alternating current of the AC power supply 190 through the respective electrical component; and the appropriate operation and actuation of an individual electrical component 69, 125, 64, 50, 86, 280, 40, 130, 87 and the solenoid of the blower detent means is disabled when the electrical communication of the alternating current of the AC power supply 190 through the respective electrical component 69, 125, 64, 50, 86, 280, 40, 130, 87 and the solenoid of the blower detent means is disabled.
Accordingly, the closing of switch 161 enables the actuation of mixing valve 69. The closing of switch 162 enables the actuation of test solenoid 125. The closing of switch 163 enables the actuation of rinsing valve 64. The closing of switch 164 enables the actuation of cleansing valve 50. The closing of switch 166 enables the operation of motor 86. The closing of switch 167 enables the actuation of solenoid 280. The closing of switch 168 enables the operation of air compressor 40, the heating by heating element 130, the operation of motor 87 and the actuation of the solenoid of the blower detent means. Air compressor 40, heating element 130, motor 87, and the solenoid of the blower detent means are electrically connected in series.
AC power supply 190 is a standard 110 volt AC power supply and may be, as in an alternative embodiment (not shown), substituted by a DC power supply with other appropriate changes in the circuitry of the apparatus of the present invention. Each of the electrical grounds (standardly designated in FIG. 4) of the electrical circuitry are common electrical grounds and are, thus, in direct electrical communication with each other of the electrical grounds of the electrical circuitry.
The electrical contacts 93 and 287 of motors 86 and 87, respectively, are connected in direct electrical communication with the positive terminal of AC power supply 190; however, operation of motors 86 and 87 is initiated only by enabling electrical communication of the alternating current of the AC power supply 190 through shafts 90 and 290, respectively. Referring again to the operation of motors 86 and 87, when the rotatable arms of motors 86 and 87 respectively are in certain positions, electrical communication is enabled between the contacts (93 and 287) and the shafts (90 and 290) through the rotatable arms of the motors 86 and 87, respectively.
Referring briefly to FIGS. 9 and 10, control box 150 is shown, enabling particular clarity with regard to buttons 155 and 156 and lever 591. Lever 591 is similar to a toggle switch, being pivotally connected to control box 150 and positionable in two positions--an actuated position, which is the position shown in FIG. 10, and a deactuated position 591' (shown in broken line in FIG. 10). The actuated and deactuated positions correspond to the closing and opening, respectively, of switch 161 and lever 191 is interconnected with switch 161 in a manner that enables such function.
In addition to overhanging portion 159, button 155 also has overhanging extension 592 which is similar to overhanging portion 159, but extends over the pivotal connection of lever 591 rather than button 156. Note that both overhanging portion 159 and extension 592 are rigidly bonded to button 155. Overhanging extension 592 is such that lever 591 bears against the rearward edge 593 of overhanging extension 592 when 591 is in its actuated position. When button 155 is depressed toward control box 150, the rearward edge 593 forces lever 591 to move to its deactuated position 591. Lever 591 is manually moved to its actuated position by a person utilizing the apparatus of the present invention.
The switches 162 through 168 are closed by certain ones of buttons 151 through 158. The depression of button 151 closes switch 162. The depression of button 152 closes switch 163 and releases any others of buttons 152 through 158 that are detained by the detaining means within control box 150. The depression of button 153 closes switches 164 and 166 and releases any others of buttons 152 through 158 that are detained by the detaining means within control box 150. The depression of button 154 closes switches 163 and 166 and releases any others of buttons 152 through 158 that are detained by the detaining means within control box 150. The depression of button 155 causes the simultaneous depression of button 156 and the movement of lever 591 to its deactuated position 591. The depression of button 156, more particularly, closes switch 167. Recall that the simultaneous depression of buttons 155 and 156 release one another and also releases any others of buttons 152 and 158 that are detained by the detaining means within control box 150. The depression of button 157 closes switch 168 and releases any others of buttons 152 through 158 that are detained by the detaining means within control box 150. The depression of button 158 merely releases any others of buttons 152 through 158 that are detained by the detaining means within control box 150. Upon release of a button 151 through 158 that closes certain respective switches 161 through 168 as outlined above, the certain respective switches 161 through 168 are simultaneously opened unless otherwise closed by others of buttons 151 through 158. Note that the discussion of the functions of the depression of these buttons 151 through 158 in this paragraph does not limit the previously and subsequently described functions of buttons 151 through 158.
Referring again to FIG. 1, the electrical circuitry schematically represented in FIG. 4 thus enables communication between buttons 151 through 158 and their appropriate electrical components 69, 125, 64, 50, 86, 280, 40, 130, 87 and the solenoid of the blower detent means; this communication between the buttons and the electrical components is further enabled by electrically conductive wiring (schematically represented as lines in FIG. 4) positioned through support 230, which support 230 functions in part as a conduit 230. Support conduit 230 is rigidly connected to control box 150 in a manner that enables communication between the communicating space of support conduit 230 and the space enclosed by control box 150. Control box 150 is positioned with respect to an ordinarily positioned body seated upon seat 20 so that the ordinarily positioned body can easily operate the buttons of control box 150. The lateral section 231 of support conduit 230 is a grippable section that is grippable by the hand of a human for enabling the support of the human, particularly for enabling support while the human is utilizing the apparatus of the present invention. The horizontal positioning of the lateral section 231 also enables the human supporting aspect of lateral section 231, and lateral section 231 is appropriately positioned horizontally. The base (not shown) of support conduit 230 is rigidly connected to right planar member 14 in a manner that enables communication between the communicating passage of support conduit 230 and the space enclosed by housing 10. Support conduit 230 has a cylindrical shape.
In operation, the user of the apparatus of the present invention controls the apparatus by manually actuating lever 591 and depressing buttons 151 through 158 in a sequence. A particular sequence is ideal. The ideal particular sequence, in brief, is the sequential depressing of buttons 152, 151, and 153 through 158. The particular ideal sequence is further discussed in this description.
According to the particular ideal sequence, after or while utilizing the toilet 100 for excretory purposes, lever 591 is manually moved to its actuated position and valve 69 is accordingly actuated for mixing cold and hot water from lines 71 and 72, respectively, to produce warm water source 62. Subsequently button 152 is depressed and valve 64 is accordingly actuated for spraying warm water through orifice 82 upward into recess 297. Since the water in hot water line 72 is often initially cool, warm water source 62 will become warmer, approaching a steady-state temperature as time progresses. Accordingly, the temperature of the water sprayed upwardly through orifice 82 will approach a steady state in time.
By depressing button 151, the operator tests the temperature of the water spraying from rinsing nozzle 75 through orifice 82 as portions of this spray through orifice 82 are directed upwardly past lip 129 and onto a small part of the body of the user for enabling determination of the temperature of the water spraying through orifice 82 by the user. The temperature of the water spraying through orifice 82 approximately equals the temperature of warm water source 62, likewise, approximately equals the temperature of the water flowing through coaxial line 55. When the temperature of the water spraying through orifice 82 has reached a temperature suitable to the user, which temperature is ideally a steady-state warm temperature of the water, the user depresses button 153. Obviously, if the user does not desire to test the temperature of the water spraying through orifice 82, the depressing of buttons 151 is omitted from the sequence. When button 153 is depressed, the soap-water mixture (being mixed in nozzle 56 from water having the suitable temperature and from soap drawn from the inner line of coaxial line 55, the temperature of which soap has approached the suitable temperature of the water also flowing through coaxial line 55) is sprayed from nozzle 56 through port 57 onto the crotch area of the body of the user as arm 63 pivots within excretion receiving chamber 109 and nozzle 57 pivots beneath the crotch area of the body of the user. Thus, cleansing fluid (the soap-water mixture) is sprayed onto the crotch area from a nozzle moving directly beneath those crotch area.
After adequate cleansing fluid has been sprayed on the crotch area of the body of the user, the user depresses button 154, and the soap-water spray is ceased while the rinsing fluid is sprayed onto the crotch area of the body of the user through orifice 82 of rinsing nozzle 75. When adequate rinsing of the crotch area of the body of the user has been accomplished by the rinsing fluid being sprayed through orifice 82 as arm 63 pivots beneath the crotch area of the body of the user, button 155 is depressed by the user. The depression of button 155 causes the actuation of solenoid 280 and simultaneously depresses button 156. Solenoid 280, accordingly, causes the flushing of excretion receiving chamber 109. The simultaneous depression of button 156 causes the spray of fluid through orifice 82, and nozzles 56 and 75 are returned by motor 86 to beneath recess 297 and the spray of fluid through orifice 82 is ceased.
Next, the user depresses button 157 and the drying operation of the apparatus of the present invention begins. Air is accordingly compressed by compressor 40, heated by heating element 130 and blown upwardly across the crotch area of the body of the user through blower port 45 as blower nozzle 132 pivots beneath the the user. Once blower port 45 has pivoted from the inoperative position 300 of blower port 45 past the operating limit 302, blower port 45 pivots about vertical axis through port 29 and between second position 301 and operating limit 302 until button 158 is depressed. When button 158 is depressed, the blower detent means is deactuated, and motor 87 returns blower port 45 to the inoperative position 300; spring 116 also enables the return of blower port 45 to the inoperative position 300. Once the drying operation has thus been completed, crotch area of the body of the user has been cleansed, rinsed and dried.
Another alternative embodiment of the present invention is shown in FIGS. 5 and 6. The main purpose of this alternative embodiment is to provide an apparatus which performs substantially the same functions as the preferred embodiment of the present invention, but which alternative embodiment is controllable in its operation by movement of the back of an ordinarily positioned user seated on seat 20' rather than controllable by operating control box 150 (shown in FIG. 1). Many aspects and components of the alternative embodiments shown in FIGS. 5, 6 and 7 are identical in structure and function to aspects of the preferred embodiment of the present invention, and these particular aspects and components are, accordingly, numbered in FIGS. 5, 6 and 7 with numbers that correspond to the numbers in FIGS. 1 through 4. Other aspects and components of the alternative embodiments of the present invention are similar in structure and function but have slight variations; such slightly varied aspects and components are indicated in FIGS. 5, 6 and 7 with reference numerals that are the same as those in referencing the similar aspects and components in FIGS. 1 through 4, however, they are indicated with a prime notation following the numerals in FIGS. 5, 6 and 7. For example, seat 20' (shown in FIGS. 5 and 6) is substantially similar in structure and function to seat 20 (shown in FIGS. 1 and 2) but seat 20' comprises variations to seat 20. While these similarities between the preferred embodiment and the alternative embodiments have been previously described in this description, the following description of the alternative embodiments of the present invention concentrates on the material differences between the alternative embodiments and the preferred embodiment.
Referring again to the alternative embodiment shown in FIGS. 5 and 6, since a pubic seal connected to rise 31' is not included, nozzles 56 and 75 are positioned to spray liquid through port 57 and orifice 82 in an upward direction slightly canted from the vertical for avoiding the spray of fluids through port 57 and orifice 82 upwardly past the pubic area of a user seated in an ordinary position on seat 20'. Additionally, upper planar member 13' comprises a composite member formed by sections 501 and 502.
Enclosed space 27' which communicates with port 28 also communicates with a plurality of blower ports 45'. Heat (provided by heating element 130) from the air contained within space 27' communicates directly with the upper surface 503 of seat 20', and the upper surface 503 is composed of a thermally conductive, semi-rigid material for transferring heat from the air within space 27' to the body of a user positioned in an ordinary position on seat 20'. Blower ports 45' are each provided with flaps 504 hinged at hinges 505 to seat 20'. Flaps 504 are positionable in opened and closed positions (closed position shown in FIG. 5) for enabling and disabling, respectively, fluid communication from space 27' to a space beneath the body of the user positioned on seat 20' in an ordinary position, which space fluidly communicates with excretion receiving chamber 109. Flaps 504 are biased by the force of gravity in the closed position; however, air pressure within space 27' generated by compressor 40 opposes the gravitational bias on flaps 504 and, thus, forces flaps 504 into opened positions when compressor 40 is operated. Flaps 504, thus, function as one-way valves preventing the flowing of fluids into space 27' through blower ports 45'. A seal preventing the escape of fluids from the space beneath the body of an ordinarily positioned user on seat 20', which space communicates with excretion receiving chamber 109, is thus enabled by flaps 504.
Weight sensitive control 506 is positioned within space 27' adjacent upper surface 503. Weight sensitive control 506 comprises pad 507 rigidly connected to flexible cable 508 which is slideably engaged through flexible tubing 509. Flexible tubing 509 is rigidly connected to seat 20' at a weight sensor port (not shown). Flexible tubing 509 has a fixed operative end 510, which fixed operative end is rigidly connected to left planar member 15 by rigid bracket 511. Flexible cable 508 is slideably engaged through flexible tubing 509 to the actuating part of switch 161', which actuating part is actuable to close switch 161' as switch 161' is an electrical switch for completing an electrical circuit. Switch 161', when actuated, completes the electrical circuit for actuating mixing valve 69' for enabling the production of warm water source 62. Flexible cable 508 has a switch actuating end 512 that abuts the actuating part of switch 161'. When pad 507 is forced downwardly by the weight of a user on the upper surface 503 of seat 20', flexible cable 508 accordingly moves toward switch 161' through the actuating end 510 of flexible tubing 509 to actuate switch 161'. The semi-rigid nature of the material of the upper surface 503 of seat 20' enables the downward movement of pad 507 when the upper surface 503 supports the weight of a user seated on seat 20'.
The pivoting of nozzles 56 and 75 beneath access 17 is operated by the back of a user seated on seat 20' in an ordinary position as enabled by a pivotal linkage system between lid 513 and cam-like lever 76'. Lid 513 is pivotally connected to support 514 by shaft 515 through journals (not shown) in support 14. Support 514 is rigidly connected to upper planar member 13' with a plurality of bolts 516. Shaft 515 is rigidly connected to lid 513 at the appendages 516 and 517 of lid 513. Shaft 515 is substantially horizontal and is positioned with the longitudinal ends of shaft 515 running laterally left and right.
Lid 513, although appearing as a lid of a common toilet, is restricted by torsional spring 518 from moving to a position which closes access 17. Torsional spring 518 encircles shaft 515 and has fixed end 519 and an opposing end 520. Fixed end 519 is rigidly connected to appendage 517. Opposing end 520 is slideably engaged through arced slot 521 in support 514, which arced slot 521 is an arc about the journal in support 514 through which shaft 515 pivots. Torsional spring 518 effects a torsional force about shaft 515 between fixed end 519 and opposing end 521, which torsional force opposes the rearward (i.e. toward holding tank 101) pivoting of lid 513 beyond an approximately upright position of lid 513, which positions lid 513 slightly forward of an exactly vertical position. Torsional force of torsional spring 518 additionally opposes the forward pivoting of lid 513 beyond a half-closed position. In the half-closed position, lid 513 is positioned at approximately 60 degrees from the horizontal for avoiding the necessity of opening the lid 513 from access 17 when a user is attempting to position the user's body in an ordinary position on seat 20'.
Cam-shaped lever 522 is rigidly connected to shaft 515. A first end of flexible cable 524 is rigidly connected to cam-shaped lever 522 at connection 523. The second end 525 of flexible cable 524 is rigidly connected to eyelet 120 for transferring pivoting force from flexible cable 524 to cam-like lever 76', which pivoting force enables the pivoting of cam-like lever 76' about the vertical axis of rigid line 78. Flexible cable 524 is slideably engaged through flexible tubing 526. A first end of flexible tubing 526 is fixed to support 514 by bracket 527. A second end of flexible tubing 526 is fixed to left planar member 15 by bracket 529. Thus, the rearward pivoting of lid 513 about shaft 515 translates into the sliding of flexible cable 524 through flexible tubing 526 toward cable connection 523; eyelet 120 accordingly moves toward bracket 529 and the pivoting of cam-like lever 76' is effected; and nozzles 56 and 75 pivot beneath access 17 for positioning nozzles 56 and 75 beneath the user's crotch area. The angular range of positions through which lid 513 necessarily pivots for pivoting nozzles 56 and 75 between their first position 310 (shown in FIG. 3) and their second position 311 is the nozzle pivoting range. By pivoting lid 513 through the nozzle pivoting range in this manner, with torsional spring 518 returning lid 513 to the upright position, a user of this alternative embodiment can, thus, manually pivot nozzles 56 and 75 beneath the user's crotch area without utilizing electronic means for pivoting nozzles 56 and 75.
Cam-like post 530 is also rigidly connected to shaft 515 for rotating post 530 about the axis of shaft 515. This rotating of post 530 about the axis of shaft 515 controls the deactuation of valve 69' and the actuation of the flush handle 110 (shown in FIG. 2) with flush actuator 531. L-shaped lever 532 pivots about vertical shaft 533. Vertical shaft 533 is rigidly connected to upper planar member 13' and is positioned in a substantially vertical position. Lever 532 is shown in its unactuated position in FIG. 6. After a user ordinarily positions the user's body on seat 20', lever 532 remains in the unactuated position of lever 532 until lid 513 is pivoted rearwardly about shaft 515 beyond the nozzle pivoting range, post 530 engages the actuating portion 534 of lever 532 and pivoting of lid 513 further rearward beyond this engaging position causes the pivoting of lever 532 about pin 533 by post 530. When post 530 pivots lever 532 about shaft 533, lever 532 is pivoted to an actuated position (not shown) of lever 532. When the user removes himself from seat 20', lid 513 pivots forwardly to its forward-most position at approximately 60 degrees from the horizontal. This pivoting to the forward-most position of lid 513 is imparted by torsional spring 518 as well as the force of gravity on lid 513. When lid 513 pivots to this forward-most position, post 530 engages the deactuating surface 535 of lever 532 and pivots lever 532 to the unactuated position of lever 532.
When lever 532 is in the actuated position of lever 532, L-shaped rod 536 is caused to deactuate valve 69' by causing the pivoting of switch 161' about pivotal connection 537. A first end 587 of L-shaped rod 536 is pivotally connected about a vertical axis at the actuating end of lever 532, and a second end 539 of L-shaped rod 536 is pivotally connected to plate 538 about a laterally disposed horizontal axis. Switch 161' is operably mounted on plate 538. Plate 538 is pivotally connected to valve 69' at pivotal connection 537, pivoting about a forwardly and rearwardly running horizontal axis. When plate 538 pivots toward left planar member 15 about pivotal connection 537 in correspondence with the actuation of lever 532, the actuating end 512 (shown in FIG. 5) of flexible cable 508 within flexible tubing 509 moves with respect to the actuating part of switch 161' to a position (not shown) which allows the opening of switch 161' despite the operation of weight sensor 506. Recall that switch 161' is biased in the open position of switch 161'. The pivoting of lever 532 into the actuating position of lever 532 thus moves L-shaped rod 536 away from bracket 540 and causes the pivoting of plate 538 to a position which allows the opening of switch 161' and the corresponding deactuation of valve 69'.
Simultaneously, when lever 532 is pivoted to its actuating position, flush actuator 531 is also actuated. Flush actuator 531 comprises a rigid tubing 541 having an L-shape positioned with one leg of the L-shape in a substantially vertical position, and a hook-shaped rigid tubing member 542 having a telescopically engaged portion telescopically engaged with the vertical leg of L-shaped tubing 541 for enabling movement of hook shaped member 542 in vertical directions. A flexible cable (not shown) is rigidly connected to the inside of hook-shaped member 542, and this flexible cable is disposed through rigid tubing 541 to the actuating end 587 of lever 532. This flexible cable rigidly connected within hooked tubing 542 is also rigidly connected to lever 532 at actuating end 587 of lever 532. Thus, when lever 532 is pivoted to the actuating position of lever 532, the flexible cable connected to the actuating end 587 is pulled through rigid tubing 541 to effect the downward movement of hook-shaped member 542. This downward movement of hook-shaped member 542, when hook-shaped member 542 is engaged with the flush handle 110 (shown in FIG. 2), actuates the flushing of excretion receiving chamber 109.
The operation of this alternative embodiment of the present invention (shown in FIGS. 5 and 6) is as follows: Upon the positioning of the body of the user on seat 20', weight sensitive control 506 (shown in FIG. 5) causes the mixing of warm water source 62 within mixing valve 69'; when the user desires cleansing of the user's crotch area, the user pivots nozzles 56 and 57 beneath the user's crotch area by pivoting the user's back; (assuming valves 50 and 64 being omitted or otherwise opened by means not shown in FIGS. 5 and 6) fluids are sprayed through port 57 and orifice 82 of nozzles 56 and 75, respectively, onto the user's crotch area; lever 532 is actuated by the user pivoting the user's back further rearward than the nozzle pivoting range; lever 532 is pivoted to the actuating position of lever 532, causing the actuation of flush actuator 531 and simultaneously causes the opening of switch 161'; the flow of fluids through ports 57 and 82 are, thus, ceased; the excretion receiving chamber 109 is accordingly flushed; when desired, the user removes his body from the ordinary position on seat 20'; and lever 532 is returned to its ready, deactuated position by the pivoting of lid 513 to the half-closed position.
Note also that additional electronic or manual means may be incorporated with this alternative embodiment of the present invention (shown in FIGS. 5 and 6) in order to further enable operations similar to the operation of the preferred embodiment of the present invention (shown in FIGS. 1 through 4).
Accordingly, another alternative embodiment of the present invention, referring additionally to FIGS. 7 and 8, utilizes a rotating electrical connection 559 which is actuable by the back of the user to complete electric circuits for operating such components as valves 50 and 64, solenoid 280, compressor 40 and heating element 130 of the alternative embodiment of the present invention shown in FIGS. 5 and 6. The rotating connection 559 replaces lever 532 of the alternative embodiment shown in FIGS. 5 and 6, and rotating connection 559 also has additional advantages that enable a resulting care operation substantially identical to that of the preferred embodiment (shown in FIGS. 1 through 4).
More particularly (referring still to FIGS. 7 and 8, rotor arm 560 is rigidly connected to rotatable drum 574 and is pivotally engaged around shaft 515, rotor arm 560 having a journal (not numbered) through which shaft 515 is engaged. Shaft 515 is also provided with a large notch 575 in the right longitudinal end of shaft 515, which right longitudinal end is pivotally engaged through rotating connection 559. The pivotal engagement between shaft 515 and rotor arm 560 is such to enable electrical communication between shaft 515 and rotor arm 560, and shaft 515 is further in electrical communication with the positive post of AC power supply 190 (represented schematically in FIG. 4). Rotatable drum 574 pivots about the axis of shaft 515 with respect to housing 571, but friction screws 576 through 578 prevent rotatable drum 574 from pivoting freely. Rather, friction screws 576 through 578 restrict the pivoting of drum 574 so that the rotation of drum 574 is quite dampened. This dampening drum 574 is for stopping the pivoting of drum 574 virtually immediately when the forces which cause the pivoting of drum 574 are ceased. When shaft 515 rotates, the circumferential edges of notch 575, which circumferential edges are adjacent the journal of rotor arm 560, eventually engage with tooth 579 of rotor arm 560. This engagement between the circumferential edges of notch 575 and tooth 579 enables the conveyance of pivotal forces from shaft 575 to rotor arm 560. Thereby, the rotation of shaft 515 causes the pivoting of rotor arm 560 about the longitudinal axis of shaft 515 and with respect to housing 571.
Rotor arm 560 is composed of an electrically conductive material and also has electrical contact 580, integrally formed with rotor arm 560 at the outer end of rotor arm 560. Electrical contact 580 is spring biased by rotor arm 560 to slideably engage arc-shaped strip 570 as well as contacts 562 through 565. Each of contacts 562 through 565 is in electrical communication with an electrically conductive line 566 through 569 respectively. Each of electrically conductive lines 566 through 569 is in electrical communication with electrical components 64, 50, 280, 130, 40, and 600 as schematically represented in FIG. 4 (omitting motor 87 represented in electrical communication with line 569). Electrical contacts 562 through 565 are integrally formed with housing 571; however, electrical contacts 562 through 565 are electrically insulated with respect to housing 571 by electrically insulative strip 570 which is adjacent each of electrical contacts 562 through 565. Housing 571 is rigidly connected to support 514 with brackets 572 and 573; and rotor arm 560, accordingly, pivots about the axis of shaft 515 with respect to housing 571.
The rotation of the rotor arm 560 of the rotating electrical connection 559 completes electrical circuits between shaft 515 and contacts 562 through 565. This completion of electrical circuits with contacts 562 through 565 sequentially controls the actuations of valve 50, valve 64, flush solenoid 280 (connected as shown in FIG. 1), and the simultaneous actuation of compressor 40 and the operation of heating element 130.
The operation of the rotating electrical connection 559 with respect to the pivoting of lid 513 is similar to the pivoting of lid 513 in the alternative embodiment pictured in FIGS. 5 and 6. Rotating electrical connection 559 is incorporated in an apparatus which includes means for manually pivoting nozzles 56 and 75 beneath the user's body by pivoting lid 513 through a nozzle pivoting range of positions of lid 513. When lid 513 is pivoting within the nozzle pivoting range of lid 513, rotor arm 560 is pivoted from its forwardmost, first position 581 (shown in hidden line) to the position 582 shown in FIG. 7. When rotor arm 560 is pivoted by the rotation of shaft 515 to a position in which contact 580 contacts contact 562, valve 50 is actuated for providing the flow of a cleansing solution through port 57 onto the user's crotch area when nozzle 56 is positioned beneath the user's crotch. Similarly, the pivoting of rotor arm 560 by the rotation of shaft 515 engaging tooth 579 enables the respective operations according to the electrical circuit completed between contact 580 and contacts 563, 564, and 565, appropriately. Thus, the rearwardly forcing edge 583 of notch 575 causes the completion of electrical circuits between shaft 515 and contacts 562 through 565, sequentially. This sequential completion of electrical circuits with contacts 562 through 565 controls the sequential actuations of valve 50, valve 64, flush solenoid 280 (connected as shown in FIG. 1), and the actuation of compressor 40 with the simultaneous operation of heating element 130.
When the user of this alternative embodiment of the present invention removes his body from seat 20', torsional spring 518 (shown in FIG. 6) along with gravitational force returns seat 513 to the half-closed position of seat 513; and the resetting edge 584 of notch 575 is engaged with tooth 579, and the further movement of lid 513 toward the half-closed position of lid 513 causes the pivoting of rotor arm 560 toward the initial position 581 of rotor arm 560.
Thus, the manually operable functions of the alternative embodiment shown in FIGS. 5 and 6, being the pivoting of nozzles 56 and 75 beneath the user's crotch and the actuation of valve 69' for generating the warm water source 62 are combined with the cleansing, rinsing, blow drying, and flushing functions of the preferred embodiment of the present invention. These functions are accomplished by the incorporation of rotating connection 559 instead of lever 532 in the alternative embodiment of FIGS. 5 and 6 while also operatively including the appropriate means for providing cleansing fluid, providing rinsing fluid, providing compressed heated air, and actuating the flush handle as in the preferred embodiment of FIGS. 1 through 4.
Yet another alternative embodiment (not shown) of the present invention substitutes a timer-like control mechanism for buttons 153 through 158 of the preferred embodiment shown in FIGS. 1 through 4. Thus, the sequential depression of buttons 153 through 158 is replaced by a timer that appropriately controls the operation of electrical components 69, 64, 50, 86, 280, 40, 130, 87 and the solenoid of the blower detent means, which operations are controlled by buttons 153 through 158 in the preferred embodiment of the present invention. The timer sequentially operates such electrical components in a sequence of respective durations that are predetermined through experimentation to be ideal. Accordingly, after testing the temperature of the water blowing through orifice 82, the user of the apparatus of this alternative embodiment of the present invention merely initiates the operation of the timer. The cleansing, rinsing, drying, and flushing cycles of the operation of the present invention are controlled by the timer until their appropriate predetermined durations are complete.
Additionally, although the present invention has been characterized in terms of the foregoing preferred embodiment, many other alterations, variations and modifications will be apparent to those of ordinary skill in the art who have the benefit of this disclosure. The invention is not limited by the above described preferred embodiment, and the characteristics of such skilled observations are intended and expected to be encompassed within the spirit and scope of the following claims. | Addressing primarily the needs of physically incapacitated individuals, this invention is a device connected to a common toilet for aiding such individuals in their cleansing of their private body parts with an apparatus that has a unique seat that seals fluids beneath the body of the user. The apparatus is basically an automatic cleansing device that one can connect to a toilet for spraying a warm water-soap solution followed by the spray of a warm water rinsing fluid and completed with the automatic flushing of the toilet as well as the blowing of heated air across the user's private body parts for drying the private body parts; this device is controlled in a variety of ways including electric switches, timers, or other manually operated mechanisms. | 4 |
BACKGROUND OF THE INVENTION
This invention relates to compositions of matter classified in the art of chemistry as salicylate esters, compositions containing them, their combination with polyisocyanates, and the use of said combinations as pot life extenders for hydroxy terminated polybutadiene based polyurethanes useful as binders in propellant grains for solid fuel rocket motors.
Polyurethane binders may be used to prepare solid propellant grains with superior physical properties. It is advantageous to use hydroxy terminated polybutadienes as prepolymers for these binder systems. These prepolymers consist of a backbone of repeating polybutadiene units having terminal hydroxyls and an average molecular weight of about 3000. Additional hydroxyl functions are randomly located along the chain in such fashion that the average hydroxyl functionality per average 3000 molecular weight is in the range of from 2.1 to 2.7. The additional hydroxyl groups provide cross-linking sites necessary for firm cures, as the typical common polyisocyanates employed in the curing reaction are difunctional.
Binders may also include, in addition to prepolymers and curing agent, a plasticizer. This will be included to enhance such desirable physical properties as strain capability, softness, flexibility and the like. Plasticizers, being normally of lower viscosity than the prepolymer may also be useful in improving processing characteristics of the propellant during mixing and casting. Usually such common plasticizers as alkyl esters, for example, dioctyl adipate, or dinonyl phthalate, are employed although dual purpose materials such as n-butyl ferrocene which is also a burn rate catalyst may be employed.
The solid ingredients of the propellant will normally be an oxidizer or oxidizers, for example, ammonium perchlorate, or ammonium nitrate, a metal fuel, for example, aluminum powder, and frequently a solid burn rate catalyst, for example, iron oxide. The blending, casting and curing of these propellant grains is, of course, a procedure quite familiar to those skilled in the art.
The time required for manufacture of a solid propellant grain is, of course, limited generally by factors common to all plastic resin processes, those of pot life and cure time. Pot life in this instance is practically defined as the time required for the mix to reach a viscosity in the range of about 40 Kp. After this viscosity limit is reached, defect free casting can no longer be assured. In the usual case useful pot life will be about 10 to 14 hours. The time for cure to a rubbery state which permits motor tooling removal, and finishing operation is, as would be expected, dependent upon specific formulations and cure conditions but is generally of the order of 7 to 14 days.
Pot life and cure time are dependent primarily on the speed of the reaction between the hydroxyl terminals of the prepolymer and the polyisocyanate. Excessive pot life and cure time may be shortened by the use of conventional urethane cure catalysts in the mix. Typical are such catalysts as tertiary amines, metal salts or complexes, and organo tin compounds, for example, dibutyl tin diacetate. The expedient of raising the temperature to speed cure, which might at first glance seem attractive, must be applied cautiously because of the highly energetic nature of the materials involved and the necessity of avoiding excessive strain in the cured grain caused by cool down to ambient temperature after processing. Normally temperatures in the region of 63° C are employed for cure, and seldom, if ever, would temperatures above 76° C be permissible.
It is more common to encounter situations where, in order to obtain a cure rate within the acceptable range, the pot life is excessively shortened. This condition may also be encountered where high solids loading produces an inherently high viscosity. Remedies for this condition are inherently more difficult to obtain. High solids loading for certain applications cannot be reduced because for high burn rates oxidizer quantity and particle size must remain invariant. Processing aids, which are generally surface active materials, may reduce viscosity slightly and lengthen pot life. An inherently fast cure reaction may be somewhat modified by additives but the solution very often is only to change to other less reactive polyisocyanates as cure reagents. These frequently are more expensive, or impart less desirable physical properties to the cured grain.
It has been known in other urethane processing areas that the reactivity of polyisocyanates may be modified by treating them with a "blocking agent" such as phenol. The reaction between the isocyanate and phenol leads to a urethane which is stable at lower temperatures but which dissociates in a reverse reaction at temperatures greater than 160° C regenerating the isocyanate and the phenol.
Because of the temperature required for reversion it is obvious that phenol itself cannot be used as a blocking agent in the manufacture of propellant grains.
A number of modified phenols have been reported to give lower unblocking temperatures.
U.S. Pat. No. 3,317,463 teaches that the use of alkyl and aryl p-hydroxy benzoates as blocking agents will enable unblocking to occur at temperatures of from 60° to 110° C.
U.S. Pat. No. 3,798,090 teaches that nitrocellulose bound propellants are curable with isocyanates blocked with phenols substituted with "negative groups," that is, nitro, nitroso, cyano, bromo, chloro, iodo, chloromethyl, dichloromethyl, trichloromethyl, ester, keto and the like, which will unblock at appropriate cure temperatures (about 60° C).
Marchenko et al in "Effect of the Structure of Urethanes on Their Dissociation Temperatures" in Soviet Urethane Technology Chapter 31, Technomic Publishing Co., Westport, Conn. (1973), discuss the relationship between structure and dissociation temperature of a series of monomeric urethanes of the general structure ##STR1## wherein R was hydrogen, ortho-, meta; or para-methyl, or para-methoxy, and R' was hydrogen, ortho-, meta-, or para-nitro, ortho-, or para-fluoro, ortho-, or para-bromo, para-chloro, or ortho-methoxy. Other compounds and parameters related to dissociation are also discussed.
There is no suggestion in any of these references that salicylate ester blocked polyurethane prepolymers will have the requisite stability within the restrictive temperature ranges suitable for polyurethane based propellant processing, while dissociating within the similarly restrictive range of temperatures suitable for their cure reaction.
SUMMARY OF THE INVENTION
The invention provides a compound of the formula: ##STR2## wherein X is an n+m valent organic radical; R is hydrogen, or lower alkyl of from 1 to about 10 carbon atoms; R' is lower alkyl of from 1 to about 10 carbon atoms or carbocyclic aryl of from 6 to about 10 carbon atoms; n is on the average at least 1; m is 0 or 1; and n+m must be at least 2.
The tangible embodiments of this composition aspect of the invention possess the inherent applied use characteristic of being blocked isocyanates enabling admixture of these compounds with the prepolymer, with which it is desired that the parent isocyanate cure, at normal propellant grain mixing temperatures, while postponing onset of the cure reaction until the temperature is elevated to normal propellant curing temperatures whereupon said compound dissociates, freeing said parent isocyanate allowing normal urethane cure to occur.
The tangible embodiments of this composition aspect of the invention also possess the additional inherent applied use characteristic that upon dissociation the salicylate ester so liberated is an advantageous plasticizer in the propellant grain rather than being either a volatile material or a solid, the liberation of which would tend to introduce additional stress factors in the cured grain.
The invention further provides a curable composition comprising a hydroxy terminated polybutadiene and a compound of Formula I.
The invention further provides a cured hydroxy terminated polybutadiene based polyurethane bound propellant grain wherein the binder and plasticizer comprise the reaction products of a hydroxy terminated polybutadiene with the dissociation products of a compound of Formula I.
The invention further provides a process for the control of the pot life of a curable hydroxy terminated polybutadiene based polyurethane propellant binder which comprises mixing a hydroxy terminated polybutadiene with a compound of Formula I and maintaining the temperature at about 28° C or below.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The manner of making and using the invention will now be described with reference to a specific embodiment thereof namely the preparation of 2-(carboctyloxy phenyl)-N-(isocyanato methyl benzene) carbamate (II) and its use in preparing and curing a propellant grain derived from a hydroxy terminated polybutadiene.
A salicylate ester, conveniently n-octyl salicylate and an equimolar portion of organic diisocyanate, conveniently toluene diisocyanate such as, Hylene T a toluene diisocyanate sold by DuPont Co., and a basic catalyst, conveniently triethylamine are mixed and allowed to stand at ambient temperature for a short period of time, conveniently about 1 to about 2 hours. Reaction is indicated by the still fluid mixture becoming thick. The reaction product containing principally II is suitable for use directly as a blocked curing agent.
A hydroxy terminated polybutadiene, conveniently that sold under the tradename R45M by the Arco Chemical Co., and II, are mixed at about ambient temperature, conveniently about 28° C, oxidizer, conveniently ammonium perchlorate, and if desired a cure catalyst, for example, dibutyl tin diacetate, and/or a plasticizer, for example, dioctyl adipate are then blended in while maintaining ambient temperature. After deaeration by standard techniques the mix is then cast into the desired form and cured at elevated temperature, conveniently about 63° C.
One skilled in the art would readily recognize that the general procedure illustrated for the preparation of II would be readily applicable to the other salicylate esters including 3 alkyl salicylate esters as well as the di and poly isocyanates well-known in the art which are contemplated within the invention, all of which are either available commercially or from synthetic methods familar to organic chemists. In addition to the toluene diisocyanate illustrated other suitable polyisocyanates include for example, isophorone diisocyanate, 4,4'-diphenyl methane diisocyanate, 4,4'-dicyclohexylmethylene diisocyanate, hexamethylene diisocyanate, 1,3,5, triisocyanate benzene and the like. Other suitable salicylate esters and 3-alkyl salicylate esters, in addition to the n-octyl salicylate illustrated are for example, ethyl salicylate, and 2-(ethyl)-hexyl-3-methyl salicylate, nonyl-3-ethyl-salicylate, and the like.
One skilled in the art will also recognize that when reacting the salicylate ester blocking agent with the polyisocyanate it will be possible to vary the proportion of the reactants so that one or more of the isocyanate groups present up to the total number present may be blocked. It will frequently be advantageous to allow one free isocyanate in the blocked curing agent as very frequently this will be less reactive and even if it does react with the prepolymer, it cannot act as a cross-linking agent. The blocking of less than all the isocyanates has the two obvious advantages of reducing cost in that less blocking agent is required, and in that less blocking agent will be released as extra plasticizer in the propellant grain upon unblocking and cure. Reaction of a free isocyanate with a hydroxyl function of the prepolymer also will aid in preventing migration of the curing agent from the mixed binder material prior to cure. It will also be apparent that, as the blocked curing agent and hydroxyl terminated prepolymer are stable to cross-linking when blended at ambient temperatures or below, master batches of propellant binder can be prepared, stored until needed, and then blended as a one component binder system with the propellant solids when required. This will allow easier processing as multiple weigh ups, and dry mixing required by addition of propellant ingredients will be eliminated.
Blocking also, of course, allows the use of isocyanates particularly the known faster reactive aromatic isocyanates such as toluene diisocyanate which themselves are too quickly reactive when mixed directly in an unblocked condition with the normal propellant compositions. Aromatic isocyanates frequently lead to cured propellant grains having superior stress and strain characteristics. Blocking of the isocyanates also greatly reduces their volatility, consequently the handling of these toxic materials is rendered safer and more simplified.
One skilled in the art would also recognize that, as the unblocking reaction may be catalyzed by various agents which also speed the cure reaction, the pot life and cure time may be controlled with considerable accuracy and varied at will over a wide range by judicious choice of catalyst, catalyst concentration and temperature. Typical catalysts may be, for example tertiary amines, dibutyl tin diacetate, iron linoleate, copper stearate, iron acetyl acetonate, calcium 2-ethyl hexanoate, and the like. Some other suitable catalysts are given in U.S. Pat. No. 3,705,119.
In addition to the R45M hydroxy terminated polybutadiene illustrated it will be obvious that any other commercially available hydroxy terminated polybutadiene will be equally suitable in the practice of the invention.
One skilled in the art will also recognize that in addition to the hydroxy terminated polybutadienes illustrated other hydroxy terminated prepolymers such as polyethers and polyesters known in the art as suitable precursors for polyurethanes will be suitable for use in the invention and are contemplated as full equivalents herein.
It will also be obvious that the above mentioned prepolymers may be end capped with polyisocyanates and that these isocyanate terminated prepolymers may then be blocked with the salicylate esters of this invention and such salicylate ester blocked isocyanate terminated prepolymers are also full equivalents contemplated within the scope of the blocked isocyanates of this invention.
The following examples further illustrate the best mode contemplated by the inventors for the practice of their invention.
EXAMPLE 1
Preparation of Blocked Isocyanates
(A) -- Preparation of Blocked Isocyanate using a 2:1 Ratio of Salicylate Ester to Isocyanate
n-Octyl salicylate (2.50 g.) is blended with toluene diisocyanate (0.87 g, Hylene T, DuPont Co.), and triethylamine (0.02 g.). After standing at room temperature for from about 1 to about 2 hours the material turns to a thick glassy liquid which is readily soluble in dichloromethane and in R45M (hydroxy terminated polybutadiene, Arco Chemical Co.).
(B) -- Preparation of a Blocked Isocyanate Using a 1:1 Ratio of Salicylate Ester to Isocyanate
n-Octyl salicylate (2.50 g.) is combined with Hylene T (1.74 g.) and triethylamine (0.02 g.) and allowed to stand as in part A. The material thickened but was more fluid than the material from part A above. The solubility and compatibility with R45M appeared even greater than that of the material of part A.
(C) -- Illustration of the Preparation of a Blocked Isocyanate Using a 1:1 Ratio of Blocking Agent to Isocyanate and Employing a 3-Alkyl Salicylate as the Salicylate Ester Blocking Agent
n-Octyl-3-methyl salicylate (2.64 g.) was combined with Hylene T (1.74 g.) and triethylamine (0.02 g.) under the conditions of part A above. This material also thickened but was fluid and readily soluble in R45M.
EXAMPLE 2
Curing of R45M with Salicylate Blocked Isocyanate
(A) The product of Example 1A (3.37 g.) was blended with R45M (26 g.). This mixture was divided into 3 portions which were warmed at various temperatures to effect cure as shown:
______________________________________Portion Temperature (° C) Time to Cure______________________________________1 60 7 days (soft cure)2 80 overnight3 100 1.5 hours______________________________________
(B) The product of Example 1B (4.24 g.) and R45M (26.0 g.) were blended. Heating the mixture at 60° C leads to a soft rubbery cure in 5 to 7 days. The cured product was clear and void free.
EXAMPLE 3
Effect of Catalysts on the Unblocking and Cure Reaction
(A) Toluene diisocyanate (TDI) and hexamethylene diisocyanate (HMDI) were treated with ethyl salicylate by a procedure analogous to that of Example 1B. The products were then blended with R45M in a procedure analogous to that of Example 2A. 1% by weight, unless otherwise indicated, of the catalysts shown below were then blended into portions of the curing agent-R45M mix and viscosities were measured at the times indicated while maintaining the temperature at 60° C.
______________________________________ Viscosity (Kp) 1 2Curing Agent Catalyst hour hours______________________________________Ethyl Salicylate-TDI None .06 .06Ethyl Salicylate-TDI Lead Acetyl acetonate .18 .40Ethyl Salicylate-TDI Copper Stearate .96 2.2Ethyl Salicylate-TDI Dibutyl tin diacetate .08 .12Ethyl Salicylate-TDI Calcium 2-ethylhexanoate 1.5 4.8Ethyl Salicylate-TDI Triethylamine .56 1.0Ethyl Salicylate-TDI Ferric Acetyl acetonate .10 .10Ethyl Salicylate- Dibutyl tin diacetate .24 .76HMDI (0.3%)Ethyl Salicylate- Dibutyl tin diacetate .26 .58HMDI (0.1%)Ethyl Salicylate- Dibutyl tin dilaurate .32 1.1HMDIEthyl Salicylate- Iron linoleate .38 1.5HMDIEthyl Salicylate- Copper Stearate 153 TooHMDI thickEthyl Salicylate- Calcium 2-ethylhexanoate .12 .45HMDI______________________________________
(B) R45M based gumstocks were prepared from the 1:1 ratio blocked curing agent at the relative concentration levels of Example 2 and catalyst (1% by weight) shown.
the gel times at 60° C were as shown.
__________________________________________________________________________Curing Agent Catalyst Gel Time__________________________________________________________________________Ethyl salicylate-Hexamethylene diisocyanate Copper stearate 1.3 hr.n-Octyl salicylate-Toluene diisocyanate Dibutyl tin diacetate 4 hrs.2-ethylhexyl 3-methyl salicylate-diisocyanate Dibutyl tin diacetate 4.5 hrs.n-octyl-3-methyl salicylate-diisocyanate Dibutyl tin diacetate 8 hrs.n-octyl-3-methyl salicylate-diisocyanate Uncatalyzed 14 hrs.__________________________________________________________________________
EXAMPLE 4
Effectiveness of Dibutyl Tin Diacetate as Cure Catalyst
Gumstocks of R45M were cured at 60° C with 1:1 n-octyl-salicylate-toluene diisocyanate or 1:1 n-octyl-3-methyl-salicylate-toluene diisocyanate at the relative concentration levels of Example 2 in the presence of 1% by weight dibutyl tin diacetate. Penetrometer readings with a 50 g. weight for 30 seconds were recorded as a function of days after mixing.
__________________________________________________________________________Curing Agent Time (Days) Penetrometer__________________________________________________________________________n-Octyl salicylate-toluene diisocyanate 1 28n-Octyl salicylate-toluene diisocyanate 2 24n-Octyl 3-methyl salicylate-toluene diisocyanate 2 31n-Octyl 3-methyl salicylate-toluene diisocyanate 3 29n-Octyl 3-methyl salicylate-toluene diisocyanate 6 26__________________________________________________________________________
EXAMPLE 5
Stability on Storage of Various Pre-mixed Binder Formulations
Various R45M based gumstocks were prepared at ambient temperature and stored at 28° C and 1° C. The curing agents shown were incorporated in the relative proportions of Example 2. All cure agents were 1:1 ratio of blocking agent and diisocyanate. The changes in viscosity with time of storage were measured with the results as shown:
__________________________________________________________________________Ambient Temp. Storage Viscosity (Kp)Curing Agent Catalyst (Days after Mixing)__________________________________________________________________________n-Octyl 3-methyl salicylate-toluene None .34 (0), .70 (1), .90 (2),diisocyanate 1.07 (3), .75 (4), 1.02 (6), .85 (7), .80 (8), .93 (13), 1.08 (20), 1.29 (45).n-Octyl 3-methyl salicylate-toluene (1%) Dibutyl tin 1.04 (0), 1.10 (1), 1.27 (2),diisocyanate diacetate 1.52 (3), 1.07 (4), 1.45 (6), 1.33 (7), 1.32 (10), 1.79 (13), 2.54 (20), 5.26 (45).2-Ethyl hexyl 3-methyl salicylate-toluene None .88 (1), 1.84 (18).diisocyanaten-Octyl salicylate-toluene diisocyanate None .20 (0), .40 (1), .43 (2), .44 (3), .54 (6), .62 (7), .67 (13), .68 (21), .78 (38).n-Octyl salicylate-toluene diisocyanate (1%) dibutyl in .58 (0), .70 (1), .80 (2), diacetate .97 (3), 1.68 (6), 2.16 (7), 3.20 (13), 7.0 (21), 144 (38).1° C Storagen-Octyl salicylate-toluene diisocyanate None .084 (0), .60 (9), .50 (14), .54 (19), .62 (32).n-Octyl salicylate-toluene diisocyanate (1%) Dibutyl tin- .20 (0), .64 (9), .54 (14), diacetate .50 (32).__________________________________________________________________________
EXAMPLE 6
Hydroxy terminated Polybutadiene Based Polyurethane Based Propellant Formulations
Propellant formulations based on R45M were prepared by blending the ingredients shown with R45M at ambient temperatures, followed by cure at 63° C using standard techniques for all operations. The properties obtained are given:
__________________________________________________________________________FORMULATION AmmoniumNo. Curing Agent NCO/OH Catalyst Binder Perchlorate (%) Aluminum (%)__________________________________________________________________________1 n-Octyl 3-methyl 1.0 Dibutyl tin 12.0 88 -- salicylate-toluene diacetate diisocyanate2(a) Isophorone .78 None 12.0 88 -- diisocyanate3(b) n-Octyl salicylate- 0.90 Dibutyl tin 14.0 68 18 toluene diisocyanate diacetate(a) 1% dioctyl adipate added as plasticizer(b) 2% dioctyl adipate added as plasticizerPhysical Properties Strain atFormulation No. Modulus (psi) Max Stress Max Stress (psi)__________________________________________________________________________ -65° F 77° F -65° F 77° F -65° F 77° F__________________________________________________________________________1 32,228 764 .063 .404 1006 1082 25,704 1,347 .091 .444 990 2353 9,568 425 .339 .718 674 151__________________________________________________________________________ | Salicylate esters have been found to be suitable blocking agents for polyisocyanates, enabling preparation of hydroxy terminated polybutadiene based polyurethane bound propellant grains having extended pot life. Unblocking occurs readily at normal propellant cure temperatures, allowing normal cure rates. | 2 |
BACKGROUND OF THE INVENTION
This invention relates generally to power door drive equipment for mass transit vehicles, and more particularly to door operators for use in vehicles requiring essentially uninterrupted side wall surfaces when the vehicular doors are closed. Operators of this type are commonly used to operate "plug" doors in that in a closed position, the doors occupy space essentially equal to that of the car wall were it not interrupted by a door opening. In a door open position, doors of this type move away from the opening outside of the vehicle after being "unplugged."
Known operators providing plugging and unplugging operation along with outside location of open door leaves are typified by U.S. Pat. No. 5,142,823. While these units appear satisfactory, the structures utilized incorporate certain shortcomings, particularly in properly handling the large cantilever load having a substantial inertial component imposed on the operator structure by the doors typically used. Also, if tracked guides into and out of the car wall opening are used, inertial wear on track members reduces door reliability. When rotary prime movers are required, conversion to rectilinear motion involves complicated mechanisms, including rotating screw and nut components. Also, the above-mentioned system utilizes mechanical belts or cables which, in many cases, also cannot be used.
In particular, the invention disclosed herein utilizes a rotary prime mover, mechanical drives excluding cables and belts. Further, the plugging and unplugging operation disclosed involves relatively simple mechanical linkages of the type having high reliability and requiring low maintenance.
Therefore, it is an object of this invention to provide a highly reliable outside sliding plug door system driven by a rotary electrical or fluid powered motor.
It is a further object of this invention to provide an outside sliding plug door drive in which the plugging and unplugging operation is actuated by simple and inexpensive mechanical linkages.
It is a further object of this invention to provide an outside sliding plug door drive wherein the plug/unplug operation, and sliding door movement outside the car body is provided by a single rotary actuator.
It is an additional object of this invention to provide an outside sliding plug door operator wherein in a door closed position the individual door panel hangers are maintained within the confines of the opening in the car side wall.
It is a further object of this invention to provide an outside sliding plug door operator wherein door weight loads and door drive loads are applied to separate components.
It is an additional object of the invention to provide an outside sliding plug door operator wherein door sliding and plugging movements are accomplished by separate mechanical components activated sequentially through response to drive motor torque.
SUMMARY OF THE INVENTION
The invention disclosed herein is a power door drive for moving hi-parting door panels out of and away from a passenger door opening in a transit car side wall. In the open position, door panels are suspended closely adjacent to the car side wall. In a closed position, the door panels present a relatively uninterrupted car body surface, since each panel is shaped in accordance with car body contours.
In order to achieve the relatively uninterrupted surface, a pair of bi-parting doors are suspended from a base plate mounted overhead in the car body opening.
Door motion is achieved through the use of a centrally located rotary motor having a housing mounted on the overhead base plate. Door movement over and away from the car body opening is achieved through a pinion gear on the motor output shaft and individual gear racks attached to each door panel. On rotation of the pinion gear, since opposing panels of the bi-parting pair are attached to upper and lower racks, rotation of the motor shaft pinion produces opposite or bi-parting motion of the door panels.
Movement of the door panels in a closed position into and out of the car side wall termed "plugging" is achieved through the use of pivots intermediate each end of the door base plate and the car side wall. Plugging or shifting the operator base plate into and out of the door opening is achieved by torque controlled mounting of the rotary motor housing on the operator base plate.
In operation, with the doors unplugged or out of the car body opening, unidirectional rotation of the pinion gear provides reciprocal movement of the door panels such that they are moved either together over the opening or away to uncover the opening. In keeping with the invention disclosed, when the pinion and rack drive system moves the doors into a closed position with adjacent edges of the door panels in abutment over the car body opening. In this position there is an increase in the drive motor shaft torque required to simply move the doors into the closed position. This increased torque on the motor shaft, acting on the aforementioned novel drive motor mounting, essentially counter-rotates the motor housing through a limited and predetermined mount.
Affixed to the housing is a sector gear section cooperating with an additional base mounted pinion and a rotating lever affixed to the pinion. The motor housing reverse motion is thereby transmitted to the pinion gear lever. Also attached to the reverse movement pinion gear lever are base shifting rods or links attached to the above described base plate pivots. The geometry of this linkage is such that reverse or reaction motor housing movement is transmitted to the base plate pivots, thereby moving or shifting the door operator base plate into and out of the car body door opening.
Limit switches (not shown) are utilized in the conventional manner to detect door movement into the car body wall and interrupt power to the drive motor. Similarly, limit switches are used in a conventional manner to detect bi-parting panel movement away from the door opening after unplugging, thereby interrupting power to the drive motor with the doors in fully open or closed and plugged position.
Other objects and advantages of the invention will become apparent from the drawings and the specification.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1, 2, and 3 are perspective views of a portion of the car body side wall and door operator of the invention, particularly showing the bi-parting door panels, respectively, in a fully closed and plugged position, a closed and unplugged position, and a fully open position.
FIG. 4 is a perspective view of the operating portion of the invention incorporating an exploded view of the limited motion door drive assembly, location of the door drive rack and pinion assembly, and door support brackets mounted on the door base plate.
FIG. 5 is a perspective view with partial tear-always of the entire door operator in position overhead of a pair of hi-parting doors in a closed, unplugged position, particularly showing door mounting on the operator base plate and base plate shifting pivots.
FIG. 6 is an additional perspective view and partial tear-away of the operator and hi-parting doors with the doors in a fully closed and plugged position. Direction arrows adjacent the motor housing and door panels indicate door movement position to a closed and plugged position from the closed and unplugged position of FIG. 5.
FIG. 7 is a top view of a portion of the operator and door assembly with the doors in an unplugged and fully opened position, particularly showing the position of the lower door support actuating links.
FIG. 8 is a front view of the door drive assembly portion of FIG. 7, particularly showing the motor housing setter gear and its associated pinion and door actuating links with direction arrows corresponding to the door pivot motion of FIG. 7.
FIG. 9 is a top view of a portion of the operator of the invention as shown in FIG. 7 with the bi-parting door panels in a fully closed and plugged position with door motion and pivot link direction arrows for door plugging, particularly showing position of the lower door support links.
FIG. 10 is a partial front view of the operator shown in FIG. 9, particularly showing a base shifting linkage arrangement as driven by the motor housing sector gear, with direction arrows for moving the operator base from a fully closed and unplugged to a plugged position.
FIG. 11 is a partial section of the operator base plate along the line 11--11 of FIG. 8, particularly showing a door in the plugged position and location of door drive brackets as attached to the operator base plate. Door and base plate locations for an unplugged position are shown in a phantom view.
DETAILED DESCRIPTION OF THE INVENTION
With particular reference to FIGS. 1 to 3, there is shown a partial transit vehicle exterior 1 having a side wall 3 and oppositely sliding doors 5 and 7 mounted for a flush or plugged closed position, and unplugged or motion to the exterior of car wall 3 in the opened position (reference FIG. 3).
Plugging and unplugging of doors 5 and 7 and sliding movement away from the opening 2 in car side wall 3 is achieved by use of an overhead operator assembly 20. As shown, doors 5 and 7 are of a contoured flush fitting design having windows 6 and 8 therein.
With particular reference to FIGS. 4, 5, 7 and 8, the overhead operator assembly 20 utilizes a rotary drive motor 21 of either electric, hydraulic, or pneumatic type having an output shaft 23. The motor housing is movably mounted to the operator base plate 43 using a shaft reaction drive assembly 24. As the drive assembly 24 is an important portion of the invention disclosed, its operation will be described in more detail below.
A door drive pinion gear 41 is fixed to output shaft 23 and positioned so as to operatively engage upper and lower door drive gear racks 59 and 61.
Doors 7 and 5 are movably attached to the door operator base plate 43 through door carrying bracket assemblies 63 and 65, respectively.
The slide plug overhead door operator assembly 20 base plate 43 is mounted at each edge of the side wall opening 2 to car side wall structural members 47. To properly support assembly 20, massive base plate mounting brackets 45 and 51 are attached to members 47. Intermediate the upper edge of brackets 45 and 51 and the base plate 43 are pivotal linkages 53, 55 and base plate plugging levers 49. Plugging members 49 operatively pivot around pivots 50 in brackets 45 and 51. An additional pivotal motion between plugging brackets 49 in the base plate 43 is achieved through ends 54 and 56, respectively.
Doors 7 and 5 are operatively attached to the gear racks 59 and 61, respectively, by door carrying bracket assemblies 63 and 65, respectively. Bracket assemblies 63 and 65 are movably attached to the base plate 43 by slidable guides 72 cooperating with door support 70 (reference FIG. 4). Rollers 74 and 76 are operatively attached to assemblies 63 and 65, respectively, for load carrying along the back side of base plate 43. A part of the door support and guide system also attached to base plate 43 is roller guide 67. Roller guide 67 contains rollers 60 and 62 attached to opposite ends of gear racks 59 and 61.
The door motor reaction drive assembly 24 cooperates with door plugging rods 57 pivotally attached to plugging levers 49 and a pinion rod lever 35 attached to reaction pinion 33 (reference FIG. 8).
With particular reference to FIG. 5, also attached to the base plate 43 is lower door support shaft drive link 90. Link 90 and lower door support drive link 88 are pivotally connected, with the opposite end of link 88 drivingly attached to lower door support shaft 84. The upper portion of shaft 84 is journaled in a bracket 86 attached to car structure 47. The lower end of shaft 84 is fixed to lower door support 80 for limited rotation therearound. The door support pin 82 extends upward from the opposite end of link 80, engaging a slot or guide 81 in the lower edge of door 7.
Operation of drive assembly 24 is as follows:
Torque from drive motor 21 is transmitted through shaft 23 and ultimately turns pinion 41. The motor housing of drive motor 21 is attached to the primary friction plate 25. Plate 25 and secondary friction plate 27 form a limited motion torque controlled coupling between the primary plate 25 and the secondary plate 27. Motion is limited to the peripheral length of slots 28 in the secondary friction plate 27 by pins 30. Plate 27 is rigidly attached to reaction drive flanged journal 29 and further fixedly attached to the base plate 43 allowing shaft 23 to be journaled and attached to pinion 41.
With reference to FIGS. 8 and 10, also attached to the primary reaction drive friction plate 25 is sector gear 31. Also attached to the lower edge of base plate 43 is a reaction pinion 33 consisting of a pivoting lever 35 and reaction pinion 33 rotatably attached to base plate 43 at one end of lever 35. Lever 35 is fixed to and rotates with pinion 33, and at its opposite end, is rotatably attached to rods 57. As sector gear 31 and reaction pinion 33 are in operative engagement, rotation of motor plate 25, turns lever 35 thereby rotating plugging levers 49.
With particular reference to FIGS. 4, 5, and 6, with doors fully open and brackets 63 at either extremes of the base plate 43 and the motor shaft 23 operating in a counterclockwise rotation (as shown), the controllable torque generated between friction plates 25 and 27 is such that no relative motion occurs between them, thereby allowing the pinion 41 to move gear racks 59 and 61 in a direction which moves the doors to a closed but unplugged position (reference FIG. 5).
Since at this point, interior or mating edges of doors 5 and 7 abut, thereby essentially increasing the drive torque requirement of drive motor 21, the friction adjustment of plates 25 and 28 is exceeded. The limited excursion during relative motion of disks 25 and 27 allows the drive motor housing and plate 25 to rotate in a clockwise position (reference FIG. 6). With particular reference to FIG. 8, clockwise rotation of plate 25 (not shown) moves gears 31 and 33 so as to move the lever 35 and rods 57 as shown by direction arrows in FIG. 6. With reference to FIG. 9, clockwise rotation of plugging levers 49 in pivotal motion around pivots 50 and links 55 and 53 moves the base plate 43 pivoting around points 50 of brackets 45 and 51 inward of the car side wall opening 2, thereby "plugging" the door into its opening.
As indicated above, (reference FIG. 9) the inward movement of base plate 43 essentially moves link 88 acting through link 90 in a clockwise direction, thereby turning lower door support 82 (reference FIGS. 5 and 6) operating through shaft 84 in a direction so as to simultaneously follow the lower edge of the door 7 into the car side wall opening 2.
In door opening, the above described procedure is reversed. In this operation, drive motor torque exceeds the friction between disks or plates 25 and 27 allowing the motor housing 21 in reaction to the shaft torque to move in a counterclockwise direction (reference FIG. 10), thereby rotating reaction pinion lever 35 in a counterclockwise direction, thereby moving rods 57 and plugging levers 49 counterclockwise (reference FIG. 7). Counterclockwise rotation of levers 49 moves the door base plate 43 out of its opening and disks 25 having reached the end of travel grooves 28, thus limiting motor housing lost motion providing shaft torque to the pinion 41 in a clockwise rotation, thereby moving door support lever 63 in an outward direction thereby opening the door space (reference FIG. 8).
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 the present invention: | A power door operator for vehicles requiring uninterrupted car surfaces in a door area and minimal use of car interior space, particularly in the closed position. The equipment provided utilizes a rotary motor drive and distributed gear system for moving opposing door panels away from an opening in the car wall. Movement of the doors into and out of the car door opening is accomplished through use of controlled reaction travel of the rotary drive motor. | 4 |
This is a continuation of copending application Ser. No. 07/378,144, filed on July 11, 1989, now abandoned, which is a divisional of Ser. No. 07/276,376, filed Nov. 23, 1988, now U.S. Pat. No. 4,933,534.
BACKGROUND OF THE INVENTION
This invention relates to electrical heaters powered from automotive type cigarette lighter sockets, and to electrical plugs for such sockets.
Such an electrical heater could be used, for example, to keep a pizza pie warm on the way home from the pizza shop. It has been proposed to put such a heater directly into the cardboard pizza box beneath the pizza or to include it in a carrier into which the cardboard box is placed. The heater is powered from the cigarette lighter socket via a plug. It is known to use such plugs to power a wide variety of electrical devices.
SUMMARY OF THE INVENTION
In one aspect, the invention provides an electrical heater, complete with a plug for an automotive cigarette lighter socket, whose configuration and materials are so economical and simple to fabricate that the entire device may be discarded after use.
One general feature of the invention is the combination of a heating element, a plug configured to be inserted into the cigarette lighter socket, and a pair of conductors permanently connecting the heating element to the plug.
In another general feature of the invention, the cable connecting the heating element to the plug has a flat substrate and a pair of conductors mounted on the substrate.
Preferred embodiments of the invention include the following features. The conductors comprise wires. The flat substrate comprises two layers of biodegradable paper (held together by adhesive) with the conductors sandwiched between the layers. The heating element and the plug comprise substrates bearing flat conductive layers. The heating element includes a flexible substrate (e.g., biodegradable paper) bearing a resistance coating (e.g., deposited metal). The cable has a periodic series of transverse folds along the length of the substrate. The plug includes a flat substrate having a width corresponding to (e.g., slightly greater than) the diameter of the cigarette lighter socket, and a pair of conductors attached to the substrate for touching a pair of contacts in the lighter socket. The substrate of the plug is, e.g., a sheet of plastic laminated paper. The plug has a series of teeth located to touch the inner wall of the socket, each tooth having a more tapered leading edge to make insertion of the plug easier, and a less tapered trailing edge to make removal of the plug more difficult. One of the flat conductors of the plug lies along an axis of the plug for making connection with a central contact of the socket, and that conductor extends beyond the end of the substrate and has a contour which provides resilience to the conductor in the direction of the axis of the plug.
Another general feature of the invention is the plug itself.
Food (e.g., pizza pie) and other items may be kept warm while in transit. In the case of pizza, the devices are so inexpensive that they can be given away to the customer with the pizza box. The invention can be stored compactly and conveniently, ready for use, and can be used without any modification to the pizza box. Because the resistance coating draws relatively little power and operates at relatively low temperature, the heating element need have no insulating or mechanical support and can simply be a sheet of paper with a metal coating. The plug is disposable, easy to use, and is held securely in the socket. Multiple stacked plugs can be inserted into a single socket to serve multiple heaters or other devices. The heater is attractive and interesting to look at and use and thus provides a natural promotional device for pizza shops. Logos and other marketing slogans can be printed on the heating element, the cable, and the plug. Because all of the elements of the heater have flat substrates, economical, web-type continuous processing equipment may be used.
Other advantages and features will become apparent from the following description of the preferred embodiment, and from the claims.
DESCRIPTION OF THE PREFERRED EMBODIMENT
We first describe the drawings.
FIG. 1 is a perspective view of a pizza heater in a pizza box.
FIG. 2 is a perspective view of the heater element curled slightly to emphasize its flexibility.
FIG. 3 is a perspective view of the plug, paper cable, and a portion of the heater element of the FIG. 1 heater.
FIG. 4 is a perspective view illustrating the fabrication of heater elements.
FIG. 5 is a perspective view of a stack of pizza boxes with heaters.
STRUCTURE
Referring to FIG. 1, to keep hot pizza pie 10 (with pepperoni 11) warm while it is being carried in a car, a heating element 12 of a disposable electrical heater is placed on the bottom of the cardboard pizza box 14 beneath the pizza. Electrical power is delivered to the heater from a car cigarette lighter socket via a disposable cigarette lighter plug 18 connected by a disposable cable 20 to the heating element 12. Cable 20 is prefolded to fit over the side wall 22 of the box and under the side wall 24 of the box lid 16 (in FIG. 1, only a small fragment of the box lid is shown in place as if the lid were closed).
Referring to FIG. 2, heating element 12 has a single sheet of flexible biodegradable kraft paper (0.006 inches thick) as a substrate 26 which bears a sputtered nickel resistance coating 28. The sputtered coating is thin, e.g., 3000 A, to provide a resistance (between the conductive stripes 30, 32) of about 9.6 ohms for a coating area that is 8" by 8" (for a 10" pizza), or 12" by 12" for a 16" pizza. This would achieve a temperature of about 130° F. using 15 watts of power at 12 volts and 1.25 amps (the required current and wattage rise proportionally with the area of the coating). The 130° temperature is appropriate for keeping a pizza warm. A pizza, when just removed from the oven, has a temperature of about 150° F., and should thereafter be kept warm at a temperature that is lower than 150° F. and declines slowly over time.
Two edges of coating 28 are overcoated respectively with two metal conductive stripes 30, 32 (e.g., silver approximately 5000 A thick, having approximately ten times the conductivity of the resistance coating). Stripes 30, 32 in turn meet (and are electrically connected to) two other conductive stripes 34, 36 which are insulated from coating 28 by a region 37. Stripes 34, 36 make connection with cable 20 at a junction 38.
Referring to FIG. 3, cable 20 has two biodegradable kraft paper substrates 50 and 51 in between which are sandwiched two parallel copper wires 42, 44. Paper substrate 51 is adhesive coated on the side facing substrate 50, but substrate 50 is not adhesive coated. At one end 46 of cable 20, substrate 50 is skived to expose the surfaces of wires 42, 44 which are then attached to two tin plated and presoldered copper tabs 47, 49. The tabs are in turn connected to the heating element at junction 38 (using conductive adhesive) so that tab 47 makes electrical contact with heater conductive stripe 36, and tab 49 with stripe 34. At the other end 78 of cable 20, substrate 50 is similarly skived and cable 20 is attached to plug 18 (by soldering) so that wires 42, 44 respectively make electrical contact with two metal conductors 150, 152 on plug 18.
Conductors 150, 152 are small strips of metal (e.g., presoldered tin plated copper) foil that are glued to plug 18. Conductor 152 folds over and lies on both faces of the plug as does conductor 154. When the plug is inserted into a cigarette lighter socket, conductor 150 touches the metal wall of the inside of the lighter socket and the leading tip of conductor 152 touches the central contact of the socket.
Plug 18 includes a biodegradable paper substrate 54 laminated on both sides with plastic layers 5, 57. One end 56 of plug 18 has a width w approximately the size of (in particular slightly greater than) the inside diameter of the cigarette lighter socket. The leading end 58 of plug 18 has tapered edges 60, 62 to make the plug easier to insert into the socket. Along one edge of end 56, the plastic laminate extends beyond the paper substrate and is cut to form a row of teeth 64. Each tooth 64 has one tapered leading edge 66 and a square trailing edge 68. As a result, end 56 is relatively easier to insert into the socket than it is to remove. The teeth also provide a degree of adaptability to the plug, enabling it to be used in sockets having a variety of configurations. In addition the gaps along the edge of the plug provided by the teeth reduce the tendency of the plug to creep out of the socket in reaction to the process of insertion. The other end 160 of the plug is square shaped, like a pizza box, for imprinting a logo of the pizza shop. Logos can also be imprinted on the heating element itself and repeatedly along the cable.
The adhesive which holds conductor 152 on the substrate of the plug ends at point 154, and the tip of the conductor is given a bulging contour such that the tip extends slightly beyond the end of the plug substrate at point 156 and rises slightly above each face of the substrate. This contour imparts a resiliency to the conductor which keeps the conductor tip pressed against the cigarette lighter socket contact when the plug is inserted, notwithstanding any slight tendency for the plug to creep out of the socket after insertion.
Manufacture
Referring to FIG. 4, for economy, a series of heater elements are made from a single continuous sheet 70 of kraft paper. The sheet is coated (by sputtering or vapor deposition) with a series of resistance coatings 28. Next parallel conductive stripes 30, 32 are coated (by sputtering or vapor deposition) all along the two edges of sheet 70. Conductive stripes 73 are then coated (by sputtering or vapor deposition) across the sheet 70 at regular intervals. A small hole 74 is punched in each stripe 73 thus electrically splitting the stripe 72 to form the two stripes 34, 36 (FIG. 2). Finally, sheet 70 is severed cross-wise at locations 76 to free the individual heater elements.
Cable 20 is made by sandwiching wire from two continuous coils between paper from two continuous rolls (one adhesive coated). The cable is then cut to the proper lengths, accordion folded, and skived as previously explained. The combination of the wires sandwiched between the paper layers provides a neat, compact, and attractive assembly. A paper tab 21 (FIG. 2) is then glued around the folded cable to hold it compactly until ready for use.
Plug 18 is made by plastic laminating a paper substrate, die cutting the teeth, and gluing the conductors onto the laminated substrate.
The heater is finally assembled by soldering one end of the cable to the plug and then soldering the other end of the cable to tabs 47, 49 while simultaneously gluing tabs 47, 49 to stripes 36, 34 with conductive adhesive.
Operation
At the pizza shop, the heater is dropped into the bottom of the box before the pizza is put in. In the car, the user pulls on the plug to release tab 21, then extends the cable and inserts the plug into the lighter socket. By pressing on the plug the conductor 152 is compressed at its tip so that when the user stops pressing and the plug creeps back very slightly, the electrical connection continues to be made, due to the resilience of the conductor tip. The heater maintains the pizza at a temperature of, e.g., 130° F., and thus keeps the pizza both warm and crisp.
Referring to FIG. 5, because plug 18 is flat, up to, e.g., four plugs 90 may be stacked together and inserted into a single cigarette lighter socket, with each plug serving a separate heater in one of four pizza boxes 14.
Other embodiments are within the following claims. For example, the resistance coating could be applied by other deposition processes and could be other metals, such as tin, copper, or aluminum. The plug could be unlaminated cardboard. The heating element could have a different substrate, such as a paper coated with a biodegradable polymer (one ten thousandth of an inch thick), with the metal coated lying on the polymer (this improves the uniformity of the electrical characteristics of the resistance coating). The resistance coating could be covered with, e.g., a wax coating. The wires of the cable could be replaced by conductive metal stripes, at greater cost. Foods other than pizza and non-food items could be heated. | An electrical heater, to be powered from an automotive-type cigarette lighter socket, includes a heating element, a plug configured to be inserted into the cigarette lighter socket, and a pair of conductors permanently connecting the heating element to the plug. The plug has a flat substrate and a pair of conductors mounted on the substrate. An electrical plug, for a lighter socket of the kind having an inner wall of a predetermined diameter and a pair of electrical contacts, includes a flat assembly having a flat dielectric base having a width corresponding to the predetermined diameter, and a pair of flat conductors attached to the base for touching the pair of electrical contacts in the socket. | 7 |
CROSS REFERENCE TO RELATED APPLICATION
This application is a conversion of and claims the benefit of U.S. provisional patent application Ser. No. 60/798,267 filed May 4, 2006.
TECHNICAL FIELD
This invention relates to the reduction of sulfur in gasoline and other petroleum products produced by a catalytic cracking process. The invention uses a specific FCCU catalyst additive. This invention relates to a novel approach to FCCU gasoline sulfur reduction. The approach uses a specified ratio of the transition metal oxides of cobalt and molybdenum to accomplish gasoline and diesel blendstock sulfur reduction. This approach also reduces emitted NO x .
BACKGROUND OF THE INVENTION
Catalytic cracking is a petroleum refining process which is applied commercially on a very large scale. A majority of the refinery gasoline blending pool in the United States is produced by this process. In the catalytic cracking process heavy hydrocarbon fractions are converted into lighter products by reactions taking place at elevated temperature in the presence of a catalyst, with the majority of the conversion or cracking occurring in the vapor phase. The feedstock is thereby converted into gasoline, distillate and other liquid cracking products as well as lighter gaseous cracking products.
During catalytic cracking, heavy material, known as coke, is deposited onto the catalyst. This reduces its catalytic activity and regeneration is desired. After removal of hydrocarbons from the spent cracking catalyst, regeneration is accomplished by burning off the coke which restores the catalyst activity. The three characteristic steps of the catalytic cracking can be therefore be distinguished: a cracking step in which the hydrocarbons are converted into lighter products, a stripping step to remove hydrocarbons adsorbed on the catalyst and a regeneration step to burn off coke from the catalyst. The regenerated catalyst is then reused in the cracking step. Catalytic cracking feedstocks normally contain sulfur in the form of organic sulfur compounds such as mercaptans, sulfides and thiophenes. The products of the cracking process correspondingly tend to contain sulfur impurities even though about half of the sulfur is converted to hydrogen sulfide during the cracking process.
For modern refineries, the Fluid Catalytic Cracking Unit (FCCU) produces 40 to 60+% of the gasoline in the gasoline pool. In addition, the FCCU produces a blendstock component for diesel manufacture. Air quality regulations for these transportation fuels will require a further reduction in sulfur content as mandated by the Clean Air Act. For the FCCU process, there are two routes a refiner can utilize to further reduce the sulfur content of these transportation fuels. The first route is via a hydrotreatment process on the feedstock to the FCCU. This hydrotreatment process can by operational severity and design, remove a substantial amount of the feed sulfur to produce a gasoline sulfur content of 100 ppmw or less. The second route a refiner can take involves the use of a specialized catalyst or additive in the FCCU circulating catalyst inventory that can catalytically remove sulfur from the FCCU product distributions. Refiners may elect to use this route for both non-hydrotreated and/or hydrotreated FCCU feedstock derived from various crude sources. In addition, if a refiner utilizes the first route for desired gasoline sulfur content, when the hydrotreater is taken out of service for an outage, this specialized catalyst or additive can be utilized to minimize the increase of gasoline sulfur during the outage period.
A need exists to continue to remove SO 2 gas. A need also remains in the refining industry for improved compositions and processes which minimizes the content of gas phase reduced nitrogen species and NO x emitted from a partial or complete combustion FCCU riser during an FCC process, which compositions are effective and simple to use.
Other objects and advantages of the present invention will become apparent to those skilled in the art upon a review of the following detailed description of the preferred embodiments and the accompanying drawings.
SUMMARY OF THE INVENTION
We have now found catalytic materials for use in the catalytic cracking process which are capable of improving the reduction in the sulfur content of the liquid products of the cracking process including, in particular, the gasoline and middle distillate cracking fractions. The present sulfur reduction catalysts may be used in the form of an additive catalyst in combination with the active cracking catalyst in the cracking unit, that is, in combination with the conventional major component of the circulating cracking catalyst inventory.
This invention focuses on the specialized catalyst additive for lower FCCU gasoline and diesel blendstock sulfur reduction. Compared to commercially available catalysts and additives, this invention offers the following benefits over current commercial offerings at a constant wt %. The improvements are: a significant improvement in gasoline sulfur reductions, a significant reduction in diesel blendstock component sulfur content, a significant reduction in thiophenic, benzothiophenic and di-benzothiophenic compounds, a significant increase in propylene, a significant increase in iso-butylenes, a significant increase in total pentenes with a corresponding increase in amylenes and iso-amylenes, a significant reduction in ethane, propane and butane, a significant reduction of organic sulfur compounds in the Liquefied Petroleum Gas (LPG) an increase in FCC gasoline (R+M/2) octane, a significant reduction of H2S and a reduction in flue gas NOx.
This is accomplished by; minimizing sulfur compound formation in the FCCU riser. The cobalt and molybdenum oxides in the presence of H2S from cracked organic sulfur compounds are converted to metal sulfides. A portion of the overall sulfur reduction in the gasoline and diesel blendstock occurs by minimizing the availability of H2S to combine with olefinic compounds formed in the cracking reactions. It further is accomplished by maximizing the amount of refractory sulfur left uncracked in the slurry oil while maintaining a specified slurry oil production target. As slurry oil refractory sulfur is reduced via cracking, the various lighter cracked sulfur compounds formed are distributed or cracked “upwards” into the diesel blendstock, gasoline and LPG range products.
While this specification is described in terms of cobalt and molybdenum oxides, the invention comprises a mixture of particulate metal oxides of Group
VIB metal oxides and Group VIII metal oxides.
In the preferred embodiment, the mixture of particulate metal oxides is pulverized particulate. In another embodiment, a conventional cracking catalyst is impregnated with the additive mixture.
BRIEF DESCRIPTION OF THE DRAWINGS
The file of this patent contains at least one drawing executed in color. Copies of this patent with color drawing(s) will be provided by the Patent and Trademark Office upon request and payment of necessary fee.
FIG. 1 is a schematic diagram of an FCCU unit comprising a reactor and a riser showing the catalyst system of the present invention in place for the operating that FCCU unit.
FIG. 2 is a chart showing a significant improvement in dry gas conversion according to this invention.
FIG. 3 is a chart showing a significant improvement in C2 conversion according to this invention.
FIG. 4 is a chart showing a significant improvement in LPG conversion according to this invention.
FIG. 5 is a chart showing a significant improvement in C3 conversion according to this invention.
FIG. 6 is a chart showing a significant improvement in butane conversion according to this invention.
FIG. 7 is a chart showing a significant improvement in pentane conversion according to this invention.
FIG. 8 is a chart showing a significant improvement in transportation fuel selectivity according to this invention.
FIG. 9 is a chart showing a significant improvement in mercaptan reduction according to this invention.
FIG. 10 is a chart showing a significant improvement in LCN thiophene conversion according to this invention.
FIG. 11 is a chart showing a significant improvement in HCN thiophene conversion according to this invention.
FIG. 12 is a chart showing a significant improvement in HCN benzothiophene conversion according to this invention.
FIG. 13 is a chart showing a significant improvement in gasoline octane according to this invention.
FIG. 14 is a chart showing a significant reduction in H2S and shift in sulfur distribution according to this invention.
FIG. 15 is a chart showing a significant reduction in NOx according to this invention.
DETAILED DESCRIPTION OF THE INVENTION
The present additives are used as a component of the circulating inventory of catalyst in the catalytic cracking process referred to as an FCCU process. Briefly, the FCCU process in which the heavy hydrocarbon feed containing the organosulfur compounds will be cracked to lighter products takes place by contact of the feed in a cyclic catalyst recirculation cracking process with a circulating fluidizable catalytic cracking catalyst inventory. The significant steps in the cyclic process are: (i) the feed is catalytically cracked in a catalytic cracking zone, normally a riser cracking zone, operating at catalytic cracking conditions by contacting feed with a source of hot, regenerated cracking catalyst to produce an effluent comprising cracked products and spent catalyst containing coke and strippable hydrocarbons; (ii) the effluent is discharged and separated, normally in one or more cyclones, into a vapor phase rich in cracked product and a solids rich phase comprising the spent catalyst; (iii) the vapor phase is removed as product and fractionated in the FCC main column and may be associated side columns to form liquid cracking products including gasoline; (iv) the spent catalyst is stripped, usually with steam, to remove occluded hydrocarbons from the catalyst, after which the stripped catalyst is oxidatively regenerated to produce hot, regenerated catalyst which is then recycled to the cracking zone for cracking further quantities of feed.
Slurry oil can be combined and fed to a fluid catalytic cracking unit (FCCU) to crack the hydrocarbons contained therein to smaller chained hydrocarbons, especially gasoline boiling range and heating oil. Hydrotreating prior to cracking is considered beneficial in gasoline. The gasoline is improved and a considerable amount of the sulfur will be removed which reduces SO 2 emissions from FCCU itself.
The organic sulfur compounds are almost always considered to be contaminants. They hinder in downstream processing and at the very least make obnoxious SO2 gas when burned. For these reasons it is very desirable to remove these compounds. The degree of removal is dependent upon the use of the fraction. For instance, feed streams to catalytic reforming require extremely low sulfur concentrations.
The particulate additive of this invention is used in combination with an active catalytic cracking catalyst. Normally this is a faujasite such as zeolite Y and REY. Zeolite USY and REUSY also are known to process hydrocarbon feedstocks in the FCC unit to produce low-sulfur products.
The additive of this invention comprises a mixture of particulate metal oxides of Group VIB metal oxides and Group VIII metal oxides. The mixture of particulate metal oxides further comprises 5 to 30 wt. % of Group VIB metal oxides and 2 to 10 wt % of a Group VIII metal oxides. Preferably, the mixture of particulate metal oxides is pulverized particulate. Another embodiment of this invention further comprises the step of impregnating the cracking catalyst with the additive prior to catalytically cracking the petroleum feed fraction.
Preferably the Group VIB metal oxide is molybdenum oxide and the Group VIII metal oxide cobalt oxide. Preferably, the additive contains 5 to 20 wt. % of the Group VIB metal oxide and 2 to 5 wt. % of the Group VIII metal oxide.
Generally, the additive is present in an amount ranging from 1 to 25 weight percent of the weight of the cracking catalyst. Preferably, the additive is present in an amount ranging from 5 to 25 weight percent of the weight of the cracking catalyst. More preferably, the additive is present in an amount ranging from 10 to 25 weight percent of the weight of the cracking catalyst.
Generally, the additive has a particle size ranging from 1 nm to 900 nm. Preferably the additive has a particle sizing ranging from 50 nm to 800 nm. More preferably, the additive has a particle size ranging from 100 nm to 700 nm.
FIG. 1 is a schematic diagram of a typical FCC unit showing a regenerator, separator and stripper. FIG. 1 shows an FCC unit, comprising standpipe 16 that transfers catalyst from regenerator 12 at a rate regulated by slide valve 10 . A fluidization medium from nozzle 8 transports catalyst upwardly through a lower portion of a riser 14 at a relatively high density until a plurality of feed injection nozzles 18 (only one is shown) inject feed across the flowing stream of catalyst particles. The resulting mixture continues upwardly through an upper portion of riser 14 to a riser termination device. This specific device utilizes at least two disengaging arms 20 tangentially discharge the mixture of gas and catalyst through openings 22 from a top of riser 14 into disengaging vessel 24 that effects separation of gases from the catalyst. Most of the catalyst discharged from openings 22 fall downwardly in the disengaging vessel 24 into bed 44 . Transport conduit 26 carries the separated hydrocarbon vapors with entrained catalyst to one or more cyclones 28 in reator or separator vessel 30 . Cyclones 28 separate spent catalyst from the hydrocarbon vapor stream. Collection chamber 31 gathers the separated hydrocarbon vapor streams from the cyclones for passage to outlet nozzle 32 and into a downstream fractionation zone (not shown). Diplegs 34 discharge catalyst from the cyclones 28 into bed 29 in a lower portion of disengaging vessel 30 which pass through ports 36 into bed 44 in disengaging vessel 24 . Catalyst and adsorbed or entrained hydrocarbons pass from disengaging vessel 24 into stripping section 38 . Catalyst from openings 22 separated in disengaging vessel 24 passes directly into stripping section 38 . Hence, entrances to the stripping section 38 include openings 22 and ports 36 . Stripping gas such as steam enters a lower portion of the stripping section 38 through distributor 40 and rises counter-current to a downward flow of catalyst through the stripping section 38 , thereby removing adsorbed and entrained hydrocarbons from the catalyst which flow upwardly through and are ultimately recovered with the steam by the cyclones 28 . Distributor 40 distributes the stripping gas around the circumference of stripping section 38 . In order to facilitate hydrocarbon removal, structured packing may be provided in stripping section 38 . The spent catalyst leaves stripping section 38 through port 48 to reactor conduit 46 and passes into regenerator 12 . The catalyst is regenerated in regenerator 12 as is known in the art and sent back to riser 14 through standpipe 16 .
In cracking carbo-metallic feedstocks in accordance with FCC processes, the regeneration gas may be any gas which can provide oxygen to convert carbon to carbon oxides. Air is highly suitable for this purpose in view of its ready availability. The amount of air required per pound of coke for combustion depends upon the desired carbon dioxide to carbon monoxide ratio in the effluent gases and upon the amount of other combustible materials present in the coke, such as hydrogen, sulfur, nitrogen and other elements capable of forming gaseous oxides at regenerator conditions.
The regenerator is operated at temperatures in the range of about 1000.degree to 1600.degree. F., preferably 1275.degree. to 1450.degree. F., to achieve adequate combustion while keeping catalyst temperature below those at which significant catalyst degradation can occur. In order to control these temperatures, it is necessary to control the rate of burning which in turn can be controlled at lest in part by the relative amounts of oxidizing gas and carbon introduced into the regeneration zone per unit time.
The catalyst of this invention, with or without the metal additive is charged to a FCCU unit of the type outlined in FIG. 1 or to a Reduced Crude Conversion (RCC) unit. Catalyst particle circulation and operating parameters are brought up to process conditions by methods well-known to those skilled in the art. The equilibrium catalyst at a temperature of 1100.degree.-1500.degree. F. contacts the oil feed at riser wye 17 . The feed can contain steam, water, naphtha and/or flue gas and can be injected at point 8 or 18 . The catalyst and vaporous hydrocarbons travel up riser 14 at a contact time of 0.1-5 seconds, preferably 0.5-3 seconds. The catalyst and vaporous hydrocarbons are separated in riser termination device outlet 26 at a final reaction temperature of 900.degree.-1100.degree. F. The vaporous hydrocarbons are transferred to cyclones 28 where any entrained catalyst fines are separated and the hydrocarbon vapors are sent to a fractionator (not shown) via transfer line 32 . The coked catalyst then is transferred to stripper 38 for removal of entrained hydrocarbon vapors and then to regenerator vessel 12 to form a dense fluidized bed 13 . An oxygen containing gas such as air is admitted to the bottom of dense bed 13 in vessel 12 to combust the coke to carbon oxides. The resulting flue gas is processed through cyclones 11 and exits from the regenerator vessel 12 via line 23 . The regenerated catalyst is transferred to stripper 60 to remove any entrained combustion gases and then transferred to riser 14 via line 16 to repeat the cycle.
At such time that containment metals on the catalyst becomes intolerable high such that catalyst activity and selectivity declines, additional catalyst and additive can be added and deactivated catalyst withdrawn at addition-withdrawal point 9 into the dense bed 13 of regenerator 12 and/or or at addition-withdrawal point 7 into regenerated catalyst standpipe 16 . Addition-withdrawal points 7 and 9 can be utilized to add virgin catalysts containing one or more metal additives of the invention.
The additive generally contains 5 to 30 wt. % of a Group VIB metal, oxide and 2 to 10 wt. % of a Group VIII metal oxide and alumina. In the following Examples, the additive contained 5 to 20 wt. % of molybdenum and 2 to 5 wt. % of cobalt.
EXAMPLE
To demonstrate this invention, a ground Cobalt oxide-Moly oxide hydrotreating, catalyst was introduced to the laboratory FCC catalyst evaluation testing unit as an additive. The protocol used to evaluate this invention is identical to the protocol and conditions used to evaluate commercially available gasoline sulfur reducing catalysts. The additive was combined with a conventional zeolite catalyst. The following summarizes the test data and results at constant conversion weight percent and shows:
1) A significant improvement in gasoline sulfur reduction. 2) A significant reduction in diesel blendstock component sulfur cont. 3) A significant reduction in thiophenic, benzothiophenic and de-benzothiophenic compounds. 4) A significant increase in propylene. 5) A significant increase in iso-butylenes. 6) A significant increase in total pentenes with a corresponding increase in amylenes and iso-amylenes. 7) A significant reduction in ethane, propane and butane. 8) A significant reduction of organic sulfur compounds in the Liquefied Petroleum Gas (LPG). 9) An increase in FCC gasoline (R+M)/2) octane. 10) A decrease in H2S. 11) A decrease in flue gas NOx.
FIG. 2 is a chart showing a significant improvement in dry gas conversion according to this invention.
FIG. 3 is a chart showing a significant improvement in C2 conversion according to this invention.
FIG. 4 is a chart showing a significant improvement in LPG conversion according to this invention.
FIG. 5 is a chart showing a significant improvement in C3 conversion according to this invention.
FIG. 6 is a chart showing a significant improvement in butane conversion according to this invention.
FIG. 7 is a chart showing a significant improvement in pentane conversion according to this invention.
FIG. 8 is a chart showing a significant improvement in transportation fuel selectivity according to this invention.
FIG. 9 is a chart showing a significant improvement in mercaptan reduction according to this invention.
FIG. 10 is a chart showing a significant improvement in LCN thiophene conversion according to this invention.
FIG. 11 is a chart showing a significant improvement in HCN thiophene conversion according to this invention.
FIG. 12 is a chart showing a significant improvement in HCN benzothiophene conversion according to this invention.
FIG. 13 is a chart showing a significant improvement in octane according to this invention.
FIG. 14 is a chart showing a significant reduction in H2S and shift in sulfur distribution according to this invention.
FIG. 15 is a chart showing a significant reduction in NOx according to this invention.
In the above protocols, the additive is typically used in an amount from about 0.1 to about 10 weight percent of the inventory in the FCCU. Preferably, the amount will be from about 0.5 to about 5 weight percent. About 2 weight percent represents a norm for most practical purposes. The additive may be added in the conventional manner, with make-up to the regenerator or by any other convenient method. The additive remains active for sulfur removal for extended periods of time although very high sulfur feeds may result in loss of sulfur removal activity in shorter times.
The effect of the present additives is to reduce the sulfur content of liquid cracking products, especially the light and heavy gasoline fractions, although reductions are also noted in the light cycle oil, making them more suitable for use as a diesel or home heating oil blend component. The significant reduction in H2S will also have a benefit on downstream processing units where H2S is removed via caustic and amine treatment. The lower H2S load on these units will improve unit efficiency and debottleneck capacity. The sulfur removed in the FCC is absorbed as a metal sulfide and released as Sox in the regenerator.
The ability of the additives of the invention to convert NO x in a FCCU regenerator operated in a partial or complete burn mode also may be determined. The key performance measurement in this test is the NO x conversion. It is desirable to have high NO x conversion for a wide range of O 2 and CO amounts. The activity of the compositions for converting NO x to nitrogen under various O 2 levels, in the reducing/oxidizing conditions possible in a regenerator operating in partial or complete burn are possible due to the oxygen storage capability of the additive. No other nitrogen oxides like N 2 O or NO 2 were detected.
MODIFICATIONS
Specific compositions, methods, or embodiments discussed are intended to be only illustrative of the invention disclosed by this specification. Variation on these compositions, methods, or embodiments are readily apparent to a person of skill in the art based upon the teachings of this specification and are therefore intended to be included as part of the inventions disclosed herein.
The above detailed description of the present invention is given for explanatory purposes. It will be apparent to those skilled in the art that numerous changes and modifications can be made without departing from the scope of the invention. Accordingly, the whole of the foregoing description is to be construed in an illustrative and not a limitative sense, the scope of the invention being defined solely by the appended claims. | This invention focuses on the specialized catalyst and/or additive for lower FCCU gasoline and diesel blendstock component sulfur content. This invention utilizes a specified ratio of the transition metal oxides of cobalt and molybdenum to accomplish gasoline and diesel blendstock sulfur reduction. This is accomplished by minimizing sulfur compound formation in the FCCU riser. The cobalt and molybdenum oxides in the presence of H 2 S from cracked organic sulfur compounds are converted to metal sulfides. A portion of the overall sulfur reduction in the gasoline and diesel blendstock occurs emitted NO x also is reduced. | 2 |
FIELD OF THE INVENTION
This invention relates to a method for separating isopropyl ether from isopropanol using certain higher boiling liquids as the extractive agent in extractive distillation.
DESCRIPTION OF PRIOR ART
Extractive distillation is the method of separating close boiling compounds or azeotropes by carrying out the distillation in a multiplate rectification column in the presence of an added liquid or liquid mixture, said liquid(s) having a boiling point higher than the compounds being separated. The extractive agent is introduced near the top of the column and flows downward until it reaches the stillpot or reboiler. Its presence on each plate of the rectification column alters the relative volatility of the close boiling compounds in a direction to make the separation on each plate greater and thus requires either fewer plates to effect the same separation or make possible a greater degree of separation with the same number of plates. When the compounds to be separated normally form an azeotrope, the proper agents will cause them to boil separately during extractive distillation and thus make possible a separation in a rectification column that cannot be done at all when no agent is present. The extractive agent should boil higher than any of the close boiling liquids being separated and not form minimum azeotropes with them. Usually the extractive agent is introduced a few plates from the top of the column to insure that none of the extractive agent is carried over with the component of highest vapor pressure. This usually requires that the extractive agent boil twenty Centigrade degrees or more higher than the lowest boiling component.
At the bottom of a continuous column, the less volatile components of the close boiling mixtures and the extractive agent are continuously removed from the column. The usual methods of separation of these two components are the use of another rectification column, cooling and phase separation, or solvent extraction.
The breaking of this azeotrope by extractive distillation is a new concept. One of the first applications of this concept might be the breaking of the ethanol-water azeotrope. J. Schneible, U.S. Pat. No. 1,469,447 used glycerol; P. V. Smith & C. S. Carlson, U.S. Pat. No. 2,559,519 employed ethoxyethanol and butoxyethanol for this purpose and W. E. Catterall, U.S. Pat. No. 2,591,672 reported gasoline as being effective. These are dehydrations and operate more conventionally as a solvent extraction process rather than an extractive distillation. Smith, U.S. Pat. No. 2,559,520 described an extractive distillation process for separating one alcohol from another alcohol, specifically ethanol from isopropanol. Finkel, U.S. Pat. No. 4,469,491 described an extractive distillation process for separating diisopropyl ether from similar boiling hydrocarbons.
The most common method of manufacturing isopropanol is by the hydration of propylene using sulfuric acid as the catalyst. However before the isopropanol can be removed from the reaction mixture, some of its reacts with the sulfuric acid to form isopropyl ether. Thus isopropanol made by this method invariably contains some isopropyl ether as an impurity. Normally a mixture of several solvents are separated and recovered by fractionation in a multiplate rectification column and the ease of separation depends upon the difference in boiling points of the compounds to be separated. However isopropanol, isopropyl ether and water form three binary azeotropes and one ternary azeotrope as shown in Table I. Thus any mixture containing these three compounds subjected to rectification will produce an overhead product boiling at 61.6° C. and containing 4.7% water, 7.3% isopropanol and 88% isopropyl ether.
TABLE I______________________________________Azeotropes of Isopropyl Ether, Isopropanol and Water. B.P., AzeotropeCompounds °C. Composition, Wt. %______________________________________Water 100Isopropanol 82.5Isopropyl ether 69.0Water-Isopropanol 80.3 12.6 87.4Isopropanol-Isopropyl ether 66.2 16.3 83.7Water-Isopropyl ether 62.2 4.5 95.5Water-Isopropanol-Isopropyl ether 61.6 4.7 7.3 88.0______________________________________
Extractive distillation would be an attractive method of effecting the separation of isopropyl ether from isopropanol and water if agents can be found that (1) will break the isopropyl ether-isopropanol-water azeotrope and (2) are easy to recover from the isopropanol and water, that is, form no azeotrope with isopropanol and boil sufficiently above isopropanol to make the separation by rectification possible with only a few theoretical plates.
Extractive distillation typically requires the addition of an equal amount to twice as much extractive agent as the isopropyl ether-isopropanol-water on each plate of the rectification column. The extractive agent should be heated to about the same temperature as the plate into which it is introduced. Thus extractive distillation imposes an additional heat requirement on the column as well as somewhat larger plates. However this is less than the increase occasioned by the additional agents required in azeotropic distillation. Another consideration in the selection of the extractive distillation agent is its recovery from the bottoms product. The usual method is rectification in another column. In order to keep the cost of this operation to a minimum, an appreciable boiling point difference between the compound being separated and the extractive agent is desirable. It is also desirable that the extractive agent be miscible with isopropanol otherwise it will form a two phase azeotrope with the isopropanol in the recovery column and some other method of separation will have to be used, as well as having a deleterious effect on the extractive distillation.
The ratios shown in Table II are the parts by weight of extractive agent use per part of isopropyl ether-isopropanol-water azeotrope and the two relative volatilities correspond to the two different ratios. For example in Table II, one part of isopropyl ether-isopropanol-water azeotrope with one part of diethylene glycol methyl ether gives a relative volatility of 2.72, 6/5 parts of diethylene glycol methyl ether gives 2.17. One half part of diethylene glycol diethyl ether mixed with one half part of diethylene glycol ethyl ether with one part of isopropyl ether-isopropanol-water azeotrope gives a relative volatility of 2.01, 3/5 parts of diethylene glycol diethyl ether plus 3/5 parts of diethylene glycol ethyl ether gives 1.60.
Several of the compounds and mixtures listed in Table II and whose relative volatility had been determined in the vapor-liquid equilibrium still, were then evaluated in a glass perforated plate rectification column possessing 4.5 theoretical plates. The results are listed in Table III. The isopropyl ether-isopropanol-water mixture studied contained 10% isopropyl ether, 85% isopropanol, 5% water. The ternary azeotrope contains 88.0 wt.% isopropyl ether, 7.3 wt.% isopropanol and 4.7 wt.% water. What is remarkable is that pure isopropyl ether comes off as overhead product. In every case the feed or bottoms product contained less than 88% isopropyl ether and in every case the overhead is richer than 88% isopropyl ether. Without extractive distillation agents, the overhead would be the azeotrope, 88% isopropyl ether. This proves that the extractive agent is negating the azeotrope and makes the rectification proceed as if the azeotrope no longer existed and brings the more volatile component, isopropyl ether, out as overhead. It is our belief that this is the first time that this has been reported for this azeotrope.
The data in Table III was obtained in the following manner. The charge designated "blank" was 10% isopropyl ether, 85% isopropanol and 5% water and after 1.5 hours operation in the 4.5 theoretical plate column, the relative volatility of the separation between the isopropyl ether-isopropanol-water azeotrope and isopropanol was 3.28. The remaining data is for the extractive distillation agents designated. Here we have negated the azeotrope and brought out the pure isopropyl ether as overhead. The temperature of the overhead approaches 63° C., the boiling point of pure isopropyl ether at 630 mm. Hg.
OBJECTIVE OF THE INVENTION
The object of this invention is to provide a process or method of extractive distillation that will enhance the relative volatility of isopropyl ether from isopropanol and water in their separation in a rectification column. It is a further object of this invention to identify suitable extractive distillation agents which will eliminate the isopropyl ether-isopropanol-water azeotrope and make possible the production of pure isopropyl ether and isopropanol by rectification. It is a further object of this invention to identify organic compounds which, in addition to the above constraints, are stable, can be separated from isopropanol and water by rectification with relatively few plates and can be recycled to the extractive distillation column and reused with little decomposition.
SUMMARY OF THE INVENTION
The objects of this invention are provided by a process for separating isopropyl ether from isopropanol and water which entails the use of certain oxygenated organic compounds as the agent in extractive distillation.
DETAILED DESCRIPTION OF THE INVENTION
We have discovered that certain oxygenated organic compounds, some individually but principally as mixtures, will effectively negate the isopropyl ether-isopropanol-water azeotrope and permit the separation of oure isopropyl ether from isopropanol and water by rectification when employed as the agent in extractive distillation. Table II lists the compounds, mixtures and approximate proportions that we have found to be effective. The data in Table II was obtained in a vapor-liquid equilibrium still. In each case, the starting material was the isopropyl ether-isopropanol-water azeotrope. The ratios are the parts by weight of extractive agent used per part of isopropyl ether-isopropanol-water azeotrope. The relative volatilities are listed for each of the two ratios employed.
The compounds that are effective as extractive distillation agents when used alone are ethylene glycol hexyl ether, propylene glycol methyl ether, diethylene glycol methyl ether, diethylene glycol ethyl ether, diethylene glycol butyl ether, diethylene glycol diethyl ether, propylene glycol and ethylene glycol. The compounds that are effective when used in mixtures of two or more components are propylene glycol ethyl ether, diethylene glycol butyl ether and diethylene glycol hexyl ether.
TABLE II______________________________________Extractive Distillation Agents Which Are Effective InSeparating Isopropyl Ether As Overhead From Isopropanol RelativeCompounds Ratios Volatilities______________________________________Diethylene glycol methyl ether 1 6/5 2.72 2.17Diethylene glycol ethyl ether 1 6/5 3.55 2.30Ethylene glycol hexyl ether 1 6/5 2.00 1.33Propylene glycol methyl ether 1 6/5 1.72 1.35Diethylene glycol butyl ether 1 6/5 1.55 1.46Diethylene glycol diethyl ether, (1/2).sup.2 (3/5).sup.2 2.01 1.60Diethylene glycol ethyl etherDiethylene glycol diethyl ether, (1/2).sup.2 (3/5).sup.2 1.41 1.62Propylene glycol ethyl etherDiethylene glycol butyl ether, (1/2).sup.2 (3/5).sup.2 1.10 1.52Diethylene glycol hexyl ether______________________________________
TABLE III______________________________________Data From Runs Made In Rectification Column. Overhead Phases in RelativeCompounds Temp. °C. Overhead Volatility______________________________________Blank (no agent) 56.8 2 *Diethylene glycol diethyl ether 62.6 2 3.20Propylene glycol 63.2 1 4.88Ethylene glycol 62.2 2 5.18______________________________________ Notes: *did not negate the azeotrope Feed composition was 50 gr. isopropyl ether, 425 gr. isopropanol, 25 gr. water.
THE USEFULNESS OF THE INVENTION
The usefulness or utility of this invention can be demonstrated by referring to the data presented in Tables II & III. All of the successful extractive distillation agents show that isopropyl ether can be removed from its ternary minimum azeotrope with isopropanol and water by means of distillation in a rectification column and that the ease of separation as measured by relative volatility is considerable. Without the extractive distillation agents, no improvement above the azeotrope composition will occur in the rectification column. The data also show that the most attractive agents will operate at a boilup rate low enough to make this a useful and efficient method of recovering high purity isopropyl ether from any mixture with isopropanol and water including the ternary minimum azeotrope. The stability of the compounds used and the boiling point difference is such that complete recovery and recycle is obtainable by a simple distillation and the amount required for make-up is small.
WORKING EXAMPLES
Example 1: The isopropyl ether-isopropanol-water ternary azeotrope is 88% isopropyl ether, 7.3% isopropanol and 4.7% water. Thirty grams of the isopropyl ether-isopropanol-water azeotrope and 30 grams of diethylene glycol methyl ether were charged to an Othmer type glass vapor-liquid equilibrium still and refluxed for 11 hours. Analysis of the vapor and liquid by gas chromatography gave vapor 97.3%, isopropyl ether, 2.7% isopropanol; liquid of 93% isopropyl ether, 7% isopropanol. This indicates a relative volatility of 2.72. Ten grams of the azeotrope were added and refluxing continued for another nine hours. Analysis indicated a vapor composition of 97.6% isopropyl ether, 2.4% isopropanol, a liquid composition of 94.8% isopropyl ether, 5.2% isopropanol which is a relative volatility of 2.17. The lower concentration of extractive agent gives a lower relative volatility as expected.
Example 2: Thirty grams of the isopropyl ether-isopropanol-water azeotrope, 15 grams of propylene glycol methyl ether and 15 grams of diethylene glycol diethyl ether were charged to the vapor-liquid equilibrium still and refluxed for six hours. Analysis indicated a vapor composition of 97.6% isopropyl ether, 2.4% isopropanol, a liquid composition of 96.7% isopropyl ether, 3.3% isopropanol which is a relative volatility of 1.41. Ten grams of the azeotrope were added and refluxing continued for another six hours. Analysis indicated a vapor composition of 97% isopropyl ether, 3% isopropanol, a liquid composition of 95.2% isopropyl ether, 4.8% isopropanol which is a relative volatility of 1.62.
Example 3: A glass perforated plate rectification column was calibrated with ethylbenzene and p-xylene which possesses a relative volatility of 1.06 and found to have 4.5 theoretical plates. A solution of 50 grams of isopropyl ether, 425 grams of isopropanol and 25 grams of water was placed in the stillpot and heated. When refluxing began, an extractive agent containing pure ethylene glycol was pumped into the column at a rate of 20 ml/min. The temperature of the extractive agent as it entered the column was 58° C. After establishing the feed rate of the extractive agent, the heat input to the isopropyl ether, isopropanol and water in the stillpot was adjusted to give a total reflux rate of 10-20 ml/min. After one hour of operation, overhead and bottoms samples of approximately two ml. were collected and analysed using gas chromatography. The ratio of isopropyl ether to isopropanol in the overhead was 97.98%. The ratio of isopropyl ether to isopropanol in the bottoms was 3.59%. Using these ratios in the Fenske equation, with the number of theoretical plates in the column being 4.5, gave an average relative volatility of 4.92. After 1.5 hours of operation, the overhead and bottoms samples were taken and analysed. The ratio of isopropyl ether to isopropanol in the overhead was 98.03%. the ratio of isopropyl ether to isopropanol in the bottoms was 2.94%. This gave an average relative volatility of 5.18. After two hours of total operating time, the overhead and bottoms samples were again taken and analysed. The ratio of isopropyl ether to isopropanol in the overhead was 97.9%, the ratio of isopropyl ether to isopropanol in the bottoms was 4.84%. This gave an average relative volatility of 4.55.
We have shown that by the use of the proper compound or combination of compounds as agents, isopropyl ether can be effectively removed from its mixture with isopropanol and water in any proportion including the minimum ternary azeotrope. | Isopropyl ether cannot be completely removed from isopropyl ether--isopropanol--water mixtures by distillation because of the presence of the minimum ternary azeotrope. Isopropyl ether can be readily removed from mixtures containing it, isopropanol and water by using extractive distillation in which the extractive distillation agent is a higher boiling glycol, glycol ether or a mixture of them. Typical examples of effective agents are ethylene glycol, propylene glycol, diethylene glycol diethyl ether plus propylene glycol ethyl ether. | 2 |
This application is a continuation-in-part of co-pending provisional application Ser. No. 60/071,310, filed Jan. 13, 1998.
FIELD OF INVENTION
The present invention is directed to methods, compositions, kits and apparatus to identify and detect the presence or absence of target analytes. The embodiments of the present invention have utility in medical diagnosis and analysis of various chemical compounds in specimens and samples, as well as the design of test kits and apparatus for implementing such methods.
BACKGROUND OF INVENTION
Molecular biology advances in the last decade gave great promise for the introduction of new, sensitive technologies to identify various analytes in test specimens, including the ability to diagnose cancer, infectious agents and inherited diseases. Clinical molecular diagnostics depend almost exclusively on restriction enzyme analyses and nucleic acid hybridization (Southern and Northern blots) (Meselson and Yuan, 1968, Southern, 1975). Clinical tests based on molecular biology technology are more specific than conventional immunoassay procedures and can discriminate between genetic determinants of two closely related organisms. With their high specificity, nucleic acid procedures are very important tools of molecular pathology. However, nucleic acid procedures have limitations, the most important of which are the procedures consume time, are labor intensive and have low sensitivity (Nakamura 1993).
There exists a need to perform analytical and diagnostic assays of high sensitivity and high specificity. There exists a need for analytical methods, compositions and devices which facilitate the performance of a analytical or diagnostic procedure in less than one hour. There exists a need for analytical methods, compositions and devices which are directed to targets which are present in cells in quantities greater than one to one thousand copies. There exists a need for analytical and diagnostic procedures which identify small or large organic molecules, peptides or proteins, the tertiary structure of nucleic acids or complex or simple carbohydrates.
SUMMARY OF THE INVENTION
The present invention features methods, compositions, kits, and apparatus for determining the presence or absence of a target molecule. One embodiment of the present invention is a composition. The composition comprises a first ribonucleic acid (RNA) molecule. The first RNA molecule binds a target molecule and has the following formula:
5′-A-B-C-D-E-3′.
As used above, A is a section of the RNA molecule having 10-100,000 nucleotides which section is, with another RNA sequence, E, replicated by an RNA replicase. The letter “B” denotes a section of the RNA molecule having approximately 1 to 50000 nucleotides which section, with another sequence D, binds the target molecule under binding conditions. The letter “C” denotes a section of the RNA molecule having approximately 1 to 10000 nucleotides which section is capable preventing the replication of the first molecule by the RNA replicase. The letter “D” denotes a section of the RNA molecule having approximately 1 to 50000 nucleotides which section, with another sequence B, binds the target molecule under binding conditions. The sections B and D, in combination, comprise in total at least 10 nucleotides. The first RNA molecule, with sections B and D bound to target, is acted upon by the RNA replicase to form a second RNA molecule. The second RNA molecule has the following formula:
5′-E′-X-A′-3′.
As used above, E′ is the complement to E, and A′ is the complement to A. The letter “X” denotes the complement of parts of the sections B, and D which may be replicated, or the letter denotes the direct bond between sections E′ and A′. The second RNA molecule is replicated by the RNA replicase under replicating conditions.
Preferably, the sequences represented by the letters “A” and “E” are selected from the group of sequences consisting of MDV-I RNA, Q-beta RNA microvariant RNA, nanovariant RNA, midivariant RNA, RQ-135 and modifications of such sequences which maintain the ability of the sequences to be replicated by Q-beta replicase. Preferably, the replicase is Q-beta replicase.
Preferably, the sections B and D have a combined total of 20-5,000 nucleotides and, even more preferred, 20-50 nucleotides. Preferably, the sections B and D bind to target through non-nucleic acid base pairing interactions. Sections B and D bind to the target in the manner of naturally occurring nucleic acid which form RNA-protein complexes. Or, the B and D sections are non-naturally occurring sequences which are selected to bind the target. These non-naturally occurring sequences are selected by computer modeling, or aptamers or partial aptamers, and other nucleic acids exhibiting affinity to the target. The term “aptomer” is used in the manner of Klug, S. J. and Famulok, M. “All you wanted to know about SELEX”, Molecular Biology Reports, 20:97-107 (1994) and other nucleic acids which are selected for affinity to a selected target. Aptamers are selected for a particular functionality, such as binding to small or large organic molecules, peptides or proteins, the tertiary structure of nucleic acids or complex or simple carbohydrates.
Preferably, the section B has a hybridization sequence of 1-100, and more preferred, 1-50, and most preferred, 1-5 nucleotides adjacent to the section A which form a hybridization product with a complementary hybridization sequence of section D. The nucleotides of the hybridization sequence of section D are adjacent section E. The hybridization sequences of sections B and D preferably define a loop or hairpin at such times that section B and D are bound to target. In the absence of target, the hybridization sequences do not form a stable hybridization product. In the presence of the target, and the formation of a complex between sections B and D with the target, a hybridization product is formed that allows the RNA replicase to skip sections B, C and D and replicate sections A and E.
Preferably, X comprises less than five nucleotides of sections B and D, and the second molecule resembles a wild-type template.
Preferably, the section C has 1-10,000 nucleotides, and more preferred, 1-1000 nucleotides, and most preferred, 1-100 nucleotides which sequences define a stop sequence for the RNA replicase. Stop sequences comprise one or more sequences which the RNA replicase can not read through to effect replication of the sequence. These sequences include, by way of example, without limitation, a sequence of poly A, poly C, poly G, multiple initiation sites, modified nucleotides which do not allow the RNA replicase to act on the sequence, sugar linkages without nucleotides and altered phosphate or sugar linkages.
Preferably, the sections A and E comprise at least one sequence that hybridizes to a third nucleic acid. Such third nucleic acid forms a hybridization product which hybridization product can be detected by known means.
A second embodiment of the present invention features paired RNA molecules comprising a first RNA molecule. The first RNA molecule binds a target molecule and has the following formula:
5′-A-F-B-3′.
And, the second RNA binds the target and has the following formula:
5′-D-H-E-3′
As used above, A is a section of the RNA molecule having 10-100,000 nucleotides which section is, with another RNA sequence, E, replicated by an RNA replicase. The letter “B” denotes a section of the RNA molecule having approximately 1 to 50000 nucleotides which section, with another sequence D, binds the target molecule under binding conditions. The letter “D” denotes a section of the RNA molecule having approximately 1 to 50000 nucleotides which section, with another sequence B, binds the target molecule under binding conditions. The sections B and D, in combination, comprise in total at least 10 nucleotides. The letter “F” denotes a section of the RNA molecule having has a hybridization sequence of 1-10,000, and more preferred, 1-50, and most preferred, 1-5 nucleotides which form a hybridization product with a complementary hybridization sequence of section H. The letter “H” denotes a section of the RNA molecule having has a hybridization sequence of 1-10,000, and more preferred, 1-50, and most preferred, 1-5 nucleotides which form a hybridization product with a complementary hybridization sequence of section F. The hybridization sequences of sections F and H preferably define a loop or hairpin at such times that section B and D are bound to target. In the absence of target, the hybridization sequences do not form a stable hybridization product. In the presence of the target, and the formation of a complex between sections B and D with the target, a hybridization product is formed that allows the RNA replicase to skip sections B and D and replicate sections A and E to form a third RNA molecule. The third RNA molecule has the following formula:
5′-E′-X-A′-3′.
As used above, E′ is the complement to E, and A′ is the complement to A. The letter “X” denotes the complement of parts of the sections B, F, H and D which may be replicated, or the letter denotes the direct bond between sections E′ and A′. The third RNA molecule is replicated by the RNA replicase under replicating conditions. Preferably, X comprises less than five nucleotides of the complement of sections B and D, and the third molecule resembles a wild-type template.
Preferably, the sections F and H may comprise sequences which are associated with RNA replicase templates.
A further embodiment of the present invention features a method of determining the presence or absence of a target molecule. One method comprises the steps of providing a first RNA molecule. The first RNA molecule is capable of binding to a target molecule and has the formula:
5′-A-B-C-D-E-3′.
The sections A, B, C, D and E are as previously described. The method further comprises the step of imposing binding conditions on a sample potentially containing target molecules in the presence of the first RNA molecule. In the presence of the target molecule, the first RNA molecule forms a target-first RNA molecule complex. The method further comprises the step of imposing RNA replicase reaction conditions on the sample, in the presence of an RNA replicase, to form a second RNA molecule in the presence of target. The second RNA molecule has the formula:
5′-A′-X-E′-3′.
The sections A′, X and E′ are as previously defined. The sample is monitored for the presence of the second RNA molecule or its complement, which presence or absence is indicative of the presence or absence of the target molecule.
A second method comprises the steps of providing paired RNA molecules comprising a first RNA molecule and a second RNA molecule. The first RNA molecule is capable of binding to a target molecule and has the formula:
5′-A-F-B-3′.
The second RNA molecule has the formula:
5′-D-H-E-3′
The sections A, B, D, E, F and H are as previously described. The method further comprises the step of imposing binding conditions on a sample potentially containing target molecules in the presence of the first RNA molecule and second RNA molecule. In the presence of the target molecule, the first RNA molecule and the second RNA molecule forms a target-first second RNA molecule complex. The method further comprises the step of imposing RNA replicase reaction conditions on the sample, in the presence of an RNA replicase, to form a third RNA molecule in the presence of target. The third RNA molecule has the formula:
5′-E′-X-A′-3′.
As used above, E′ is the complement to E, and A′ is the complement to A. The letter “X” denotes the complement of parts of the sections B, F, H and D which may be replicated, or the letter denotes the direct bond between sections E′ and A′.
A further embodiment of the present invention comprises a kit for determining the presence or absence of a target molecule. The kit comprises a one or more reagents comprising a first RNA molecule for use with an RNA replicase. The first RNA molecule has the formula:
5′-A-B-C-D-E-3′.
In the presence of target, the first RNA molecules is capable of forming a target-first-RNA complex and in the presence of an RNA replicase, forming a second RNA molecule having the formula:
5′-A′-X-E′-3′.
The letters A, B, C, D, E, A′ E′ and X are as previously described. The second RNA molecule is preferably capable of being replicated by Q-beta replicase.
A second embodiment of the kit for determining the presence or absence of a target molecule features paired RNA molecules. The kit comprises a one or more reagents comprising a first RNA molecule and a second RNA molecule. The first RNA molecule has the formula:
5′-A-F-B-3′.
The second RNA molecule has the formula:
5′-D-H-E-3′
In the presence of target, the first RNA molecule and the second RNA molecule are form a target-first-second RNA complex and in the presence of an RNA replicase, forming a third RNA molecule having the formula:
5′-A′-X-E′-3′.
The letters A, B, C. D, E, ,F, H, A′ E′ and X are as previously described. The third RNA molecule is preferably capable of being replicated by Q-beta replicase.
An embodiment of the present invention further comprises a method of making a first RNA molecule, wherein the first RNA molecule has the formula:
5′-A-B-C-D-E-3′.
As used above, the letters A, B, C, D, and E are as previously described. The method comprises the step of combining a sample containing the target molecule with a library of RNA molecules having the formula:
5′-A-B′-C-D′-E-3′.
to form a mixture of one or more target bound RNA molecules and one or more unbound RNA molecules. The letters B′ and D′ represent potential sections B and D. Next, primer nucleic acid corresponding to at least one section is added to the mixture with an enzyme capable of degrading the unbound RNA molecules. Next, bound RNA molecules are released from target and amplified to form an amplification product. Next, the RNA molecules comprising the amplification product having the formula:
5′-A-B′-C-D′-E--3′
are sequenced. Or, a cDNA formed and such cDNA cloned into suitable vectors.
Preferably, the steps of forming a mixture, degrading unbound RNA molecules and amplifying the bound RNA molecules are repeated.
Preferably, the sections B′ and D′ are randomized nucleotides. Or, in the alternative, are generated through in vitro selection.
Preferably the step of degrading the unbound RNA molecules is performed in the presence of the enzyme reverse transcriptase. Sections B and D identified in the method above can be used to make paired RNA molecule of the formula:
5′-A-F-B-3′;
and,
5′-D-H-E-3′.
An embodiment of the present invention further comprises a kit for performing performing the above method of identifying first and second RNA molecules. The kit comprises one or more nucleic acid molecules having sections corresponding to the sections A, B′, C, D′, and E. Preferably, the kit comprises sections B′ and E′ as randomized nucleotide sequences.
As used herein the term “kit” refers to an assembly of parts, compositions and reagents with suitable packaging materials and instructions.
The present invention is further described in the following figure and examples, which illustrate features and highlight preferred embodiments and the best mode to make and use the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 depicts a kit having features of the present invention;
FIG. 2 depicts plasmid pT7 MDV-XhoI;
FIG. 3 depicts the binding element of an aptomer for ATP;
FIG. 4 depicts a modified MDV-1 template.
FIGS. 5 a , 5 b , and 5 c depict plasmid construction.
DETAILED DESCRIPTION
The present invention features methods, compositions, kits, and apparatus for determining the presence or absence of a target molecule. The target molecule may comprise any small or large organic molecules, peptides or proteins, the tertiary structure of nucleic acids or complex or simple carbohydrates the detection of which is desired.
This detailed description will begin with a close examination of one embodiment of the present invention. The composition comprises a first RNA molecule. The first RNA molecule binds a target molecule and has the following formula:
5′-A-B-C-D-E-3′.
As used above, A is a section of the RNA molecule having 10-100,000 nucleotides which section is, with another RNA sequence, E, replicated by an RNA replicase.
Preferably, the sequences represented by the letters “A” and “E” are selected from the group of sequences consisting of MDV-I RNA, Q-beta RNA microvariant RNA, nanovariant RNA, midivariant RNA, RQ-135 and modifications of such sequences which maintain the ability of the sequences to be replicated by Q-beta replicase. Preferably, the replicase is Q-beta replicase.
The sequence of MDV-I RNA has been widely reported. For convenience, it is presented below as Seq. ID No. 1.
Seq. ID No. 1
5′ GGGGACCCCC CCGGAAGGGG GGGACGAGGU GCGGGCACCU UGUACGGGAG UUCGACCGUG ACGCAUAGCA GGCCUCGAGA UCUAGAGCAC GGGCUAGCGC UUUCGCGCUC UCCCAGGUGA CGCCUCGUGA AGAGGCGCGA CCUCGUGCGU UUCGGCAACG CACGAGAACC GCCACGCUGC UUCGCAGCGU GGCUCCUUCG CGCAGCCCGC UGCGCGAGGU GACCCCCCGA AGGGGGGUUC CCGGGAAUUC 3′.
A preferred sequence derived from MDV-I RNA for sequences represented by the letter A, is set forth below as Seq ID No. 2:
Seq. ID No. 2
5′ GGGGACCCCC CCGGAAGGGG GGGACGAGGU GCGGGCACCU UGUACGGGAG UUCGACCGUG ACGCAUAGCA GGAA UU 3′
A preferred sequence derived from MDV-I RNA for sequences represented by the letter E, is set forth below as Seq ID No. 3:
Seq. ID No. 3
5′-GGGGACCCCC CGGGCCUCGA GAUCUAGAGC ACGGGCUAGC GCUUUCGCGC UCUCCCAGUG ACGCCUCGUG AAGAGGCGCG ACCUUCGUGC GUUUCGGCAA CGCACGAGAA CCGCCACGCU GCUUCGCAGC GUGGCUCCUU CGCGCAGCCC GCUGCGCGAG GUGACCCCCC GAAGGGGGGU UCCC-3′.
A preferred sequence derived from RQ-135 for sequences represented by the letter A, is set forth below as Seq ID No. 4:
Seq. ID No. 4
5′-GGGGUUUCCAACCGGAAUUUGAGGGAUGCCUAGGCAUCCCCCGUGCGUCCCUUU ACGAGGGAUUGUCGACUCUAG UCGAC-3′
A preferred sequence derived from RQ-135 for sequences represented by the letter E, is set forth below as Seq ID No. 5:
Seq. ID No. 5
5′-GGUACCUGAGGGAUGC CUAGGCAUCCCCGCGCGCCGGUUUCGGACCUCCAGUGCGUGUUACCGCACUGUCG ACCC-3′
The letter “B” denotes a section of the RNA molecule having approximately 1 to 50000 nucleotides which section, with another sequence D, binds the target molecule under binding conditions. The letter “D” denotes a section of the RNA molecule having approximately 1 to 50000 nucleotides which section, with another sequence B, binds the target molecule under binding conditions. The sections B and D, in combination, comprise in total at least 10 nucleotides.
Preferably, the sections B and D have a combined total of 20-5,000 nucleotides and, even more preferred, 20-50 nucleotides. Preferably, the sections B and D bind to target through non-nucleic acid base pairing interactions. Sections B and D bind to the target in the manner of naturally occurring nucleic acid which form RNA-protein complexes. Or, the B and D sections are non-naturally occurring sequences which are selected to bind the target. These non-naturally occurring sequences are selected by computer modeling, or aptamers or partial aptamers, and other nucleic acids exhibiting affinity to the target.
The term “aptomer” is used in the manner of Klug, S. J. and Famulok, M. “All you wanted to know about SELEX”, Molecular Biology Reports, 20:97-107 (1994) and other nucleic acids which are selected for affinity to a selected target. Aptamers are selected for a particular functionality, such as binding to small or large organic molecules, peptides or proteins, the tertiary structure of nucleic acids or complex or simple carbohydrates. The sequences for nucleic acids that bind to a polymerase, bacteriophage coat protein, serine protease, mammalian receptor, mammalian hormone, mammalian growth factor, ribosomal protein, and viral rev protein are disclosed in U.S. Pat. No. 5,475,096. The method presented in such patent may also be used to identify other aptomer sequences.
In addition, nucleic acid which bind to a target may also be identified by in vitro selection. After such nucleic acid has been selected and identified, such nucleic acid is sequence in a manner known in the art.
Preferably, the section B has a hybridization sequence of 1-100, and more preferred, 1-50, and most preferred, 1-5 nucleotides adjacent to the section A which form a hybridization product with a complementary hybridization sequence of section D. The nucleotides of the hybridization sequence of section D are adjacent section E. The hybridization sequences of sections B and D preferably define a loop or hairpin at such times that section B and D are bound to target. In the absence of target, the hybridization sequences do not form a stable hybridization product. In the presence of the target, and the formation of a complex between sections B and D with the target, a hybridization product is formed that allows the RNA replicase to skip sections B, C and D and replicate sections A and E.
The Example of this application uses nucleic acid which binds adenosine triphosphate (ATP). A preferred sequence for section B is set forth below as Seq. ID No. 6:
Seq ID No. 6
5′-AGUUGGGA AGAAACUGUG GGACUUCG-3′
A preferred sequence for section D is set forth below as Seq. ID No. 7:
Seq ID No. 7
5′-GUCCCA GCAACU-3′
The letter “C” denotes a section of the RNA molecule having approximately 1 to 10000 nucleotides which section is capable preventing the replication of the first molecule by the RNA replicase. Preferably, the section C has 1-10,000 nucleotides, and more preferred, 1-1000 nucleotides, and most preferred, 1-100 nucleotides which sequences define a stop sequence for the RNA replicase. Stop sequences comprise one or more sequences which the RNA replicase can not read through to effect replication of the sequence. These sequences include, by way of example, without limitation, a sequence of poly A, poly C, poly G, multiple initiation sites, modified nucleotides which do not allow the RNA replicase to act on the sequence, sugar linkages without nucleotides and altered phosphate or sugar linkages.
A preferred stop sequence is such sequence recognized by the enzyme sarcin. Sarcin acts on such sequence to effect a modification of the nucleic acid, the removal of the base. Such a preferred sequence for the section C is set forth below as Seq ID No 8:
Seq ID No. 8
5′-AUGUACG AGAGGACC-3′
The first RNA molecule, with sections B and D bound to target, is acted upon by the RNA replicase to form a second RNA molecule. The second RNA molecule has the following formula:
5′-E′-X-A′-3′.
As used above, E′is the complement to E, and A′ is the complement to A. The letter “X” denotes the complement of parts of the sections B, C and D which may be replicated, or the letter denotes the direct bond between sections E′ and A′. The second RNA molecule is replicated by the RNA replicase under replicating conditions.
Preferably, the sections A and E comprise at least one sequence that hybridizes to a third nucleic acid. Such third nucleic acid forms a hybridization product which hybridization product can be detected by known means.
A second embodiment of the present invention features paired RNA molecules comprising a first RNA molecule. The first RNA molecule binds a target molecule and has the following formula:
5′-A-F-B-3′.
And, the second RNA binds the target and has the following formula:
5′-D-H-E-3′
As used above, A is a section of the RNA molecule having 10-100,000 nucleotides which section is, with another RNA sequence, E, replicated by an RNA replicase. The letter “B” denotes a section of the RNA molecule having approximately 1 to 50000 nucleotides which section, with another sequence D, binds the target molecule under binding conditions. The letter “D” denotes a section of the RNA molecule having approximately 1 to 50000 nucleotides which section, with another sequence B, binds the target molecule under binding conditions. The sections B and D, in combination, comprise in total at least 10 nucleotides. The first RNA molecule, with sections B and D bound to target, is acted upon by the RNA replicase to form a third RNA molecule. The letter “F” denotes a section of the RNA molecule having has a hybridization sequence of 1-100, and more preferred, 1-50, and most preferred, 1-5 nucleotides which form a hybridization product with a complementary hybridization sequence of section H. The hybridization sequences of sections F and H preferably define a loop or hairpin at such times that section B and D are bound to target. In the absence of target, the hybridization sequences do not form a stable hybridization product. In the presence of the target, and the formation of a complex between sections B and D with the target, a hybridization product is formed that allows the RNA replicase to skip sections B and D and replicate sections A and E to form a third RNA molecule. The third RNA molecule has the following formula:
5′-E′-X-A′-3′.
As used above, E′ is the complement to E, and A′ is the complement to A. The letter “X” denotes the complement of parts of the sections B, F, H and D which may be replicated, or the letter denotes the direct bond between sections E′ and A′. The third RNA molecule is replicated by the RNA replicase under replicating conditions.
Preferably, the sections F and/or H have 1-10,000 nucleotides, and more preferred, 1-1000 nucleotides, and most preferred, 1-100 nucleotides which sequences define a stop sequence for the RNA replicase.
A further embodiment of the present invention features a method of determining the presence or absence of a target molecule. The method comprises the steps of providing a first RNA molecule. The first RNA molecule is capable of binding to a target molecule and has the formula
5′-A-B-C-D-E-3′.
The sections A, B, C, D and E are as previously described. The method further comprises the step of imposing binding conditions on a sample potentially containing target molecules in the presence of the first RNA molecule. In the presence of the target molecule, the first RNA molecule forms a target-first RNA molecule complex.
The second RNA molecule has the formula:
5′-A′-X-E′-3′.
The sections A′, X and E′ are as previously defined. It is believed that the RNA replicase skips sections B, C, and D as such sections are held, sterically hindered, by the target molecule. Further binding between sections B and D by short sequences adjacent sections A and E facilitate skipping by bringing the template sections in close proximity to each other.
A second method comprises the steps of providing paired RNA molecules comprising a first RNA molecule and a second RNA molecule. The first RNA molecule is capable of binding to a target molecule and has the formula:
5′-A-F-B-3′.
The second RNA molecule has the formula:
5′-D-H-E-3′
The sections A, B, D, E, F and H are as previously described. The method further comprises the step of imposing binding conditions on a sample potentially containing target molecules in the presence of the first RNA molecule and second RNA molecule. In the presence of the target molecule, the first RNA molecule and the second RNA molecule forms a target-first second RNA molecule complex. The method further comprises the step of imposing RNA replicase reaction conditions on the sample, in the presence of an RNA replicase, to form a third RNA molecule in the presence of target. The third RNA molecule has the formula:
5′-E′-X-A′-3′.
As used above, E′ is the complement to E, and A′ is the complement to A. The letter “X” denotes the complement of parts of the sections B, F, H and D which may be replicated, or the letter denotes the direct bond between sections E′ and A′.
Binding conditions are described by Gold L., Polisky B., Uhlenbeck O, and Yarus M., (1995). In brief, binding conditions comprise room temperatures and 50 mM potassium acetate plus 50 mM Tris acetate, pH 7.5, 1 mM dithiothreitol
The method further comprises the step of imposing RNA replicase reaction conditions on the sample, in the presence of an RNA replicase, to form a further RNA molecule in the presence of target. Reaction conditions for RNA replicases are known in the art. Q-beta replicase reactions are performed at 37° C. during 25-30 minutes in 50-ul reactions containing 88 mM Tris-HCL (pH 7.5), 12 mM MgCl 2 , 0.2 mM of each ribonucleoside triphosphate, 25 uCi of [alpha- 32 P]GTP, 90 pm/ml of Q-beta replicase, and 11.2 pm/ml of template RNA.
The sample is monitored for the presence of the second RNA molecule or its complement, which presence or absence is indicative of the presence or absence of the target molecule. The detection of RNA replicase templates is well known. Propidium iodine is commonly used as an intercalating agent to create a color change.
A further embodiment of the present invention comprises a kit for determining the presence or absence of a target molecule. The kit comprises a one or more reagents comprising a first RNA molecule for use with an RNA replicase. The first RNA molecule has the formula:
5′-A-B-C-D-E-3′.
In the presence of target, the first and the second RNA molecules are capable of forming a target-first-RNA complex and in the presence of an RNA replicase, forming a second RNA molecule having the formula:
5′-A′-X-E′-3′.
The letters A, B, C. D, E, A′ E′ and X are as previously described. The second RNA molecule is preferably capable of being replicated by Q-beta replicase.
A second embodiment of the kit for determining the presence or absence of a target molecule features paired RNA molecules. The kit comprises a one or more reagents comprising a first RNA molecule and a second RNA molecule. The first RNA molecule has the formula:
5′-A-F-B-3′.
The second RNA molecule has the formula:
5′-D-H-E-3′
In the presence of target, the first RNA molecule and the second RNA molecule are form a target-first-second RNA complex and in the presence of an RNA replicase, forming a third RNA molecule having the formula:
5′-A′-X-E′-3′.
The letters A, B, C. D, E, ,F, H, A′ E′ and X are as previously described. The third RNA molecule is preferably capable of being replicated by Q-beta replicase.
Turning now to FIG. 1, a kit, generally designated by the numeral 11 , is depicted. The kit 11 comprises the first RNA molecule or paired RNA molecules contained in one or more vials 13 , of which only one is shown, or means for making a first RNA molecule or paired RNA molecules. Preferably, the kit 11 has an RNA replicase illustrated as being contained in a second vial 15 , suitable buffers and reagents illustrated as being contained in a third vial 17 and instructions 19 . It is customary to package the elements of the kit 11 in suitable packaging such as box 21 .
An embodiment of the present invention further comprises a method of making a first RNA molecule, wherein the first RNA molecule has the formula:
5′-A-B-C-D-E-3′.
As used above, the letters A, B, C, D, and E are as previously described. The method comprises the step of combining a sample containing the target molecule with a library of RNA molecules having the formula:
5′-A-B′-C-D′-E-3′.
to form a mixture of one or more target bound RNA molecules and one or more unbound RNA molecules. The letters B′ and D′ represent potential sections B and D. Next, primer nucleic acid corresponding to at least one section is added to the mixture with an enzyme capable of degrading the unbound RNA molecules. Next, bound RNA molecules are released from target and amplified to form an amplification product. Next, the RNA molecules comprising the amplification product having the formula:
5′-A-B′-C-D′-E-3′
are sequenced. Or, a cDNA formed and such cDNA cloned into suitable vectors.
Preferably, the steps of forming a mixture, degrading unbound RNA molecules and amplifying the bound RNA molecules are repeated.
Preferably, the sections B′ and D′ are randomized nucleotides. Or, in the alternative, are generated through in vitro selection.
Preferably the step of degrading the unbound RNA molecules is performed in the presence of the enzyme reverse transcriptase. Methods and procedures for performing reverse transcripase reactions are well known.
An embodiment of the present invention further comprises a kit for performing performing the above method of identifying first and second RNA molecules. The kit 11 has been described with respect to FIG. 1 . The kit 11 comprises one or more nucleic acid molecules having sections corresponding to the sections A, B′, C, D′, and E. Preferably, the kit comprises sections B′ and E′ as randomized nucleotide sequences.
EXAMPLE 1
General Methods of Making First RNA Molecule and Paired RNA Molecules
To construct the paired RNA molecules for the target analyte with a known ligand, two sets of the complementary oligonucleotide are designed and synthesized on a DNA synthesizer. One set of oligonucleotides is dsDNA representing the 5′ part of the whole ligand. The other set of oligonucleotides is dsDNA representing the 3′ part of the same ligand. Both dsDNAs are designed with terminal restriction enzyme sites for cloning in the vector, and with additional nucleotides with lengths from one to ten nucleotides. These additional sequences are selected to define stop sequences and sections F and H of such paired RNA molecules. The first dsDNA has the following formula: 5′-M—N—O—P-3′. The second dsDNA has the following formula: 5′-P—R—S—T-3′, where M, P and T are restriction site linkers, O is sequences representing the 5′ segment of the ligand, R is sequences representing the 3′ segment of the ligand, and N and S are stop sequences.
These two dsDNAs are cloned in a recombinant plasmid containing the T7 RNA promoter, followed immediately by inserting a Q-beta replicase template cDNA. A suitable cloning vector is disclosed in FIG. 2 . Three unique restriction sites (M, P and T) for cloning dsDNA molecules are incorporated into the recombinant plasmid. One cloning site, M follows the T7RNA promoter immediately. The T cloning site is inserted into the end of the Q-beta replicase template, and the P site divides the template insert into two, 5′ and 3′, parts. Thus, the 5′ part of the Q-beta replicase template is flanked by M and P restriction sites and 3′ part of the template is flanked by P and T restriction sites.
The composition of the insert in such recombinant plasmid will be:
T7 promoter--M--Q-beta template--P--Q-beta template--T
A second recombinant plasmid is prepared by replacing the 5′ part of the Q-beta replicase template cDNA situated between the M and P restriction sites with corresponding dsDNA representing the 5′ segment of the ligand. The combined insert of the second recombinant plasmid has the following formula:
T7 promoter--M--N--O--P--Q-beta template--T.
A third recombinant plasmid is prepared by replacing the 3′ part of the Q-beta replicase template cDNA situated between the P and T restriction sites with corresponding dsDNA representing the 3′ segment of the ligand. The combined insert of the third recombinant plasmid has the formula:
T7 promoter--M--Q-beta template--P--R--S--T.
The second and third recombinant plasmids will be linearized by cleavage in the T restriction site, and the recombinant RNAs will be transcribed from each plasmid using the T7 RNA promoter.
Two recombinant RNA transcripts are formed.
The structure of the first detector-molecule is:
5′-A-F-B-3′.
And the structure of the second detector-molecule is:
5′-D-H-E-3′.
To form the single probe embodiment, essentially the same process is used, however, only one recombinant plasmid is formed encoding the entire first RNA molecule.
Recombinant plasmids containing the template sequences with the inserted sequences are used to transform competent bacterial cells, and the transformed cells are grown in a culture. The cultured cells are harvested and lysed. The DNA plasmids are purified. The recombinant plasmids are cleaved with an appropriate restriction enzyme and the recombinant Q-beta replicase templates containing the inserts of the original DNA are transcribed into the RNA using T7 RNA promoter. All procedures are performed according to the standard protocols of J Sambrook, EF Fritsch and T Maniatis (1989) known to someone skilled in the field of molecular biology.
EXAMPLE 2
Construction of RNA Molecules With MDV-1 Sequences and ATP Binding Sequences
This example describes the construction of RNA molecules with MDV-1 sequences and ATP binding sequences. An oligoribonucleotide, aptamer ATP-40-1, with a high-affinity to ATP molecules was identified (Sassanfar and Szostak, 1993). The sequence of ATP-40-1, with an XhoI cloning site incorporated at the termini, is set forth in Seq ID No 9 below:
Seq ID No 9
5′-TCGAGGGTTGGGAAGAAACTGTGGCACTTCGGTGCCAGCAACCC-3′ 3′- CCCAACCCTTCTTTGACACCGTGAAGCCACGGTCGTTGGGAGCT-5′
Turning now to FIG. 3, the binding element of the original aptamer is composed of the 11-base consensus sequence and an unpaired G which is flanked by two base-paired stems. This aptamer is incorporated into plus-strand of the MDV-I RNA template using pT7MDV-1 recombinant plasmid with T7 RNA transcription promoter and standard molecular cloning procedures as depicted in FIG. 2 (Sambrook et al., 1989).
A computer analysis, with the program RNADRAW, suggested that the structural organization of the binding element of the original secondary structure of the ATP-40-1 aptamer remains intact when this aptamer fuses with plus-strand of Q-beta RNA templates. The secondary structures for ATP aptamer and for ATP-401/MDV-1 recombinant RNA as well as secondary structures of all further discussed RNA molecules were predicted by folding algorithms which showed only one of usually several alternative structures and RNA molecules of the same species with other structures might be present in a population.
The ATP aptamer sequences do not affect MDV-I RNA's ability to be amplified by Q-beta replicase, and the ATP aptamer-insert propagated in the recombinant RNA continues to demonstrate a high level of affinity to the original ligand, ATP. A ‘short’ wild-type amplification product was generated by Q-beta replicase together with a ‘full length’ amplification product when a recombinant RNA was used as a template. Apparently, Q-beta replicase does not always faithfully amplify the whole recombinant template with the ATP aptamer insert, but occasionally, with a frequency between 20% and 50%, skipped an insert and generate a wild type template.
Affinity of the synthesized recombinant template containing ATP specific RNA sequences to ATP was measured using the method for isocratic elution of labeled RNA from an ATP-agarose column (Sassanfar and Szostak, 1993). Nearly 100% of the recombinant RNA was collected from the 6B Sepharose column in the first two fractions. The same RNA, on the other hand, showed high affinity to the ATP-agarose. The elution rate slowed significantly after collecting the first four fractions. Addition of 4 mM ATP to the elution buffer increased the elution rate fourfold. This change in the elution rate could be explained by the competition between free ATP in the elution buffer and agarose-bound ATP for the ATP-binding insert in the recombinant RNA. Practically all of the labeled recombinant RNA used in this experiment was eluted with 3.5 ml of an elution buffer containing ATP. Completion of the elution was confirmed by treating the column with 10 mM EDTA. The lack of affinity of this recombinant MDV RNA to 6B Sepharose suggests that the affinity of this RNA to ATP-agarose is determined by the aptamer-insert, rather than by the flanking insert sequences of MDV RNA itself. Thus, two direct conclusions follow from these experiments. First, the ATP aptamer sequences do not affect MDV-I RNA's ability to be a template for Q-beta replicase. Secondly, the ATP aptamer-insert propagated in the recombinant RNA continues to demonstrate a high level of affinity to the original ligand, ATP.
EXAMPLE 3
This example describes the design and a construction of paired RNA molecules that will be used for ATP. Such paired RNA molecules will not generate an amplification product separately or when they will be used together in the presence of Q-beta replicase, ribo-nucleotide mix and an appropriate buffer since neither of the recombinant RNA molecules, nor two of them together, have a full and an intact complement of the replicatable, plus-strand, MDV-1 template.
The stability of such ternary complex formed in the presence of ATP is reinforced by a large number of paired nucleotides in RNA molecules. These regions of pairing will keep in close proximity two unbound terminal assembles of the paired RNA molecules as best seen in FIG. 4 .
Furthermore, one region of RNA/ATP ternary complex will be protected from to be ‘unzipped’ by Q-beta replicase during template's amplification and Q-beta replicase will be able to use Region 1 as a ‘bridge’ and to skip the whole insert with a rate of 20-50%. Therefore, Q-beta replicase will be able to produce a functional minus-strand wild type MDV-1 template. This minus-strand will then serve as a template for wild type plus-strand in further replication. The presence of two wild type, plus and minus-templates assure an exponential amplification of RNA.
The sequence for the full length of the MDV-1 RNA is presented as Seq ID No 1. The coding DNA for this template was incorporated into the T7 MDV-1 plasmid depicted in FIG. 2 . The bold letters in the MDV-1 RNA depict the cloning sites. MDV-1 RNA has the following cloning sites: PpuMI site (GGGACCC) at the 5′ end of the template followed the T7 RNA transcription promoter, Eco1471 (AGGCCU), Xho I (CUCGAG), Bgl II (AGAUCU) and Xba I (UCUAGA) represented a multicloning site in the middle of the molecule. Two cloning sites, Sma I (CCCGGG) and Eco RI (GAAUUC) are in the 3′ end of the molecule.
Each recombinant RNA molecule will consist of two parts, sequences of ATP aptamer and of MDV-1 template. The nucleotide sequences for an original ATP-40-1 aptamer is set forth in Seq ID No. 9 (Sassanfar and Szostak, 1993). This sequence was modified in the following manner. An A-U pair was introduced into one double-stranded region and one of the G-C pair was substituted for a pair C-G in the same position. The terminal loop, which in an original aptamer was represented by four nucleotide, UUCG, were changed to ten nucleotides, AAAGAAUUGG. The first RNA molecule of the paired RNA molecules will have nucleotide sequence set forth in Seq ID No 10:
Seq ID No. 10
5′ GGGGACCCCC CCGGAAGGGG GGGACGAGGU GCGGGCACCU UGUACGGGAG UUCGACCGUG ACGCAUAGCA GGaguuggga agaaacugug ggacuucgAA UU 3′
The capital letters depict the 5′ segment of MDV-1 template; the small bold letters depict the sequences of the ATP that will substitute a 3′ segment of the MDV-1 template and to be cloned between Eco 1471 and Eco RI cloning sites of the plasmid.
The second recombinant RNA molecule will have nucleotide sequence set forth in Seq ID No. 11:
Seq ID No. 11
5′-GGGGACCCCC CGGGguccca gcaacuCCUC GAGAUCUAGA GCACGGGCUA GCGCUUUCGC GCUCUCCCAG UGACGCCUCG UGAAGAGGCG CGACCUUCGU GCGUUUCGGC AACGCACGAG AACCGCCACG CUGCUUCGCA GCGUGGCUCC UUCGCGCAGC CCGCUGCGCG AGGUGACCCC CCGAAGGGGG GUUCCC-3′.
The capital letters depict the 3′ segment of MDV-1 template; the small bold letters depict the sequences of the ATP that will substitute a 5′ segment of the MDV-1 template and to be cloned between Eco 1471 and PpuMI cloning sites of the plasmid.
The construction of the recombinant RNA molecules is performed following standard cloning procedures. The synthesis of the designed recombinant RNAs is outlined in FIGS. 5 a , 5 b , and 5 c . The construction of the recombinant RNAs will start with the pT7 MDV-1 recombinant plasmid containing T7 RNA polymerase promoter, and DNA inserts representing MDV-1 template and restriction sites, described above. The plasmid DNA will be double-digested either with PpuMI and Eco 1471 or with Eco 1471 and Eco RI restriction enzymes and purified from the excised fragments. The linearized cloning vectors will be annealed with synthetic cDNAs representing ATP-specific RNA sequences with appropriate cohesive ends and ligated with T4DNA ligase. Recombinant plasmids with desired cDNA inserts will be amplified and then transcribed using T7RNA polymerase promoter following the standard procedures (Sambrook et al., 1989). The RNA transcripts will be purified either by polyacrylamide gel (PAGE) or commercially available RNA purification kits.
We anticipate that paired RNA molecules together with ATP will form a ternary structure, where the two RNA molecules will acquire a conformation similar to the native ATP aptamer, i.e. an asymmetrical bulge flanked by two double-stranded segments. The hybridized recombinant RNAs will have a terminal gap between them that will prevent replication. However, the interaction of an ATP molecule with two recombinant RNA molecules will be strong enough to secure the stability of the double-stranded regions and to promote synthesis of a functional wild type MDV-1 template under Q-beta replicase reaction conditions. The wild-type MDV-1 template is the amplification product of interest.
The reaction is performed at 37° C. in solutions containing Tris-HCl (pH 7.5), a mixture of ribonucleoside triphosphate, appropriate Mg- and Na- salts, and Q-beta replicase enzyme. The concentrations of reaction mix components, such as triphosphates, MgCl 2 and NaCl, template/Q-beta replicase molar ratios are varied to achieve optimal conditions under which the maximal yield of the minus-strand templates and amplified product will be reached. The actual number of templates in the reaction can be estimated by adding the sample to a standardized reaction mixture and measuring the time required to produce a signal with an intercalating fluorescent dye. The response time is universally proportional to the log of the number of template molecules present in the sample (Lomeli et al., 1989).
There are several nucleotide modifications for fluorimetric assays that can be easily used by Q-beta replicase enzyme for RNA amplifications. One such compound is 8-azidoadenosine 5′-triphosphate (8-azido ATP), which could be incorporated into the replicated RNA and is useful in reactions with different fluorochromes (Czarnecki et al., 1979). Another modified nucleotide is 4-thiouridine 5′-diphosphate (4-thio UTP) which also could be incorporated into replicated RNA by Q-beta replicase. Consequently, 7-fluoro-2,1,3-benz-oxadiazole-4-sulfonamide might be used as a reagent for fluorometric identification of the thiol group in the incorporated thionucleotides (Toyooka and Imai, 1984). The amplified recombinant RNA templates can be also identified and quantified by various easily available fluorescent dyes, such as ethidium bromide or RiboGreen (Molecular Probes Inc.), which produce a fluorescent signal upon intercalation into base-paired double stranded regions of the amplified RNA.
For quantification of the template in the reaction mix, 5-ul aliquots are removed at 5 min intervals and mixed with ice-cold 90% formamide containing 50 mM Tris-borate (pH 8.2), 2 mM EDTA, 1 ug/ml carrier tRNA. From this mixture, from seven to 15 ul are applied directly onto magnesium-containing PAGE for visual analysis of the amplification product. For fluorescent analysis, the amplification reaction is filtered through DE81 (ion exchange) filters. The filters is washed two times with 5 ml buffer containing 50 mM Tris-HCl ph 7.5, 100 mM NaCl, 2 mM MgCl 2 and 1 mM EDTA. The bound material is eluted with 5 ml buffer containing 50 mM Tris-HCl ph 7.5, 500 mM NaCl, 2 mM MgCl 2 and 1 mM EDTA and collected. The filters, eluates and washing buffer are collected and fluorimetrically assayed. Aliquots of each amplification reaction are taken at 1 min intervals, and the RNA in each aliquot assessed using the fluorescence of the amplified detector molecules by photography over an ultraviolet light box, or measured in a fluorometer.
EXAMPLE 4
This example describes paired RNA molecules composed of Sarcin/Ricin and Rev protein specific sequences and RQT template sequences. The sequences specific for Sarcin and Ricin allow the formation of stop sequences and allow further stabilization of the tertiary complex. That is, the paired RNA molecule have two, tandemly-arranged RNA aptomer sequences. Each aptomer sequence has affinity to two a different target, either Rev protien or Sarcin/Ricin. The paired RNA detector molecules with two recognition sites will bind with two targeted molecules and will form a quadruple complex of two RNAs and two targets. Such quadruple RNA/target complex will be more rigid structurally than a ‘two RNAs/single target’ ternary complex and, thus, will reinforce the stability of the double stranded regions. The double stranded regions and the stable ternary complex will facilitate the generation of a wild type minus-strand replicatable template.
The recombinant pT7 RQT plasmid with DNA encoding RQT RNA, depicted in FIG. 6, was constructed in our lab. The RNA sequence of RQT RNA is set forth in Seq ID No. 12 as follows:
Seq ID No. 12
5′-GGGGUUUCCA ACCGGAAUUU GAGGGAUGCC UAGGCAUCCC CCGUGCGUCC CUUUACGAGG GAUUGUCGAC UCUAGAGGAU CCGGUACCUG AGGGAUGCCU AGGCAUCCCC GCGCGCCGGU UUCGGACCUC CAGUGCGUGU UACCGCACUG UCGACCC-3′.
The bold letters in the previous sequence depict three cloning sites XbaI, Bam HI and KpnI.
The Sarcin/Ricin specific region of the above sequence includes a near universal sequence for all of 23S rRNA sequence. This region comprises 12 ribonucleotides with a define secondary structure that appeared as a single terminal loop (Munishkin and Wool, 1997. Treatment of this oligonucleotide with low concentrations of alpha-Sarcin or Restrictocin generated two fragments as a result of the cleavage of the oligonucleotide by this protein in a specific site between G and A nucleotides (Wool, 1997 and Related Work). The same domain of 28S rRNA is a target for another, more notorious, toxin—ricin. Ricin, however, inactivates ribosomes by depurination of the A residue, which is upstream and next to the alpha-Sarcin target site (Marchant and Hartley, 1995). Ribosomes are extremely sensitive to the toxins. The K d S for the binding of the sarcin or ricin toxin to the S/R oligonucleotide are in the range of 10 −8 M (Wool, 1997).
Human Immunodeficiency Virus type-1 Rev protein binds with high affinity to a bulge structure located within the Rev-response element (RRE) RNA, Rev protein-specific ligand RBC5L. The smallest oligoribonucleotide able to bind Rev protein with 1-to-1 stoichiometry and with high affinity (K d S of approximately 5 nM) carries the bulge and two sets of four flanking base pairs. The bulge structure contains a specific configuration of non-Watson-Crick G:G and G:A base pairs and demonstrates high affinity recognition of Rev protein by hydrogen bonding to the functional groups in the major groove of the Rev binding element. Introducing truncation and base pair modifications of the double stranded regions that flank the bulge did not affect the affinity or specificity of the original ligand, as long as the nucleotide sequence of the bulge itself was not changed.
A recombinant RQT template with two heterologous RNA inserts, Rev protein-specific RNA sequences and R/S rRNA domain, organized in a tandem fashion was made. Using the ability of alpha-Sarcin and Restrictocin to cleave the Sarcin domain RNA between G and A nucleotides we generated two RNA molecules. A first RNA molecule has nucleotide sequence set forth in Seq ID No. 13:
Seq ID No. 13
5′-GGGGUUUCCA ACCGGAAUUU GAGGGAUGCC UAGGCAUCCC CCGUGCGUCC CUUUACGAGG GAUUGUCGAC UCUAGucgac gucugggcga aaaauguacg ag-3′
The 5′ portion of the first RNA molecule corresponds to RQT template sequences set forth in Seq ID No. 4. The sequence gucugggcg corresponds to one half of the Rev-specific ligand. The sequence uaguacgag corresponds to a portion of the Sarcin specific RNA domain.
A second RNA molecule has a sequence set forth in Seq ID. No. 14:
5′-aggaccuuuu cgguacagac GGUACCUGAG GGAUGCCUAG GCAUCCCCGC GCGCCGGUUU CGGACCUCCA GUGCGUGUUA CCGCACUGUC GACCC-3′
The 3′ portion of the second RNA molecule corresponds to RQT template sequences set forth in Seq ID No. 5., The sequence aggacc corresponds to a portion of the Sarcin-specific domain. The sequence cgguacagac corresponds to one half of the Rev-specific ligand. These two recombinant RNA molecules can be used as paired RNA molecules for the detection of one of the cytotoxins, such as Sarcin, Ricin or Restrictocin, in the presence of Rev protein, in a sample.
Treatment of the recombinant RQT template that incorporates Rev protein-specific RNA sequences and alpha-Sarcin domain synthetic nucleotides with different concentrations of Sarcin or Restrictocin showed that almost a perfect cleavage of the recombinant template with a production of two RNA fragments, with expected sizes of 99nt and 103nt. About 85% of the substrate was cleaved with a single cut of either enzyme at concentration of 25 ug/ml (14.7×10 −7 M). Higher concentrations of Sarcin or Restrictocin led to non-specific cleavage of the recombinant RTQ template in numerous sites. Similar results were reported when a synthetic 35-mer oligoribonucleotide with nucleotide sequences and the secondary structure of the Sarcin domain was treated with Sarcin (Wool, 1997). The two recombinant RNAs generated as a result of the Sarcin or Restrictocin treatments are purified, either by polyacrylamide gel (PAGE) or commercially available RNA purification kits.
RNA duplex formed as a result of hybidization of the constructed two recombinant RNA molecules is structured in the whole length of the RQT sequences and unstructured in the binding with the Rev protein and Sarcin targets region. Hybridization of two RNA molecules is performed in a standard renaturation buffer containing 10 mM Tris-HCl, pH 7.6, 50 mM NaCl and 10 mM MgCl 2 with final concentration of RNA molecules in a range of 30 ng/ul. The solution with RNA molecules is boiled for 2 min and then chilled to room temperature. The optimal concentration of two RNA molecules and their molar ratios are determined empirically.
The RNA complex composed of two hybridized RNA molecules is with either Rev protein or Sarcin and placed under binding conditions. An annealing reaction of RTQ Rev/Sar RNA for Rev protein is performed in 10 mM Hepes/KOH buffer, pH 7.8, containing 100 mM KCl, 2 mM MgCl 2 , 0.5 mM EDTA, 1 mM DTT and 10% Glycerol. An annealing reaction of RQT Rev/Sar RNA with Sarcin and Restrictocin is performed in reaction mix containing 10 mM Tris-HCl buffer, pH 7.6, 50 mM KCl and 4 mM EDTA. The binding complex of Rev protein and hybridized paired RNA molecules will be separated from the unbound molecules by filtration through nitrocellulose membrane filters (Tuerk and Gold, 1990.
The complex is then subjected to Q-beta replicase reaction conditions. The sample is monitored for the presence of wild type templates which are indicative that the enzyme has skipped the bound parts of the molecule.
EXAMPLE 5
This example features the construction of paired RNA molecules using Sarcin or Restrictocin as an agent that will cut a single recombinant RNA molecules into two parts. This method has the following major steps: (1) a cloning a single DNA into an available recombinant plasmid encoding Q-beta template sequences, (2) a transcription of the total length of the recombinant template RNA with the proper heterologous inserts, and (3) cleavage of the recombinant template into two parts using appropriate agent.
This simple protocol can be tailored to construct paired RNA molecules to identify any non-nucleic acid target that demonstrates affinity to the particular RNA sequence. Cleavage of a single RNA into first and second paired RNA molecule can be performed with some ribozymes or oligozymes.
Using standard cloning procedures, DNA represented Rev/Sarcin specific RNA sequences is cloned into pT7RQT plasmid using Kpn I/Xba I as a cloning sites. The new recombinant plasmid is linearized with Sma I restriction enzyme. Recombinant RNA that combined RQT, S/R and Rev protein specific RNA sequences, RQT Rev/Sar RNA, is transcribed using T7 RNA transcription promoter. The RNA sequences of the recombinant RQT RNA template with Rev-Sarcin specific insert are set forth in Seq ID No. 15:
Seq ID No. 15
5′-GGGGUUUCCA ACCGGAAUUU GAGGGAUGCC UAGGCAUCCC CCGUGCGUCC CUUUACGAGG GAUUGUCGAC UCUAGucgac gucugggcga aaaauguacg agaggaccuu uucgguacag acGGUACCUG AGGGAUGCCU AGGCAUCCCC GCGCGCCGGU UUCGGACCUC CAGUGCGUGU UACCGCACUG UCGACCC-3′.
The capital letters in the sequence above depict the nucleotides of the RQT templates, with the bold capital letters indicating the restriction sites. The small bold letters depict the Rev protein. The small, bold italic letters depict Sarcin specific RNA sequences. The Sarcin specific sequences are positioned within the sequences associated with Rev protein specific sequences. The combined Rev- and Sarcin- specific sequences is modified slightly from those reported earlier by eliminating some paired nucleotides and introducing a- and u- tetramers and UCGAC nucleotides to promote proper orientation as suggested by computer modeling. Both inserts are recognizable in the sense such molecules exhibit binding and/or are acted upon by the corresponding Rev protein, Sarcin or Restrictocin molecules.
Annealing of RTQ Rev/Sar with Rev protein is performed in 10 mM Hepes/KOH buffer, pH 7.8, containing 100 mM KCl, 2 mM MgCl 2 , 0.5 mM EDTA, 1 mM DTT and 10% Glycerol. A gel mobilty shift assays suggests that RBC5L RNA (control aptamer) was found to form a stable ribonucleoprotein complex in an excess of the Rev protein. The Rev protein specific sequences incorporated into the RQT template continue to recognize the target Rev protein.
Treatment of RQT Rev/Sar RNA with Sarcin and Restrictocin was performed in a reaction mix containing 10 mM Tris-HCl buffer, pH 7.6, 50 mM KCl and 4 mM EDTA. The same amount of internally 32 P-labeled RQT Rev/Sar RNA was treated with Sarcin or Restrictocin in concentrations of 2, 10 and 25 ug/ml. Products of the reaction were tested on 12% denatured PAGE with 7M Urea. The data suggest the amount of two RNA fragments of 95 and 102 nt is increased with the increase of the concentration of the either cytotoxin. The recombinant template is subjected to amplification by Q-beta replicase to produce a wild-type amplification product.
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15
1
250
RNA
Q-beta bacteriophage
1
ggggaccccc ccggaagggg gggacgaggu gcgggcaccu uguacgggag uucgaccgug 60
acgcauagca ggccucgaga ucuagagcac gggcuagcgc uuucgcgcuc ucccagguga 120
cgccucguga agaggcgcga ccucgugcgu uucggcaacg cacgagaacc gccacgcugc 180
uucgcagcgu ggcuccuucg cgcagcccgc ugcgcgaggu gaccccccga agggggguuc 240
ccgggaauuc 250
2
76
RNA
Q-beta bacteriophage
2
ggggaccccc ccggaagggg gggacgaggu gcgggcaccu uguacgggag uucgaccgug 60
acgcauagca ggaauu 76
3
184
RNA
Q-beta bacteriophage
3
ggggaccccc cgggccucga gaucuagagc acgggcuagc gcuuucgcgc ucucccagug 60
acgccucgug aagaggcgcg accuucgugc guuucggcaa cgcacgagaa ccgccacgcu 120
gcuucgcagc guggcuccuu cgcgcagccc gcugcgcgag gugacccccc gaaggggggu 180
uccc 184
4
80
RNA
Artificial Sequence
Description of Artificial SequenceDERIVED FROM
REACTION PRODUCT OF Q-BETA REPLICASE
4
gggguuucca accggaauuu gagggaugcc uaggcauccc ccgugcgucc cuuuacgagg 60
gauugucgac ucuagucgac 80
5
75
RNA
Artificial Sequence
Description of Artificial SequenceDERIVED FROM
REACTION PRODUCT OF Q-BETA REPLICASE
5
gguaccugag ggaugccuag gcauccccgc gcgccgguuu cggaccucca gugcguguua 60
ccgcacuguc gaccc 75
6
26
RNA
Artificial Sequence
Description of Artificial SequenceAPTOMER FOR
ATP
6
aguugggaag aaacuguggg acuucg 26
7
12
RNA
Artificial Sequence
Description of Artificial SequenceAPTOMER FOR
ATP
7
gucccagcaa cu 12
8
15
RNA
Artificial Sequence
Description of Artificial SequenceSARCIN
RECOGNITION
8
auguacgaga ggacc 15
9
70
RNA
Artificial Sequence
Description of Artificial SequenceAPTOMER FOR
ATP
9
cgagggggga agaaacgggc accgggccag caacccccca accccgacac cggaagccac 60
ggcggggagc 70
10
102
RNA
Artificial Sequence
Description of Artificial SequenceCOMBINED
MDV-1 AND ATP APTOMER
10
ggggaccccc ccggaagggg gggacgaggu gcgggcaccu uguacgggag uucgaccgug 60
acgcauagca ggaguuggga agaaacugug ggacuucgaa uu 102
11
196
RNA
Artificial Sequence
Description of Artificial SequenceCOMBINED
MDV-1 AND ATP APTOMER
11
ggggaccccc cgggguccca gcaacuccuc gagaucuaga gcacgggcua gcgcuuucgc 60
gcucucccag ugacgccucg ugaagaggcg cgaccuucgu gcguuucggc aacgcacgag 120
aaccgccacg cugcuucgca gcguggcucc uucgcgcagc ccgcugcgcg aggugacccc 180
ccgaaggggg guuccc 196
12
157
RNA
Artificial Sequence
Description of Artificial SequenceRQT RNA WITH
CLONING SITES
12
gggguuucca accggaauuu gagggaugcc uaggcauccc ccgugcgucc cuuuacgagg 60
gauugucgac ucuagaggau ccgguaccug agggaugccu aggcaucccc gcgcgccggu 120
uucggaccuc cagugcgugu uaccgcacug ucgaccc 157
13
102
RNA
Artificial Sequence
Description of Artificial SequenceRQT WITH REV
AND SARCIN RECOGNITION SITES
13
gggguuucca accggaauuu gagggaugcc uaggcauccc ccgugcgucc cuuuacgagg 60
gauugucgac ucuagucgac gucugggcga aaaauguacg ag 102
14
95
RNA
Artificial Sequence
Description of Artificial SequenceRQT WITH REV
AND SARCIN RECOGNITION SITES
14
aggaccuuuu cgguacagac gguaccugag ggaugccuag gcauccccgc gcgccgguuu 60
cggaccucca gugcguguua ccgcacuguc gaccc 95
15
197
RNA
Artificial Sequence
Description of Artificial SequenceRQT WITH
SARCIN AND REV RECOGNITION SITES
15
gggguuucca accggaauuu gagggaugcc uaggcauccc ccgugcgucc cuuuacgagg 60
gauugucgac ucuagucgac gucugggcga aaaauguacg agaggaccuu uucgguacag 120
acgguaccug agggaugccu aggcaucccc gcgcgccggu uucggaccuc cagugcgugu 180
uaccgcacug ucgaccc 197 | The present invention is directed to methods, compositions, kits and apparatus to identify and detect the presence or absence of target analytes. The embodiments of the present invention have utility in medical diagnosis and analysis of various chemical compounds in specimens and samples, as well as the design of test kits and apparatus for implementing such methods. | 2 |
FIELD OF THE INVENTION
[0001] The present invention is directed to a piezoelectric composite to which plating is applied and a method for applying such a plating to provide improved adhesion and reliability, and specifically to a ceramic piezoelectric composite ultrasonic transducer having an array of ceramic posts and a method for manufacturing such transducers.
BACKGROUND OF THE INVENTION
[0002] Ultrasonic transducers incorporate one or more piezoelectric vibrators which are electrically connected to a pulsing-receiving unit in the form of an ultrasonic test unit. The piezoelectric transducer converts an electrical pulse from the pulsing unit and converts the electrical signal to a mechanical vibration which is transmitted through a material such as a metal to which it is coupled. The piezoelectric material has the ability to receive a mechanical vibration from the material to which it is coupled and convert it to an electrical pulse which is sent to the receiving unit. By tracking the time difference between the transmission of the electrical pulse and the receipt of the electrical signal and measuring the amplitude of the received wave, various characteristics of the material can be determined. The mechanical pulse is generally in the frequency range of about 0.5 MHz to about 25 MHz, so it is referred to as an ultrasonic wave from which the equipment derives its name. Thus, for example ultrasonic testing can be used to determine material thickness or the presence and size of imperfections within a material.
[0003] Ultrasonic transducers can be used in pairs of send only and receive only units. However, frequently the transducers are transceivers that both send and receive the pulses. The transducer may be a single element or a single transducer may be comprised of a plurality of ceramic elements. This invention is broadly directed to the transducer or probe that is comprised of a ceramic element or elements and improved methods of manufacturing such transducers. Such transducers that utilize the composite ceramic include single element transducers, dual element transducers and arrayed (phased array) transducers.
[0004] These transducers currently are produced by providing a single-piece ceramic material, such as a lead-zirconate-titanate (PZT) ceramic. This ceramic is processed to produce a plurality of spaced columns/posts or planes of preselected side projecting from a solid piece of the ceramic which is unaffected by the processing. This unaffected solid piece of ceramic is referred to as the ceramic backbone. This invention is more narrowly directed to improvements in processing of the ceramic element that is used in an ultrasonic probe, the probe including not only the ceramic, but also the matching layers, the backing, the case and the connectors.
[0005] After the plurality of spaced columns or spaced planes, also referred to as a diced ceramic, has been formed, the spacing between the columns or planes is filled with an epoxy polymer. Sufficient epoxy polymer is applied to form a continuous layer of epoxy overlying the diced ceramic and opposite the ceramic backbone.
[0006] The ceramic backbone is then removed by grinding. To assure complete removal of the ceramic backbone, the ceramic removal operation extends below the backbone and slightly into the diced ceramic, removing a small portion of each post or plane. This is not significant, as it is important to maintain a flat surface with a smooth surface finish. The surface standard for parallelism is 0.0002″ after grinding, and the surface finish is about 35,000 Angstrom units or smoother, typically between about 15,000 to about 35,000 Angstrom units. After the backbone has been removed, the workpiece is flipped over and the epoxy polymer is removed by grinding. Again, some small portion of each post may be removed, but it is important to maintain a flat surface with a smooth surface finish. It is not important whether the epoxy polymer or the ceramic backbone is removed first, although the processing is somewhat easier if the ceramic backbone is removed first. At this point in the processing, the workpiece comprises a plurality of ceramic posts embedded in an epoxy polymer. Both sides of the workpiece are then finish ground. After finish grinding, the ceramic posts are depressed typically from about 15,000 to about 30,000 Angstroms below the epoxy polymer. The depression of the posts can be reduced to 2000 Angstroms below the surface of the epoxy by an optional polishing step. A cross-section of a prior art multi-arrayed transducer after an optional polishing operation is shown in FIG. 1 with a layer of plating 32 applied over its surface, depicting the ceramic posts 12 lying below the surface of the epoxy 24 .
[0007] The ceramic is cleaned in an ultrasonic cleaner to remove any damaged ceramic. The power setting of the cleaners are adjustable, and the power setting is adjusted to a level at which plating on posts is not removed is not removed from the posts during cleaning. After cleaning, the ceramic is rinsed followed by plasma cleaning, the ceramic workpiece is sputter plated, and the plating is tested for adhesion. The ceramic workpiece is then dice-deactivated and poled to activate the ceramic.
[0008] While this process can produce an effective transducer, there are problems associated with such transducers. These problems are associated with ceramic posts or planes being depressed below the surface of the epoxy. The sputter plating process provides a very thin plating over the surface. Total plating thickness is about 15000 Angstroms, which is applied by a line of sight process. Because the ceramic posts are depressed below the surface of the epoxy polymer, it is possible that the sputtering process may not provide a uniform coating of the surface, particularly along the perpendicular surfaces extending between the parallel planes of epoxy polymer and ceramic material. In addition, since the sputter plating operation is performed at temperatures of about 120° C. (about 250° F.), the epoxy is free to expand unrestrained above the ceramic posts or planes. Even though this expansion is small, because of the thinness of the plating deposited by the sputter plating process, it can be sufficient to damage the thin plating extending in the vertical direction along the epoxy polymer between the ceramic posts and the horizontal surface of the epoxy, causing poor performance of the ceramic, such as low capacitance. After sputtering, the ceramic is dice-deactivated and poled to activate the ceramic. The temperatures for poling can be in the range as high as about 100-110° C. After poling, contacts are soldered to the plating.
[0009] Another problem with this configuration is that the depressed ceramic is difficult to solder. As a result, the solder heat is borne by the epoxy during the soldering process, causing it to expand, and further increasing the possibility that the thin plating may fracture, thereby causing bad solder connections.
[0010] A transducer with a plurality of elements formed from a ceramic, which elements are not depressed below the polymer, would overcome many of the difficulties associated with the prior art transducers described above, but such a transducer and a method for fabricating such a transducer is heretofore unknown to the art.
SUMMARY OF THE INVENTION
[0011] The present invention provides a transducer having a ceramic element in which the ceramic is elevated above a polymer. This favorable configuration of the transducer is produced as a result of the method of manufacturing the transducer. The transducer may comprise a piezo-composite element comprising a ceramic element embedded in epoxy, such as is found in a single element transducer. The transducer may comprise a piezo-composite element having a plurality of ceramic elements embedded in epoxy and, the ceramic elements separated from one another by a polymer. The plurality of piezo-ceramic elements may be as simple as a dual element transducer in which two ceramic elements are separated by a non-conductive polymer, a four element array of ceramic elements or it may comprise an array having a larger number of piezo-ceramic elements, each element similarly separated. For example a 50×50 array, having about 2500 elements, with each element being rectangular and having an edge of about 0.002 inches can readily be manufactured. In an array, the ceramic elements may be in the form of posts, each post being an emitter acting as a plurality of wave point sources when excited, or the ceramic elements may be in the form of strips, forming a planar interface, each strip being an emitter of a planar wave when excited. The plurality of ceramic elements is slightly elevated above the polymer and in staggered arrangement with the polymer. As a result, the face of the composite comprising the ceramic and epoxy does not comprise a truly planar arrangement. The face includes a conductive layer such as a noble metal applied over it. Each of the ceramic elements forming emitters is individually connected to the drive signal and to ground in parallel by contacts soldered to the conductive layer. By exciting the individual ceramic members simultaneously, acoustic performance is significantly improved as the present invention provides improved reliability in the electrical connection between the ceramic element(s) and the plating. In this configuration, a transducer incorporating the ceramic made in accordance with the present invention also provides a lower acoustic impedence and better power transfer, particularly to rough surfaces. When in post configuration, a transducer incorporating a ceramic made in accordance with the present invention will also provide improved resolution.
[0012] The transducer of the present invention is formed by first providing a single-piece ceramic material having a first side and a second side. This ceramic is processed from the first side to produce a plurality of spaced columns/posts or planes of preselected size projecting from the second side, which is a solid piece of the ceramic forming a backbone unaffected by the processing. The spacing between the columns or planes is then filled with a nonconductive material such as a polymer. Sufficient polymer is applied to form a continuous layer overlying the diced ceramic and opposite the ceramic backbone. The ceramic backbone is then removed by grinding, the workpiece is flipped over, and the polymer is removed by grinding. A small portion of each post may be removed, as long as a flat surface with a smooth surface finish is provided. The workpiece comprising a plurality of ceramic posts embedded in a polymer is then finish ground. At this point the ceramic posts are depressed typically from about 15,000 to about 30,000 Angstroms below the polymer. The preparation techniques are virtually identical to the prior art techniques.
[0013] Now, the workpiece is first etched in an acid solution. The acid solution is selected to preferentially attack the ceramic. After the workpiece has been etched for a sufficient time, the workpiece is then removed from the acid and cleaned with deionized water solution for a period of time sufficient to neutralize the acid. The workpiece is then dried with a non-reactive gas and the part is then plasma etched. The plasma etching etches the polymer so that it is depressed below the surface of the ceramic elements, exposing the ceramic posts. After plasma etching, the surface of the transducer is sputter-plated at temperatures below about 75° C. The ceramic elements are then dice de-activated, and then poled at temperatures below about 60° C. After poling, the contacts can be soldered to the metallized transducer elements in the conventional manner.
[0014] A significant advantage of the present invention is that each of the plurality of ceramic elements forming the transducer of the present invention extends above the polymer matrix by as much as about 25,000 Angstroms, which provides a different surface than provided by the prior art transducers. If too much of the ceramic is exposed, it becomes susceptible to cracking.
[0015] The above-mentioned advantage overcomes a series of problems associated with the prior art transducers, thereby producing additional advantages. Because the ceramic elements extend above the polymer matrix, the ceramic will constrain the expansion of the polymer. However because the sputter plating is performed at a much lower temperature than previous sputter plating operations, the expansion will not as severe, leading to less expansion and less stress applied to the thin, fragile plating.
[0016] In a similar fashion, the dice de-activation and poling are at temperatures well below the prior art temperatures, so that these operations provide less expansion to the transducer materials, again resulting in less stress applied to the thin, fragile plating.
[0017] Another advantage that results from the ceramic elements extending above the polymer matrix is that the heat resulting from the soldering of the contacts to the elements will result in the ceramic elements being subject to the heat of soldering. This is desirable, as ceramic materials can more readily react to heat than the polymer matrix. Ceramic materials typically have a low coefficient of thermal expansion, so this heat will have less of an effect on the fragile plating, which will experience lower stresses with lower expansion.
[0018] Another advantage of the process of the present invention is that the acoustic layers are more readily adhered to ceramic posts projecting above the polymer. Acoustic layers are applied over the face of the ceramic. When the ceramic posts in an array are depressed below the surface of the polymer, it is difficult for the material adhering the acoustic layers to the face of the transducer to wet the top of the posts. Proper wetting of the posts is required in order to obtain efficient coupling between the very small posts that generate the ultrasound and the acoustic layer(s). Failure to achieve a good contact between the posts and the acoustic layer can result in a transducer having low gain. Such failures typically occur when the adhesive used to adhere an acoustic layer to the face of the ceramic failed to contact the top of the ceramic posts. Additionally, by providing a ceramic face having the ceramic posts projecting slightly above the polymer, it is possible to provide an electrical connection to the ceramic post by wedge-bonding rather than by soldering. Wedge bonding is not possible when the polymer projects above the ceramic posts, as the polymer typically is not sufficiently hard or strong to support the wedge bonding application.
[0019] Another advantage of the present invention is that the acid etching of the ceramic material in an ultrasonic bath after the grinding operation attacks the grain boundaries of the ceramic posts. The acid is formulated to accomplish this, and combined with the ultrasonic vibrations, assists in removing damage areas from the ceramic posts, thereby providing a more structurally sound surface on which to adhere the subsequently applied sputter plating.
[0020] Other features and advantages of the present invention will be apparent from the following more detailed description of the preferred embodiment, taken in conjunction with the accompanying drawings which illustrate, by way of example, the principles of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] FIG. 1 is a cross-sectional view of a prior art multi-arrayed transducer with a plating applied over its surface, depicting the ceramic posts lying below the surface of the epoxy.
[0022] FIG. 2 is a cross-sectional view of a multi-arrayed transducer.
[0023] FIG. 3 is a perspective view of ceramic posts after dicing.
[0024] FIG. 4 is a cross-sectional view of a ceramic block filled with a non-conductive polymer.
[0025] FIG. 5 is a front view of the transducer after finish grinding operations have been completed.
[0026] FIG. 6 is a cross-sectional view of the workpiece of the present invention after plasma etching, depicting the ceramic posts lying above the surface of the epoxy.
DETAILED DESCRIPTION OF THE INVENTION
[0027] FIG. 2 depicts a multi-arrayed transducer 10 that incorporates the piezo-electric composite of the present invention. The transducer is comprised of a plurality of piezo-composite ceramic posts 12 . Each ceramic post 12 is spaced from an adjacent ceramic post 12 by a nonconductive material 14 , such as a polymer. In a preferred embodiment, the polymer is an epoxy. The piezo-ceramic composite posts are characterized by their ability to vibrate when exposed to an electrical excitation, thereby generating a mechanical or sound wave, hereinafter referred to as an acoustic wave, and to generate an electrical pulse when excited by an incident acoustic wave. A preferred ceramic material is lead-zirconate-titanate (PZT), although other equivalent materials such as polycrystalline relaxor materials (PZN-PT materials) and biased electrorestrictor materials (PMN-PT ferroelastic relaxor materials) may be used as is known in the art. Each ceramic post 12 or element includes an electrical connection 16 to allow the elements to be connected in parallel with a device that includes a power source. The device typically is an ultrasonic test unit that, in addition to including a power source, includes an ability to condition signals received by the test unit and to allow the signals to be displayed. The ultrasonic test units are well known in the art and, while used in connection with the present invention, are not part of the present invention. The transducer 10 typically includes a facing material 18 that facilitates coupling the multi-arrayed transducer to a test piece.
[0028] The piezo-composite ceramic posts 12 of the present invention are initially provided as a block of ceramic material of preselected size. The preselected size is chosen on the basis of the transducer size. The ceramic block is typically mechanically cut into a plurality of posts, yielding a two dimensional array of posts. The methods of performing such cuts are well-known and any acceptable method for cutting the block may be used. It is preferred that the ceramic block be cut using a dicing saw. The diced ceramic block 20 having the ceramic posts projecting upward form a ceramic backbone 22 is shown in FIG. 3 , the spacing between the posts being the kerfs remaining after the block has been diced.
[0029] The kerfs of the diced ceramic block 20 are then filled with a nonconductive material 14 , as depicted in FIG. 4 , which is a cross-section of a block 20 filled with an epoxy 24 to provide structural support, particularly in the transverse direction under a shear load, for the thin and brittle ceramic posts 12 . As can be seen in FIG. 4 , the epoxy 24 forms an epoxy backbone 26 that overlies the ceramic posts 12 , and fills the interstitial areas 28 between the posts.
[0030] Both the ceramic backbone 22 and the epoxy backbone 26 must be removed. The ceramic backbone 22 and the epoxy backbone 26 typically initially are rough ground to remove the bulk of the material. It is desirable to rough grind both the ceramic backbone 22 and the epoxy backbone as close as possible to the ceramic posts without exposing the ceramic posts. However, sometimes the grinding may extend slightly below the backbones 22 , 26 . The next mechanical operation is a finish grinding operation to produce a smooth, uniform surface. Each side of the epoxy-filled ceramic is subjected to the grinding operations. The finish grinding operation can be accomplished by any acceptable methods that produce a smooth uniform surface. Linear grinding, lapping and back grinding all are acceptable finish grinding steps. FIG. 5 depicts the face of the finish ground transducer 30 after finish grinding. FIG. 5 depicts the ceramic posts 12 surrounded by the epoxy 24 , the ceramic posts 12 being depressed about 15,000-30,000 Angstrom units below the surface of the epoxy 24 .
[0031] In order to place the ceramic posts 12 in the same plane as the epoxy 24 , the finish ground workpiece is placed in an acid solution. The acid solution is selected to etch the piezo-ceramic composite posts as a pre-plating step. While the acid selected will depend upon the specific ceramic material used, a solution of HBF 4 and HNO 3 has been effective in etching PZT ceramic. More specifically, a preferred 2000 milliliter solution having about 200 milliliters of HNO 3 (50% concentrated acid by volume) and about 4 milliliters of HBF 4 (50% concentrated acid by volume) was mixed by adding the concentrated acids to about 1796 milliliters of water to yield a solution of about 0.1% HBF 4 by volume and about 5% HNO 3 by volume. This solution is exemplary of the solution utilized in the best mode for practicing the invention. It will be understood that other concentrations of the disclosed acids and other acids may be used, as long as the acid etches the grain boundaries of the ceramic grains. The workpiece is vibrated in this acid solution in an ultrasonic cleaner for a time sufficient to etch the ceramic posts. The preferred time for etching is about 30 seconds, although the etching time will depend on the concentration of the acid and the acids used. The time must be sufficient to etch the grain boundaries of the posts to facilitate removal of ceramic material which may have been damaged during the grinding operations. All ultrasonic cleaners described herein operate at 80 Khz, although the ultrasonic cleaners may be operated at different frequencies, so long as the required process step is successfully accomplished.
[0032] After etching, the workpiece is removed from the cleaner and the acid is neutralized. The preferred method for neutralizing the acid is a multi-step wash with deionized water. The workpiece is first rinsed with deionized water for about two minutes. Then, the workpiece is then placed into a second ultrasonic cleaner having deionized water for a preselected period of time, about 3-4 minutes, after which it is spray dried, with a non-reactive gas such as nitrogen, although an inert gas may be used. In the preferred embodiment, dry filtered air is used to dry the workpiece.
[0033] Next, the epoxy 24 is preferentially removed so that the ceramic posts 12 do not remain depressed below the epoxy 24 . The epoxy 12 is preferentially removed from the surface of the workpiece by plasma etching. Plasma etching of the epoxy 24 is accomplished with a high energy gas stream that removes the epoxy 24 from the surface of the workpiece, but does not adversely affect the ceramic posts 12 . Oxygen is the preferred plasma etching gas. During the plasma etching operation, the plasma stream may reach a temperature in the range of about 250° F.-290° F. The plasma etching was accomplished at a rate of about 1500 Angstroms per minute and continued for a sufficient length to time, to produce ceramic posts 12 having the required elevation over the epoxy. The amount of time required for the plasma etch will vary, depending upon the amount of epoxy on the workpiece after either finish grinding or polishing, a longer time being required for a greater amount of epoxy. Since etching the surface to achieve a plane including both the epoxy 24 and the ceramic posts 12 of a few atomic layers in thickness is extremely difficult to accomplish, the preferred embodiment etches the epoxy 24 sufficiently so that the ceramic posts 12 are slightly above the adjacent epoxy 24 , but no more than about 25000 Angstroms above the epoxy. This preferred configuration with the ceramic posts projecting above the epoxy is shown in FIG. 6 . Both sides of the workpiece are plasma etched in this fashion.
[0034] Immediately after the plasma etching process is completed, the workpiece is placed into the sputtering chamber, and the opposed faces of the etched workpiece are sputter plated at a maximum temperature of about 75° C. (167° F.) and more preferably at a maximum temperature of about 62° C. (144° C.). The selected temperature is related to the expansion of the polymer. If the temperature is too high, the expansion of the polymer is too great and the sputtered plating is adversely affected. For epoxy, the temperature is about 10° C. to about 15° C. above the t g (glass transition temperature) of the epoxy. As is clear, the maximum sputtering temperature will vary from polymer composition to polymer composition, as the expansion/contraction of the polymer is the determining factor affecting the plating. The combination of the lower sputtering temperature of the atoms, the etching of the ceramic posts, and the ceramic posts 12 being above or about at the same level as the epoxy provides better adhesion of the plating to the surface of the workpiece. Because of the differences in thermal expansion between the ceramic posts, the epoxy and the metallic materials comprising the plating, avoiding the elevated temperatures of the prior art processing and maintaining the plating process at 75° C. and below reduces thermally induced stresses in the very thin plating as the workpiece cools, thereby providing a workpiece having a higher reliability, since the probability of failure due to plating failure is reduced. The plating is preferably applied as a trilayer of titanium, palladium and silver. The titanium is applied as a first layer to a thickness of about 300 to about 600 Angstrom units under a vacuum of about 1.5 mTorr. The palladium layer is applied over the titanium to a thickness of about 2000-3000 Angstroms under a vacuum of about 4 mTorr. The silver layer is applied over the palladium layer to a thickness of about 9,000-12,000 Angstroms under a vacuum of about 4 mTorr. In order to maintain the temperature at 60° C. or below, it is necessary to sputter at a current of about 500 milliamps, which is carefully controlled. The initial voltage was 408 volts, but the potential in not carefully controlled and will vary depending upon the target material. However, to avoid exceeding the maximum temperature, it is necessary to sputter the silver in a plurality of stages. At the above-noted amperage and voltage, four separate plating stages of 10 minutes with an intervening period of time for cooling is required.
[0035] After sputter plating, a plated side of the workpiece is poled to activate the piezo-ceramic material at a temperature of up to about 60° C. (140° F.). Preferably the plating temperature is maintained at a temperature below about 60° C. Poling entails inducing a high voltage field across the ceramic. The ceramic is immersed in a dielectric fluid to prevent arcing. The present invention accomplishes poling at a temperature below about 60° C., which is a lower temperature than the prior art poling temperature of 110° C. recommended by the manufacturer of PZT. The present invention also accomplishes poling at a higher voltage/unit thickness, up to about 170 volts (V) per 0.001″, which is also higher than the voltage of p to a bout 150 volts per 0.001″ recommended by the manufacturer of PZT. The poling provides an electrical potential to each of the individual ceramic posts. The advantage of the lower poling temperature is that the epoxy expansion is reduced so as not to adversely affect the plating. The poling temperature that may be used will vary from polymer to polymer being dependent on the thermal expansion of the polymer and the temperature required to accomplish poling. The posts are electrically connected in parallel, so that a short electrical pulse from the power supply will cause each of them to vibrate simultaneously and generate an acoustic pulse. A reflected pulse causes the ceramic posts to vibrate and generate an electrical signal. The slight differences in timing receipt and amplitude of the reflected pulse from the different ceramic posts and the corresponding electrical signal can be resolved and conditioned by the ultrasonic equipment to which the transducer is attached to provide meaningful information to a trained technician.
[0036] Subsequent finishing operations may be performed on the workpiece in order to produce a finished transducer, such as providing acoustic layers to the transducer face. However, these processes are well known to the art, and this invention does not make further contribution to these well-known practices.
[0037] While the invention has been described with reference to a preferred embodiment, 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. | A transducer having a ceramic element in which the ceramic is elevated above a polymer and a method of manufacturing the transducer. The transducer comprises a piezo-composite element comprising a ceramic element embedded in epoxy. In an array, the ceramic elements may be in the form of posts. The plurality of ceramic elements is slightly elevated above the polymer and in staggered arrangement with the polymer. The element is manufactured by first grinding the face of the composite and removing damaged ceramic by acid etching the ceramic. The epoxy is removed by plasma etching so that the ceramic is above the epoxy. The composite is sputter plated so that a maximum temperature that could damage the plating is not exceeded. The ceramic is then poled so that a maximum temperature that could damage the plating is not exceeded. Contacts are then attached to the plating adjacent the ceramic. | 8 |
This application is a continuation of Ser. No. 07/899,690, filed Jun. 17, 1993, now abandoned.
BACKGROUND OF THE INVENTION
This invention relates to a process for the production of a shoe shaped part using a web of material with a plurality of patterns in the form of the layout of a shoe upper, cutting out these layouts from the web of material and stitching the parts of the shoe upper to a top part, and fastening the related part of the sole to the edge area of the cut-open outside edge of the assigned layout and to a shoe shaped part produced according to this process.
A process according to this general type is known from German Patent No. 627 878. There, a web of material is produced so that it successively has three crosswise strips of different weaves. Patterns in the form of the U-shaped layout of a shoe upper are printed on these crosswise strips. The crosswise strips are produced so that the first strip is suitable for the counter-stiffener, the second strip for the vamp and the side portions, and the third strip for the toe cap. Consequently, the second crosswise strip is elastic and multilayered, and the two other crosswise strips are produced in a nonelastic, hard-wearing way. Stiffening threads can also be worked in, and the crosswise strip for the counter-stiffener can be produced as a tubular material into which a heel counter can be inserted. The U-shaped parts are cut out of the material, stitched on the open U-side, which forms the counter-stiffener, and then a sole applied in a way not described in detail.
SUMMARY OF THE INVENTION
In view of the above, the primary object of this invention is to further develop this previously known process so that a shoe upper, in many cases, can be configured together with the related sole part, for example, can be produced with strip-like markings, decorations or the like, and so that, in this case, the production of such a shoe upper is nevertheless possible in an efficient and economical way.
This object is achieved by the following process steps:
in the production of a web of material, both the patterns or partial patterns in the form of layouts of the shoe upper and the patterns or partial patterns in the form of a sole part, are produced by a fabric printing process (which is generally well known in the textile industry) on the web of material and/or by a textile production process inside the web of material;
to each layout of the shoe upper there is directly assigned a sole part and is attached to the layout in the correct position of the shoe upper;
in the production of the web of material, the layouts or the areas in which the layouts are provided are produced in a woven and/or knitted type different from the sole parts or those areas in which these patterns are provided;
those areas of the layouts and/or sole pans, which are exposed to the different stresses when wearing the shoe, are produced in the woven and/or knitted types correspondingly matched to the stresses they will experience;
the layouts and the sole parts assigned to one another are not completely separated from one another when cut out of the web of material, and remain connected with one another, as a cut-out unit, by corresponding material sections;
from the cut-out units, each of which has a layout with an associated sole part, first the layout is connected on the provided seams to a shoe upper, and then, the sole part is stitched or basted to the free outside edge of the corresponding layout.
By the process according to the invention, only just those parts of the web of material are produced in the necessary quality, thickness, multilayers or the like which correspond to the pattern or to an area of a pattern of the shoe upper or the related sole part. The remaining area of the web of material in contrast can consist of a simple, lightweight or inexpensive material quality, which holds together only the patterns or areas of such patterns in the web of material after their completion. The cutting waste accumulating with cutting out therefore represents a simple, lightweight and inexpensive material. In contrast, with the known material that has crosswise strips, the entire cutting waste, for example, consists of an expensive tubular material, multilayer material or the like.
It is of further advantage in the process according to the present invention that the individual patterns or partial patterns already can be produced directly in the production of the web of material in the desired shoe size, by which the cutting waste can be still further limited, since the individual patterns or partial patterns in the provided size can directly adjoin one another. Nevertheless, it is possible to configure the individual patterns or partial patterns soft, stiff, elastic, colored differently or the like, corresponding to the later stressing or desired shaping. Only inside and/or outside stiffening elements, such as inside and/or outside toe caps, heel counters or the like have to be applied later on.
With the use of program-controlled web of material production devices, after a one-time creation of the program, the size of the layout corresponding to the shoe size, the woven or knitted type of individual areas or contours, the type of fiber or yarn and/or the color can be selected almost at will. Therefore, only a small number of individual parts have to be produced separately and applied to the upper later.
These and other objects, features and advantages of the invention will be apparent from the following detailed description when viewed in conjunction with the accompanying drawings which show, for purposes of illustration, only several embodiments in accordance with the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a top view of a section of a web of material with a layout for a shoe upper worked in during its production;
FIG. 2 is a section of a web of material with a plurality of layouts for different shoe uppers;
FIG. 3 is a side view of a shoe with an upper formed of a layout produced from a web of material according to FIGS. 1 and 2;
FIG. 4 shows a section of a web of material with a layout having sole part sections provided on both sides as well as a tongue; and
FIG. 5 shows a section of a web of material with a layout which has a forefoot sole part section on one side and a rear or heel part sole part section on the opposite side.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In FIGS. 1 and 2, a web of material is identified by 1, and is produced by a conventional textile process, tier example, by weaving and/or knitting and/or embroidering. The web of material 1 can be provided with a single or with a plurality of layouts 2 of the shape of a shoe upper 3, as it is represented from the side, for example, in FIG. 3.
The web of material has a backing 4 that can be a conventionally used material formed, for example, of a warp and filling or a knitted fabric. Layout 2 is divided into different individual parts or areas, which differ from one another, such as by being of another material style and/or by being of different fibers or yarns, for example, from wool, wool with metal yarns, silk, silk with metal yarns, wool with plastic fibers or the like and/or by being formed of different colors, such as from fibers or yarns of different colors, including those of metals, or by different color prints, and/or by being differently designed fiber extrudates or fiber extrudate compositions, such as twisted, processed parallel or the like.
The individual parts or areas of shoe upper 3 can be representations of those areas on which a trimming, for example, a part resistant to wear, is applied. For example, areas 5 and 6 are provided for applying an inside or outside heel counter 9 (FIG. 3). After cutting out layout 2 from the web of material 1, the edges 7 and 8 are stitched together and a heel seam thus is formed. Then, heel counter 9, represented in FIG. 3, is applied, for example, glued and/or stitched, to adjacent areas 5 and 6.
Correspondingly, the contours of edges 11 and 12 are stitched together in the form of shoe toe 10, and a seam is formed on the shoe toe. To reduce wear, a toe cap 15, represented in FIG. 3, can be applied, especially glued and/or stitched, on the front area, adjacent to front edge 13 of toe area 14.
Since, generally, toe area 14 is designed to be relatively deformably soft or elastic, and optionally, also permeable to air, the web of material 1, in toe area 14, according to the present invention, is correspondingly designed by suitable selection of the weave pattern, knit pattern and/or the material used, such as, for example, Silk or plastic. The type of production can, additionally, insure that the toe area 14 has a good air exchange capability. For example, this can be achieved by a net-like woven or knitted structure.
The areas identified as positions 16 and 17 represent individual parts, which serve for identification purposes, such as the "Formstrip" trademark of PUMA AG Rudolf Dassler Sport illustrated in this case. Of course, other trademarks, identifications or patterning may be incorporated instead.
Areas 20, 21 and 22, identified in FIG. 3, running from instep area 18 to heel area 19, cannot only be configured in the form of pull straps but also can be produced especially tension-proof. In the production of web of material 1, suitable measures can be used to make these upper areas so as to achieve the desired effects; for example, in this case, especially tension-proof fibers or yarns can be used. Optionally, in this case, the material can be woven or knitted in two or more layers or can be especially thick or additionally embroidered. Similarly, the lacing areas 23 and 24 can be made dimensionally stable in corresponding manners, especially if, for example, no additional trimmings, such as the lacing strips 25, shown in FIG. 3, are to be applied.
Finally, in the embodiment according to FIGS. 1 and 2, with layout 2 on the web of material 1, areas 26 and 27 are produced in a configuration, color or style that is different from the other areas. A heel counter 28, represented in FIG. 3, is applied on areas 26, 27 after formation of the initially described heel seam.
As can be seen, any number of layouts 2 in the most varied configurations and/or designs as well as of different sizes can be produced on a single web of material 1. For this purpose, above all, the use of program-controlled, particularly computer-controlled, production devices is advantageous, so that style, color, design, size or the like can be varied at will.
According to an advantageous further development of the invention, an individual part 29 in the form of an insole can be co-produced on layout 2 of shoe upper 3. After being cut out, this individual part 29 remains connected with layout 2, and after or during the shaping and fixing of shoe upper 3 from layout 2, part 29 is folded into the plane of the shoe sole and is fastened to the lower edge zone of the shoe upper 3. This lower edge zone is defined in layout 2 by outside contours 30 and 31, and the manner of its fastening can be, in a way known in the art, for example, by gluing, stitching, tacking or the like.
In the production of web of material 1 or after its production, and optionally after cutting out of layout(s) 2, layout(s) 2 can be provided with an embroidery, especially with an English embroidery (i.e., the type of embroidery by which a hole pattern is welded and which is commonly used for the sewing of button holes), of a trademark or another mark or identification on suitable or preferred places.
Finally, before or after cutting out of layout(s) 2, a tongue 32 (FIG. 3) is applied in the forefoot area. After the production of shoe upper 3, an insole and/or a midsole, optionally, is additionally applied or molded on.
Completed shoe upper 3 is then brought into a gluing, injection or casting mold, in which a midsole 33 and an outsole 34 are molded by known measures, as is represented in FIG. 3.
The advantages of the previously described process according to the invention can be seen especially in the fact that, with a fully developed loom, up to 7 different textile fibers or yarns, and the same number of colors, can be put in, especially woven in, the web of material in one operation. As already indicated, any sizes and different upper designs can be produced by computer-controlled programs, starting from corresponding basic patterns. The completed shoe uppers produced from such webs of material are marked by an extremely low weight, for example, between 70 to 80 g in a shoe size of 8. The costs for the production of such uppers are exceptionally low in comparison with previously known processes.
In FIGS. 1 and 2, unfinished surface areas, which lie outside layouts 2 for shoe upper 3 or for tongue 40, are shown with position number 1.1.
According to an advantageous further development of the invention, the sole part 29, which is represented in FIGS. 1 and 2 as an individual part, can be designed so as to be divided lengthwise, crosswise or obliquely into at least two. In such a case, at least one sole part section is provided on each outside contour 30, 31 of a layout 2.
With the embodiment according to FIG. 4, a sole part section 29.1 that extends over the entire length of the sole is provided on outside contour 31 in the approximate form of a half of sole part 29, and a sole part section 29.2 which forms the remainder of sole part 29 is provided on the outside contour 30. Both sole part sections 29.1 and 29.2 complement each other to complete sole part 29. In this case, their outside contours 29.3 and 29.4 are connected with one another, for example stitched and/or glued and/or fused or the like, preferably by a longitudinal seam.
With the embodiment according to FIG. 5, a forefoot sole part section 29.5 is provided on outside contour 31 of layout 2 of shoe upper 3, and a heel sole part section 29.6 is provided on outside contour 30. Their outside contours 29.7 or 29.8 are later folded under so as to face the middle of shoe upper 2 and are connected with one another to, then, form the entire sole part 29. The seam resulting in this case runs crosswise, obliquely, or obliquely in approximately an S-shape or the like corresponding to the configuration of outside contours 29.7 or 29.8. The path of this seam is preferably selected so that it cannot exert an unpleasant pressure on the sole of the foot.
Additionally, the tongue 40, for example, according to FIG. 4, can be provided also in the course of producing the web of material 1 with different weave structures and/or weave patterns and/or embroideries or with one or with several prints or the like. On a web of material 1, different tongues 40 can be produced corresponding to a shoe shape and/or a shoe size both in shape, size, color or colors, patterns or the like. Preferably, in each case, related tongues 40 are produced simultaneously with a layout 2 on same web of material 1.
For optimum surface use of web of mmaterial 1, a tongue 40 can be produced in the open space 41 located between the two layout sections 42 and 43, which later form the rear of foot or heel-pan shoe part.
Preferably, each layout 2 has at least five, preferably more than ten, patterns and a tongue 40 has at least two, preferably at least three patterns produced or appearing, which are different from one another in each case.
In an advantageous further embodiment of the invention, the web of material 1 is produced so that its surface areas 1.1, in which no layout(s) 2 or tongue(s) 40 are provided, consist of a lightweight material quality that is as simple and economical as possible. For example, these surface areas 1.1 can be produced like a gauze or with low to very low warp and/or filling gauge and/or, for example, by being thin-spun or the like. Thus, an especially efficient production of shoe shaped parts, such as shoe uppers is assured in connection with soles and/or tongues or the like.
Preferably, areas of layout(s) 2, sole parts 29, especially of sole part sections 29.1 and 29.2 or 29.5 and 29.6, can comprise a textile portion of material which can soak up moisture well. Preferably, cotton is used for this purpose. The portion of the absorbent material is at least about 25% of the entire material. Depending on the application, this portion can be increased up to 100%.
As already indicated, the webs of material being used can be produced by program-controlled web material production devices whose programs can be matched almost at will according to the corresponding basic setting with deviations in the size of the layouts of the individual shoe uppers or with changes of the type of weave or knit of individual areas or contours, the type of fiber or yarn and/or the color. | For the production of a shoe upper by cutting out of the shoe upper in the form of a layout from a web of material, shaping of the shoe upper with connection of material parts of the layout with formation of seams, a process is used by which such shoe uppers can be produced in a timesaving and efficient manner despite the many individual parts present or to be made visible. For this purpose, a web of material (1) is used to produce layouts (2) by different production measures, such as different styles, yarn material, color, material thickness, single layer or multilayer type of material or the like, at the same time with the production of web of material (1), and with a sole part attached to the layout. The layout is cut from the web as a unit with the sole part and processed into a shoe part having an upper and sole part. | 3 |
PRIORITY CLAIM
[0001] This application claims the benefit of U.S. Provisional Application No. 60/286,937, filed on Apr. 27, 2001.
FIELD OF THE INVENTION
[0002] This invention relates generally to control systems for automobile power convertible tops and power windows, and more particularly to a method of controlling an automobile power convertible top and power windows.
BACKGROUND
[0003] In the field of automotive design, convertible tops are used to provide automobiles that are capable of being driven with the top down or the top up. The drivers and passengers of convertible top automobiles often prefer to drive the vehicle with the top down when the weather outside is pleasant and place the top up when the weather turns foul or cold. Occupants of the vehicle also frequently put the automobile windows in the same position as the convertible top. That is, when the top is down, the occupants prefer to also have the windows down and vice-versa.
[0004] Typically, convertible tops are mechanically coupled to an electric motor that raises and lowers the convertible top in response to a command from an operator. The command is usually given through a power top switch conveniently located in the passenger compartment of the automobile, such as on the dash or center console. Similarly, typical power window arrangements are driven by electric motors that raise and lower the windows in response to commands from power window switches.
[0005] On vehicles having both a power convertible top and power windows, it is desirable to provide a control system that lowers the convertible top and windows with a single push of a button instead of the separate power top and window switches mentioned above. It is further desirable to provide a control system that protects the components of the convertible top structure and moving mechanism from damage due to excessive drive forces of the power top motor in the event the top structure becomes jammed while moving. Known control systems monitor the movement or position of the convertible top and turn off power to the electric motor when the top is completely raised, lowered, or becomes jammed. Such control systems require a feedback path that provides the control system with instantaneous information related to the positions of the structure members of the convertible top. These feedback paths require hardware that adds cost to the convertible top assembly, increases complexity in the assembly process, and requires maintenance.
SUMMARY OF THE INVENTION
[0006] The present invention provides a method and apparatus for controlling the raising and lowering of an automobile body member, such as a convertible top or power window.
[0007] One aspect of the invention is to provide a convertible top control system that is integral to a power window control system, where the combined control system has the capability of raising and lowering the convertible top and power windows in response to a single operator input or switch actuation.
[0008] Another aspect of the invention is to provide a convertible top control system that raises and lowers the top in response to a single operator input, where the control system operates without need for a feedback path.
[0009] In accordance with these aspects, a method of controlling a movable body portion of a vehicle is provided where the body portion is moved by a motor that responds to a control input. The method applies power to the motor upon actuation of the control input and maintains a timer concurrent with the application of power. Power is removed from the motor upon the earliest occurrence of either the expiration of the timer or the relinquishment of the control input. The timer provides a maximum amount of time that power may be applied to the motor, thereby preventing damage to the convertible top in the event it becomes jammed while it is being moved by the motor.
[0010] Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood however that the detailed description and specific examples, while indicating preferred embodiments of the invention, are intended for purposes of illustration only, since various changes and modifications within the spirit and scope of the invention will become apparent to those skilled in the art from this detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] [0011]FIG. 1 is a block diagram illustrating a convertible top control system;
[0012] [0012]FIG. 2 is a state diagram illustrating a method of controlling a convertible top and power windows, and;
[0013] [0013]FIG. 3 is an X-Y plot illustrating a predetermined time vs. battery voltage relationship.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0014] Turning now to FIG. 1, a convertible top control system 10 is shown. The control system 10 is centered around a body controller module (BCM) 30 that executes a method 200 shown in FIG. 2 and explained later. The BCM monitors a power top switch assembly 20 that is used by an operator to indicate whether the top should be stopped, raised, lowered, or simultaneously lowered with the windows (express down). Switch assembly 20 is an example of such an assembly that is implemented in a resistive-multiplexed (R-mux) configuration. While the R-mux switch is discussed in more detail below, such a switch arrangement is not be construed as limiting.
[0015] R-mux switch assembly 20 is referenced to ground 28 and has an output connected to an analog-to-digital converter (A/D) pin 44 of the BCM 30 . The A/D pin 44 of the BCM 30 is pulled-up to a reference voltage (+V ref ) as is well known in the art. An operator presses switch 22 to indicate a top up state, and presses switch 24 to indicate a top-down state. Pressing switch 24 past a certain point causes switch 26 to close concurrently with switch 24 , thereby indicating a top and windows down state. All of the switches 22 , 24 , and 26 are normally open. When neither switch 22 nor switch 24 is pressed, pin 44 is at a first voltage level. Pressing switch 22 causes a voltage level corresponding to a top-up command to appear at pin 44 . Pressing switch 24 causes a voltage level corresponding to a top-down command to appear at pin 44 , and pressing switch 24 even further, thereby causing switch 26 to close, effects yet another voltage level at pin 44 corresponding to the top and windows down state.
[0016] In accordance with the method 200 , the BCM 30 responds to the power top switch 20 by activating one or more of the top up relay 50 , the top down relay 40 and relays of the window relay box 60 . The output contacts of the top up relay 50 and top down relay 40 are electrically connected across a power top motor 70 . The output shaft of the power top motor 70 is mechanically connected to the convertible top (not shown) so that rotating the power top motor 70 in one direction causes the convertible top to move in a top up direction. Similarly, rotating the power top motor 70 in the opposite direction causes the convertible top to move in a top down direction and, finally, stopping the power top motor 70 causes the convertible top to stop moving. The power top motor 70 is preferably electrically protected by a top circuit breaker 120 .
[0017] As mentioned earlier, the BCM 30 is also electrically connected to a window relay box 60 . Actuating the window relay box 60 causes all window motors 80 to roll down the vehicle windows. The window relay box 60 contains a relay for each power window motor 80 . The relays inside of the window relay box 60 are electrically connected to the power window motors 80 in such a way that the relays are able to effect downward movement of the power windows by controlling electrical power to the power window motors 80 . Each power window motor 80 is preferably protected by a window circuit breaker 110 connected in series with the power window motor 80 . The system 10 also includes power window switches 90 electrically connected to the power window motors 80 to allow control of the power windows independent of the BCM 30 and window relay box 60 . Electrical power for the convertible top control system 10 is supplied by the vehicle electrical system, symbolized by the battery 100 .
[0018] [0018]FIG. 2 shows the control process executed by the BCM 30 . At power up, the method starts in state 210 and proceeds to state 220 where it reads the power top switch 20 . Upon detection that the power top switch 20 is in any of the top up, top down or top and window-down positions, the method proceeds to state 230 and determines whether the timer 32 has expired. The timer 32 keeps track of the amount of time that the power top motor 70 has been running in response to actuation of switch 20 .
[0019] Turning briefly to FIG. 3, a graph is shown indicating how the expiration time of the timer 32 is determined. The x-axis 190 of the graph represents the system voltage 100 , and the y-axis 180 represents expiration time. Curve 170 represents the maximum amount of time that it should take for the power top motor 70 to raise the convertible top at a given system voltage 100 . Similarly, curve 150 represents the maximum amount of time that it should take for the power top motor 70 to lower the convertible top at a given system voltage. Curve 160 represents the maximum amount of time that it should take for the power top motor 70 to lower the convertible top when the power windows motors 80 are simultaneously started with the power top motor 70 (express down). The method 200 allows the power top motor 70 to run for no longer than the predetermined amount of time from these curves to complete the desired operation. By limiting the amount of time the motor may run, the method 200 protects the components of the convertible top structure from being damaged by the drive forces of the power top motor 70 in the event the structure is jammed. The actual shape and relative positions of the curves 150 , 160 , and 170 will vary depending on physical parameters such as the torque of the motors, the length and gauge of wires used in the system 10 , etc. In addition to choosing the time values to correspond to the maximum amount time it should take for the power top motor 70 to complete an operation, the time is also preferably less than the time it takes for the circuit breaker 120 to open when the convertible top is jammed. This allows an operator to clear the jammed top and resume operation of the system 10 without having to wait for the circuit breaker 120 to reset. Both requirements should be satisfied over a range of system voltages to produce a locus of points such as those shown in FIG. 3.
[0020] Returning to state 230 in FIG. 2, if timer 32 has expired then the method proceeds to state 350 where the method shows that it has determined to turn off the power top motor 70 . The method then proceeds to state 340 where the BCM 30 actually turns off the power top motor 70 and resets the timer 32 before returning to state 220 .
[0021] Returning to state 230 , if the timer 32 has not expired, then the method proceeds to state 240 where it checks whether a predetermined condition has been met. In one aspect of the invention, the predetermined condition is that the vehicle must be travelling at a speed less than fifteen miles per hour. If the predetermined condition in state 240 is not satisfied then the method proceeds to state 350 and executes the aforementioned 110 sequence of states from 350 to 340 to 220 , thereby turning off the power top motor 70 , resetting the timer 32 , and returning to read the power top switch 20 .
[0022] If, instead, the predetermined condition in state 240 is satisfied, the method proceeds in accordance with the switch position determined in state 220 . More specifically, if the method determined the power top switch 20 is in the top up position then the method advances from state 240 to state 270 . In state 270 the method acknowledges the top up request before moving to state 320 . In state 320 , the method updates the timer 32 for a first duration of time 170 and activates the top-up 50 and top down 40 relays in such a manner as to cause power top motor 70 to effect raising of the convertible top. From state 320 the method returns to state 220 where the power top switch 20 is checked once again.
[0023] Returning to state 240 , if the method determined the power top switch 20 is in the top down position then the method advances from state 240 to state 280 . In state 280 the method acknowledges the top down request before moving to state 300 . In state 300 the method maintains a the timer 32 for a second duration of time 150 and activates the top-up 50 and top down 40 relays in such a manner as to cause power top motor 70 to effect lowering of the convertible top. From state 300 the method returns to state 220 where the power top switch 20 is checked once again.
[0024] Returning to state 240 , if the method determined the power top switch 20 is in the express down position, then the method advances from state 240 to state 250 . In state 250 , the method acknowledges the express down request before moving to state 260 . In state 260 , the method maintains the timer 32 for a third duration of time 160 and simultaneously activates the top-up relay 50 , top down relay 40 , and the window relay box 60 . This simultaneous activation causes the power top motor 70 to effect lowering of the convertible top concurrently with the lowering of the power windows by window motors 80 .
[0025] In each of states 300 , 320 , and 260 , the method maintains the timer 32 by initiating the timer on the first entry into the state, and updating the timer value on each entry thereafter. The timer 32 is reset in state 340 when method turns off the power top motor 70 .
[0026] The invention being thus described, it will be obvious that the same may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the invention, and all such modifications as would be obvious to one skilled in the art are intended to be included within the scope of the following claims. | A method and system of controlling a movable body portion of a vehicle where the body portion is moved by a motor responding to a control input. Power is applied to the motor upon actuation of the control input and a timer is maintained concurrent with the application of power. Power is removed from the motor as a function of expiration of the timer or relinquishment of the control input. The timer provides a maximum amount of time that power may be applied to the motor, thereby preventing damage to the movable body portion in the event it becomes jammed while being moved by the motor. | 4 |
CLAIM OF PRIORITY
The present application claims priority from Japanese application JP 2006-239724 filed on Sep. 5, 2006, the content of which is hereby incorporated by reference into this application.
FIELD OF THE INVENTION
This invention relates to a shelf-like display machine and an image display method, for example, in which shelves or the like installed at stores such as retailers have an image display function.
BACKGROUND OF THE INVENTION
As have been already described in the non-patent document 1 below, there has been provided a proposal of method in which price tags at the shelves in a store such as a retailer shop are changed into electronic forms, prices and information on goods or the like are optionally changed over and they are displayed at the front ends of goods display shelves in a form of electronic paper.
SUMMARY OF THE INVENTION
However, the aforesaid prior art had a problem that it is hard to attain a correspondence between the display part and the goods under a certain arrangement of the goods because the display part with an electronic paper is arranged at a part of the shelf.
Additionally, it was necessary to prepare some special display substrates for changing all the lengths of the shelves into display segments and so their price was expensive. In addition, as shown in FIG. 32 , it was necessary to prepare some signal lines and wirings 902 for supplying a power supply up to display segments 901 and so it was necessary to perform a processing for shielding the wirings with opaque raw material and connecting the wirings whenever the shelves were required to be moved.
In view of the situation as above, this invention provides a shelf-like display machine and an image display method in which an optical path of a light source such as a projector for projecting an image is controlled to display some images at the ends of plural shelf plates.
(1) Plural images (either still images or animations) prepared in response to the number of stages of the shelves to be displayed are projected from the light source after each of the images is corrected in response to the optical path length ranging from the light source to the end of each of the shelves and then each of the images is guided to the end of each of the shelves with plural reflection members and the images are displayed at the aforesaid ends.
More practically, according to one aspect of the present invention, there is provided a shelf-like display machine comprising a light source for outputting an image; a first reflector member for reflecting the image projected from the light source; a first shelf plate and a second shelf plate in which light can be transmitted through their inner portions; a rear member supporting the first and second shelf plates in which light can be transmitted at their inner portions; a second reflection member for guiding the image reflected by the first reflector member and guided through the rear member to the first shelf plate; and a third reflector plate for guiding the image reflected by the first reflector member and guided through the rear plate to the second shelf plate; the image having a first image and a second image, the light source outputting the first image and the second image upon performing a correction processing in correspondence with an optical path length 1 ranging from the light source to the end of the first shelf plate and an optical path length 2 ranging from the light source to the end of the second shelf plate in such a way that the first image is displayed at the end of the first shelf plate opposite to the rear member and the second image is displayed at the end of the second shelf plate opposite to the rear member.
(2) Plural images (either still images or animations) prepared in response to the number of stages of the shelves to be displayed are projected from the light source and the optical path lengths ranging from the light source to the end of each of the shelves are substantially made equal to each other, and then each of the images is guided to the end of each of the shelves by plural reflector members to display the images at the end.
More practically, according to another aspect of the present invention, a shelf-like display machine includes a light source for outputting an image; a first reflector member for reflecting the image projected from the light source; a first shelf plate and a second shelf plate in which light can be transmitted through their inner portions; a rear member supporting the first and second shelf plates in which light can be transmitted at their inner portions; a second reflection member for guiding the image reflected by the first reflector member and guided through the rear member to the first shelf plate; and a third reflector plate for guiding the image reflected by the first reflector member and guided through the rear member to the second shelf plate; and the image has a first image and a second image; an optical path length 1 ranging from the light source to the end of the first shelf plate and an optical path length 2 ranging from the light source to the end of the second shelf plate become substantially the same to each other in such a way that the first image is displayed at the end of the first shelf plate opposite to the rear member and the second image is displayed at the end of the second shelf plate opposite to the rear member.
(3) The present invention provides a method in which when an image is displayed at plural screens arranged in spaced-apart relation, plural regions are extracted from the original image under a similar shape to that of the plurality of screens and while keeping positional relations of the plurality of screens; the plurality of regions are extracted while being scrolled at a predetermined speed in a direction connecting the plurality of regions; each of the regions is enlarged or reduced in such a way that a difference in the magnifying power may be corrected in reference to a difference in optical path length ranging from the light source to each of the screens so as to display the image to each of the screens.
More practically, the present invention provides an image display method for displaying an image on the spaced-apart first and second screens which includes the steps of extracting a first region of which shape is similar to that of the first screen and a second region of which shape is similar to that of the second screen from the image while keeping a positional relation between the first and second screens; extracting the first region and the second region from the image while scrolling them at a predetermined speed in a direction where the first region and the second region are connected, correcting a difference in magnifying power caused by different optical path lengths ranging from a light source for projecting the image to each of the screens and correcting to expand or reduce the first region and/or the second region; and projecting the first region to the first screen and the second region to the second screen.
It becomes possible to display easily images (information such as animations, still pictures, letters or the like) at the end of the shelf-like display machine without preparing any special display substrates and arranging a wiring for every shelf. Additionally, detailed information about goods, for example, can be effectively transmitted to the customers at a store selling goods.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1A , 1 B, and 1 C are schematic views for showing one preferred embodiment of the present invention;
FIGS. 2A and 2B show a first image generation method of one preferred embodiment of the present invention;
FIG. 3 shows a second image generation method of one preferred embodiment of the present invention;
FIG. 4 shows a third image generation method of one preferred embodiment of the present invention;
FIG. 5 shows a fourth image generation method of one preferred embodiment of the present invention;
FIGS. 6A , 6 B, and 6 C show a fifth image generation method of one preferred embodiment of the present invention;
FIG. 7 is an illustrative view for showing a size inputting means of a shelf display machine;
FIGS. 8A , 8 B, and 8 C are illustrative views for showing a first image adjustment method;
FIG. 9 is an illustrative view for showing a second image adjustment method;
FIGS. 10A , 10 B, 10 C, 10 D, 10 E, and 10 F show some examples of a reflector member;
FIGS. 11A , 11 B, 11 C, and 11 D show some examples of a display end;
FIGS. 12A , 12 B, and 12 C show some examples of a mechanism for performing a fine adjustment of an optical reflection;
FIG. 13 is an illustrative view for showing a first structure for projecting an image to a location other than the end of a shelf of one preferred embodiment of the present invention;
FIG. 14 is an illustrative view for showing a second structure for projecting an image to a location other than the end of a shelf of one preferred embodiment of the present invention;
FIG. 15 is an illustrative view for showing a third structure for projecting an image to a location other than the end of a shelf of one preferred embodiment of the present invention;
FIG. 16 is an illustrative view for showing a first structure in which optical path lengths in one preferred embodiment are substantially the same to each other;
FIG. 17 is an illustrative view for showing a second structure in which optical path lengths in one preferred embodiment are substantially the same to each other;
FIG. 18 is an illustrative view for showing a third structure in which optical path lengths in one preferred embodiment are substantially the same to each other;
FIGS. 19A and 19B are illustrative views for showing a first structure for projecting an image to the side of a shelf of one preferred embodiment of the present invention;
FIGS. 20A , 20 B, and 20 C are illustrative views for showing a second structure for projecting an image to the side of a shelf of one preferred embodiment of the present invention;
FIGS. 21A , 21 B, 21 C, and 21 D show a first shelf-like display machine provided with a sensor of one preferred embodiment of the present invention;
FIGS. 22A , 22 B, and 22 C show a second shelf-like display machine provided with a sensor of one preferred embodiment of the present invention.
FIGS. 23A , 23 B, 23 C show a third shelf-like display machine provided with a sensor of one preferred embodiment of the present invention;
FIGS. 24A and 24B show a fourth shelf-like display machine provided with a sensor of one preferred embodiment of the present invention;
FIG. 25 shows examples of letters to be displayed at a display end;
FIG. 26 is an illustrative view for showing a first structure for displaying an image at the back of a shelf of one preferred embodiment of the present invention;
FIGS. 27A , 27 B, 27 C, and 27 D are illustrative views for showing a second structure for displaying an image at the back of a shelf of one preferred embodiment of the present invention;
FIGS. 28A and 28B are illustrative views for showing a third structure for displaying an image at the back of a shelf of one preferred embodiment of the present invention;
FIG. 29 is a view for showing a state in which display devices are arranged at the rear of a shelf to display images;
FIG. 30 is a view for showing a state in which a rear projector is arranged at the rear of each of the shelves to display an image;
FIGS. 31A and 31B show an example in which an image is displayed at the back of shelves of one preferred embodiment of the present invention; and
FIG. 32 is an illustrative view for showing the structure of the prior art.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
First Embodiment
FIGS. 1A to 1C show a side elevational view and a front elevational view of shelves of one preferred embodiment and an example of display of images to be projected to a projector. As shown in the side elevational view of FIG. 1A and the front elevational view of FIG. 1B , light projected from the light source such as a projector 110 projecting an image is reflected upward through a reflector member such as a mirror 111 , the light passes through the rear member constituted by a member with hollow state or characteristic allowing light to be passed through it, the light is reflected again with mirrors 123 , 124 , and 125 arranged at the backs of the shelves 120 , 121 , and 122 having light transparent characteristic (using cavity and member through which light is transmitted, for example) and then the light is projected to the ends 126 , 127 , and 128 of the shelves. Screen raw material for collecting light or dispersing light is applied to the ends of the shelves to enable either letters or images projected by the projector to be projected to the ends. In addition, as described later, the image can be projected onto the ends also by constituting the shelf plates in such a way that when light transmitted at their inner portions to both front and rear of the shelves, the light shows total internal reflection there even if the screen raw material is not used. An image generating device such as a PC 130 or the like is connected to the projector 110 so as to output images including images 141 , 142 , and 143 to be displayed at each of the shelves as shown at 140 in FIG. 1C . In response to whether or not an up-and-down reversal function of the projector is used, it is set whether or not the up-and-down of the image to be sent to the projector is performed. FIG. 1C shows a reversed example. A method for generating an image for each of the shelves will be described later in reference to FIGS. 2 to 5 . The image generating device is connected to the network such as LAN, for example, and it is also applicable that the content of the outputted image is controlled from outside. In addition, arrangement of sensors 150 , 151 , 152 , and 153 also enables an approaching of a person near the shelf or a person's touch at the shelf to be detected and a displayed content to be dynamically changed.
(Image Generating Method)
Then, referring to FIGS. 2 to 5 , there will be described a method for generating an image for each of the shelves to be projected to the projector of the present invention. Although an example in which the number of shelves is three will be described as follows, the number of shelves can be calculated by a similar method whatever numbers may be applied. More practically, this method is carried out by inputting the design values such as shelf height or shelf width (Z 0 a , Z 0 b , Z 0 c , Z 1 a , Z 1 b , Z 1 c , Z 2 a , Z 2 b , and Z 2 c of 201 to 209 in FIG. 2A , for example) and calculating display rectangular areas at each of the shelves to be projected to the projector (H 0 L, H 0 R, V 0 t , V 0 b , H 1 L, H 1 R, V 1 t , H 2 L, H 2 R, V 2 t and V 2 b of 220 to 231 in FIG. 2B , for example).
In order to simplify the description, the optical paths are developed in a straight line as shown at 260 , 261 , and 262 in FIG. 3 and a method for calculating the display rectangular areas will be described as follows. In this case, Z 0 , Z 1 , and Z 2 of 240 to 242 in FIG. 3 can be attained in reference to their design values as follows.
Z 0=( Z 0 a+Z 0 b+Z 0 c )
Z 1=( Z 1 a+Z 1 b+Z 1 c ) Z 0
Z 2=( Z 2 a+Z 2 b+Z 2 c )( Z 0+ Z 1)
In addition, thicknesses Y 0 h , Y 1 h , and Y 2 h of each of the shelves from 250 to 252 and a width Xt ( 270 ) of each of the shelves are also design values.
Then, referring to FIG. 4 , the method for calculating the value in a horizontal direction will be described as follows. That is, drawing regions (H 0 L, H 1 L, H 2 L, H 2 R, H 1 R, H 0 R) of the images to be projected to the end of the shelf are calculated in reference to the design values such as each of the sizes of the shelf (Z 0 , Z 1 , Z 2 : height, Xt: width, θ: image angle ( 280 ) in a horizontal direction of the projector, H: a resolution in a horizontal direction of the projector). At first, when a length in a horizontal direction within the projection range X 0 ( 281 ) of the lower stage is included within a width Xt( 270 ) of the shelf, all the ranges that can be projected are used. At this time, since a relation of X 0 =2*Z 0 *tan θ is formulated, H 0 L=0, H 0 R=H can be attained. Next, since a length X 1 ( 282 ) in a horizontal direction within a projection range in the middle stage is (X 0 +2*Z 1 *tan θ) under application of 283 , it can be attained as H 1 L=H*(Z 1 *tan θ)/X 1 , H 1 R=H H*(Z 1 *tan θ)/X 1 , H 2 R=H H*(Z 1 +Z 2 )*tan θ)/X 1 . Further, since a length X 2 ( 285 ) in a horizontal direction within a projection range in the upper stage is (X 0 +2*(Z 1 +Z 2 )*tan θ) under application of 286 , it can be attained as H 2 L=H*(Z 1 +Z 2 )*tan θ)/X 1 , H 2 R=H H*(Z 1 +Z 2 )*tan θ)/X 1 , H 2 R=H H*(Z 1 +Z 2 )*tan θ)/X 1 .
Next, referring to FIG. 5 , there will be described a method for calculating values of the projector in its vertical direction. That is, drawing regions of image to be projected to the end of the shelf (V 0 t , V 0 b , V 1 t , V 1 b , V 2 t , V 2 b ) are calculated in reference to the design values of the shelf (Z 0 , Z 1 , Z 2 : height, Y 0 h , Y 1 h , Y 2 h : shelf thickness, p: image angle in a vertical direction and Ys( 330 ), Ym( 331 ) got by a mounting angle of the projector. In this case, to make the drawing easier to understand, the illustration is shown with the vertical direction of the optical path being compressed. A length Y 2 ( 310 ) in a vertical direction in a projection range at the upper stage is (Z 0 +Z 1 +Z 2 )/tan φ. A rate among the lengths Y 0 ( 311 ), Y 1 ( 312 ) and Y 2 ( 310 ) when the optical path to be projected to the end of each of the shelf plates is extended and the clearance lengths Yk 2 ( 313 ), Yk 1 ( 314 ), Yk 0 ( 315 ) becomes a rate in a vertical direction of the original image. Each of the distances Ya 1 ( 320 ), Yb 1 ( 321 ), Ya 0 ( 322 ) and Yb 0 ( 323 ) from the center of optical axis in this figure can be attained like Ya 1 =(Ym)*(Z 0 +Z 1 +Z 2 )/(Z 0 +Z 1 ), Yb 1 =(Ym+Y 1 h )*(Z 0 +Z 1 +Z 2 )/(Z 0 +Z 1 ), Ya 0 =(Ym+Y 1 h )*(Z 0 +Z 1 +Z 2 )/Z 0 , Yb 0 =(Ym+Y 1 h +Y 0 h )*(Z 0 +Z 1 +Z 2 )/Z 0 . In addition, since the relations of Y 2 =Y 2 h , Yk 2 =Ya 1 Ym, Y 1 =Yb 1 Ya 1 , Yk 1 =Ya 0 Yb 1 , Y 0 =Yb 0 Ya 0 are attained, and finally, vertical coordinate of the images to be displayed can be attained in reference to the design values, like V 2 b =V V*((Ys/Yt), V 2 t =V V*((Ys+Y 2 )/Yt), V 1 b =V V*((Ys+Y 2 +Yk 2 )/Yt), V 1 t =V V*((Ys+Y 2 +Yk 2 +Y 1 )/Yt), V 0 b =V V*((Ys+Y 2 +Yk 2 +Yk 1 )/Yt), V 0 t =V V*((Ys+Y 2 +Yk 2 +Y 1 +Yk 1 +Y 0 )/Yt.
Next, referring to FIGS. 6A to 6C , there will be described a method for calculating a clipping region in reference to the original image when images such as photographs and illustrations are displayed at a shelf. That is, the regions of original image to be clipped (V 0 c , Y 0 c , V 1 c , Y 1 c , V 2 c and Y 2 c from 401 to 406 in FIG. 6A ) are calculated in reference to the aforesaid design values of the shelf. In this case, each of the vertical and lateral resolutions of the original image (the number of pixels) shall be defined as Vi( 410 ) and Hi( 411 ), respectively. In this case, an aspect ratio displayed at the shelf is X 0 in FIG. 6C : (Y 0 h +Z 1 b +Y 1 h +Z 2 b +Y 2 h ). If it is assumed that a clipping is carried out in such a way that the former aspect ratio is coincided with an aspect ratio Hi: (Y 2 c Y 0 c +V 2 c ) clipped from the original image in FIG. 6A , it can be attained as a relation of (Y 2 c Y 0 c +V 2 c )/Hi=(Y 2 h +Z 2 b +Y 1 h +Z 1 b +Y 0 h )/X 0 . Since an aspect ratio of a lateral rectangle cut of the original image is equal to an aspect ratio displayed at each of the shelves, it can be attained as a relation of V 0 c /Hi=Y 2 h /X 0 , V 1 c /Hi=Y 1 h +Z 1 b +Y 0 h )/X 0 . In addition, since an aspect ratio of a rectangle enclosed by the two clipped rectangles is equal to an aspect ratio of clearance of the shelves, it can be attained as (Y 1 c Y 0 c V 0 c )/Hi=Z 2 b /X 0 , (Y 2 c Y 1 c V 1 c )/Hi=Z 1 b /X 0 . If the value of Y 0 c were determined in reference to the foregoing five equations, the remaining five variables Y 1 c , Y 2 c , V 0 c , V 1 c and V 2 c could be attained. In addition, increasing or decreasing the value of Y 0 c allows the image to be displayed while scrolling the image in a vertical direction.
Next, referring to FIG. 7 , an input screen 450 for the design values will be described as follows. This input screen can be set through PC outputting the images, for example.
Reference numeral 451 denotes a region for inputting the number of shelves and reference numerals 452 , 453 , and 454 denote a region for inputting a height from the lower stage, a region for inputting a shelf thickness and a region for inputting the deep size of a shelf, respectively, and each of them corresponds to Z 0 b , Y 0 h , and Z 0 c . Similarly, reference numerals 455 , 456 , and 457 correspond to Z 1 b , Y 1 h , and Z 1 c and reference numerals 458 , 459 , and 460 correspond to Z 2 b , Y 2 h , and Z 2 c . In this way, the design values are inputted, and the coordinate system for the image to be outputted is calculated with the PC 130 and projected to the projector 110 .
Next, referring to FIGS. 8A , 8 B, and 8 C, there will be described a method for fine adjusting a value of image area displayed at the projector calculated in reference to the design values with a graphical user interface. The screen calculated by the aforesaid method is displayed as shown in FIG. 8A under a state in which the display is connected to the PC 130 connected to a pointing device. Each of reference numerals 141 , 142 , and 143 in FIG. 8A denotes the image display region at each of the upper stage, middle stage and lower stage, and rectangles for rubber band indicated at 501 , 502 , and 503 are displayed at the right lower portion of each of the rectangles. A button for the pointing device is depressed ( 510 ) under a state in which cursors are present on these pointing devices and the cursor position ( 511 ) when the button is released is applied as a coordinate at the right lower portion of a new rectangle ( 512 ). In addition, as shown in FIG. 8C , when the button is depressed ( 520 ) under a state in which the cursor is present within the rectangles 141 , 142 , and 143 and also within the region other than the rectangles for the rubber bands, a difference between the horizontal direction and the vertical direction with respect to the coordinate ( 521 ) of the cursor when the button is depressed is added to the left upper coordinate and the right lower coordinate is applied as a coordinate for a new rectangle ( 522 ). These operations are carried out through a drug-and-drop action of the mouse, for example.
Next, referring to FIG. 9 , there will be described a fine adjustment for a clipping region. On the original image 540 are displayed clipping regions 430 , 431 , and 432 and the rectangles for a rubber band similar to that of FIG. 8 . When the rectangles 530 , 531 , and 532 for the rubber band are selected within the clipping region, a width of the clipping region in a vertical direction is adjusted and when other rectangles are selected, a position of the clipping region in a vertical direction is adjusted. Also in this case, these operations are carried out through a drug-and-drop with a mouse.
(Structure of Shelf-like Member)
Next, referring to FIGS. 10A to 10F , there will be described examples of a structure of the shelf-like member. Requirements necessary for the structure of the shelf-like member of the present invention consist in the fact that light projected from below is reflected at the back of the shelf by about 90° and then projected to the end of the shelf. In FIGS. 10A to 10F , each of the left sides corresponds to the front of the shelf where the image is displayed and each of the right sides corresponds to the back of the shelf where the light is reflected by about 90°. FIG. 10A shows an example in which a screen 602 having a function for dispersing or focusing light is attached to the front of a block 601 such as acryl resin or glass having a high transmittance of light and a mirror 603 is arranged at the back of the block in an inclined state. This structure is manufactured by the simplest manufacturing method. FIG. 10B shows an example in which an end 605 at the back of the block 604 is machined to show a slant surface in place of the mirror and a screen 606 is arranged at the front of the block under utilization of characteristic of total reflection of light at this surface. Since this structure does not show any displacement of the mirror, a re-adjustment by vibration or the like after its correct design is not necessary. FIG. 10C shows an example in which a mirror 608 is arranged at the back lower portion of a transparent or opaque top plate 606 , a rod-like raw material 608 such as acryl resin or glass with a high light transmittance is arranged at the lower portion of the front and a screen 609 is arranged. This structure enables utilization of expensive transparent raw material such as acryl resin or the like to be reduced. FIG. 10D shows an example in which a screen 611 with a frame is arranged at the lower portion of the front of the top plate 601 , and a rod-like raw material 612 of high light transmittance such as acryl resin or glass and the like machined to have a slanted state in respect to the shelf plate surface such as a triangular column or truncated trapezoid column, for example, is arranged at the lower portion of the back of the shelf. Light projected from below shows a total reflection at the slant surface of the acryl resin rod 612 and is projected to the screen 611 . This structure enables a strain of the reflector member to be reduced more as compared with that of a planer-like mirror. FIG. 10E shows an example in which a screen 614 with a frame is arranged at the lower portion of the front of the top plate 613 , and a mirror 615 is arranged at the lower portion of the back of the shelf. This structure does not require at all using an expensive transparent raw material such as acryl resin or the like. FIG. 10F shows an example in which a mirror 617 is arranged at the lower portion of the back of the top plate 616 , a frame 618 for assuring a strength is arranged at the lower portion of the side and a screen 619 with a frame is arranged at the lower portion of the front of the shelf. This structure enables light to be prevented from being leaked out of the side of the shelf plate.
Referring to FIGS. 11A to 11C , there will be described shapes of the shelf. As has been described up to now, it is also possible to apply a shape as follows, for example, in addition to a shelf of cubic-block shape. FIG. 11A shows an example in which an end 630 of the shelf where the image is displayed has a curved surface. When some letters are expressed to scroll at the end in a lateral direction, this structure can provide an effect that the letters are seen to flow in a cubic manner in a forward or rearward direction. FIG. 11B shows an example in which an end 631 is machined into a slant surface and its display area is made wide. This structure improves a visual recognition when the shelf is mounted at a level lower than a customer's point of view, for example. FIG. 11C shows an example in which a band-like screen raw material 632 is partially attached to a block-like transparent raw material 633 so as to project the image in a curved surface shape. This structure can provide an effect that as if the image is displayed in the air. FIG. 11D shows an example in which an incident part 634 for an image is a curved surface and a projecting surface 635 for the image is also a curved surface. This structure enables a strain of the image to be reduced when the image is displayed in a cubic form.
Next, referring to FIGS. 12A to 12C , there will be described a mechanism for use in performing a fine adjustment of reflection of light at the back of a shelf. In FIG. 12A , a shelf 650 is fixed under application of a hinge 652 capable of freely bending a mirror 651 arranged at the back of a shelf 650 . In addition, an angle of the mirror 651 can be adjusted by arranging a spacer 654 between the shelf 650 and a structure 653 supporting the shelf and moving the spacer in a forward or rearward direction. Next, in FIG. 12B , the shelf 655 is placed at the structure 656 for supporting the shelf and then a transparent raw material 657 of triangular column machined to form a slant surface, for example, is connected to the shelf 655 by a fixing tool 658 . The transparent raw material 657 can be turned freely and its reflecting angle can be adjusted. Next, in FIG. 12C , the shelf 659 of transparent raw material machined into a slant shape is placed at the structure 660 supporting the shelf in such a way that its back may be contacted with the ground surface of the structure, and a spacer 661 is arranged at the front of the shelf 659 . A reflecting angle at the back can be adjusted by moving up or down the height of the spacer 661 .
Second Embodiment
Next, there will be described a method for projecting an image to a place other than the end of the shelf-like member. At first, referring to FIG. 13 , there will be described a method for projecting an image to the upper surface of a shelf. FIG. 13 shows a side elevational view and a front elevational view of a shelf. The image projected by the projector 110 is reflected upward by a mirror 111 , passes through a shelf 670 of transparent raw material, is reflected downward by a mirror 671 mounted at the lower portion of the shelf and the image is projected to a screen 672 arranged at the upper portion of the shelf. Projection of the image onto the upper surface of the shelf through this method enables an image to be projected to goods placed on the shelf or the image to be displayed around the goods.
Next, referring to FIG. 14 , there will be described a method for projecting an image to the screen arranged at a shelf in a vertical orientation. The image projected by the projector 110 is reflected by the mirror 111 and the mirror 680 and projected to the screen 681 arranged at the upper surface of the shelf. Projection of an image to a vertical screen by this method enables an image of existing standard of 4:3, for example, to be displayed.
Next, referring to FIG. 15 , there will be described a method for projecting an image to a back between the shelves. A part of the image projected by the projector 110 is reflected by the mirror 111 as described above, reflected by the mirrors 690 and 691 and projected to the screens 692 and 693 at the ends of the shelf. A part of another image is projected to the screens 694 and 695 applied to the surface of a deep part between the shelves. At this time, since an incident angle to the screen 695 is shallow and a view angle from the projector in respect to a projecting area becomes narrow, a resolution of the image to be projected to the screen 695 is decreased. Since an effective resolution is smaller than that of the part projected to the end of a shelf, the resolution can be increased by machining the back 696 of the shelf into a slant surface or widening the depth size, adjusting both position and angle of the mirror 111 and making the incident angle to the screen 695 deeper.
Third Embodiment
Since optical path lengths from the projector to each of the screens are different from each other, the methods described above up to now correct the image projected from the projector so as to correct a difference in magnifying powers caused by the difference in optical path length and perform an output display. In turn, setting the optical path lengths ranging from the projector to each of the screens substantially equal to each other in this preferred embodiment eliminates an image correcting processing. In addition, the preferred embodiment has an effect that the focal point is strictly set for every image because the optical path lengths ranging from the projector to each of the screens are substantially set equal to each other. This situation will be described in detail as follows.
Referring now to FIG. 16 , there will be described a method for changing a depth of a shelf. Image projected from the projector 110 is projected to screens 701 , 702 and 703 at the ends of the shelves in the same manner as described above. The optical path lengths can be set substantially the same to each other by adjusting the depths 704 , 705 , and 706 in such a way that the distances at this time ranging from the projector 110 to the ends 701 , 702 , and 703 of the shelves may become constant.
Next, referring to FIG. 17 , there will be described a method for increasing the number of times of reflection and adjusting an optical path length. A part of the image projected from the projector 110 is reflected by mirrors 711 , 712 , 713 , and 714 and projected to a screen 715 at the end of a shelf. Similarly, another part of the image is reflected by mirrors 721 , 722 , 723 , and 724 and projected to a screen 725 at the end of a shelf. In regard to the upper-most shelf, the image may be projected to a screen 733 at the end of the shelf through twice reflection at the mirrors 731 and 732 in the same manner as described up to now. At this time, the optical path lengths can be set substantially the same to each other by adjusting distances between the mirrors 712 and 713 , and the mirrors 722 and 723 in such a way that the optical path lengths become constant with an optical path length ranging from the projector 110 to the screen 733 .
Referring to FIG. 18 , there will be described a method for aligning focal points by making a surface shape of each of the mirrors mounted at the backs of the shelves. That is, a correction is carried out by changing a curvature of the mirror in response to an optical path length for every shelf in such a way that a focal point is set to the end of each of the shelves. Its structure is similar to that shown in FIG. 1 ; in which when a mirror 740 at the upper-most shelf, for example, is set to have a flat surface, the focal point of the projector is aligned with the end of the upper-most shelf. Next, the surface shapes of mirrors 741 and 742 at other shelves are set to show curved surfaces curved in a vertical direction, thereby a displacement of focal points at the images projected at the end of each of the shelves can be corrected.
Fourth Embodiment
Next, there will be described a method for projecting an image also to the side of a shelf through machining of a shape of the shelf as shown in FIG. 19A . FIG. 19B is a view taken from above the shelf. Both ends of the back of the transparent raw material 750 of the shelf are cut into a triangle shape and each of the mirrors 751 , 752 , and 753 is arranged at the central part and both ends, respectively. The image reflected at the mirror 751 is projected to the front of the shelf and the image reflected by each of the mirrors 752 , 753 is projected to the side of the shelf.
Next, referring to FIGS. 20A to 20C , there will be described a method for projecting an image also to the side of the shelf. FIG. 20A is a view taken from above, FIG. 20B is a view taken from side and FIG. 20C is a view taken from front, respectively. A part of light 754 projected from below is reflected by the mirror 760 and projected directly to the front end of the shelf. Another part 755 is reflected by the mirror 761 , reflected by a surface 762 cut in a slant direction as viewed from above the lower portion, cut in a vertical direction as viewed from a horizontal direction, reflected in a slant upward direction by a surface 763 cut in a slant direction as viewed from the front both ends of the lower portion and projected to a side 764 of the shelf. Although the structure in respect to this method is complex, all the upper surfaces of the shelf can be utilized.
Fifth Embodiment
In order to perform an effective display of information, there will be described a method for detecting that a person approaches to the shelf or the goods are transferred. Referring to FIGS. 21A to 21D , there will be described a method detecting a state of the front of the shelf while a sensor is arranged at the back of the shelf. As shown in FIG. 21A , a bar-code reader 770 is arranged at the back of the shelf, and light of the bar-code reader passes through the inner portion of the shelf of raw material such as acryl resin or glass with a high transmittance. When a goods 771 attached with a bar-code is applied to the front of the shelf, the bar-code reader 770 reads the bar-code of the goods, sends the read value to the PC 130 in FIG. 1 and the related information can be displayed. With such an arrangement as above, a customer at a store applies the goods that the customer is interested in over the end of the shelf at its bar-code portion to allow the customer to review its related information. As shown in FIG. 21B , an infrared ray proximity sensor 772 , for example, is arranged at the back of the shelf, the sensor detects at 733 that a person approaches to the front of the shelf or applies his hand over the front, similarly the sensor transmits it to PC 130 in FIG. 1 and then the corresponded information is displayed. With such an arrangement as above, it becomes possible to perform a separate operation for displaying the letter information assuming that it is read when the proximity sensor is operated and for displaying an image with a better visibility from a far location when the proximity sensor is not operated, for example. In addition, it may also be applicable to change an image to be displayed and a position where the image is displayed in response to at which position in which shelf the sensor is detected. As shown in FIG. 21C , a camera 774 may be used to perform an image processing in place of the proximity sensor. FIG. 21D shows an example in which the camera is mounted below the transparent shelf to detect whether or not the goods are removed from the shelf. When it is detected that the goods are removed from the shelf, this system can be used in such a way that either message or information about the goods is displayed to the person coming to a store.
Next, referring to FIGS. 22A to 22C , there will be described a method in which the end of each of the shelves has a touch panel function. As shown in FIG. 22A , an infrared ray camera with an infrared ray projector is mounted near a location such as a side part of the projector 110 in FIG. 1 so as to attain the image at the end of the shelf in a direction opposite to the optical path facing from the projector to the end of the shelf. When the end of the shelf is touched by a customer, the image having a bright touched portion and remaining dark portions can be attained as shown in FIG. 22B , for example, and it is possible to detect which position in which shelf is touched by the customer. In addition, when an indoor area is fully filled with infrared rays, the image as shown in FIG. 22C cannot be attained unless the infrared ray projector is installed and also in this case, it is possible to detect which position in which shelf is touched by a customer. When it is detected through these methods that the left side in the upper stage is touched, for example, it becomes possible to replace the image displayed at the left side of the upper stage from PC and provide information suitable for a customer coming to a store.
Next, referring to FIGS. 23A to 23C , there will be described a method for managing respective goods through a movable bar-code reader. FIG. 23A is a side elevational view of a shelf, FIG. 23B is a rear view, and FIG. 23C shows an example of goods to which a bar-code is attached. The rear of the shelf is provided with a movable bar-code reader 790 , its position is controlled from PC 130 in FIG. 1 , and a bar code 792 of the goods 791 at this position is read and transmitted to PC 130 . An optical path 793 of light transmitted from the projector 110 , reflected by the mirror 111 and advanced upward is partitioned by either the transparent raw material or formed into a hollow state partitioned by the transparent raw material and then the bar code of the goods 791 can be read from the rear. With such an arrangement as above, since it is possible to check what type of goods are placed at which position in which shelf, information corresponding to the position and the goods can be displayed at the end of the shelf. In addition, information for guiding a customer coming to a store to teach the customer that the desired goods are placed at which position in which shelf can be displayed by displaying either the letters or images indicating a direction such as arrow marks at the end of the shelf. In addition, since the goods can be individually managed, a work such as an inventory can be simplified. Further, the bar code to be attached to the goods is printed at either a tape or seal-like raw material having a capacitor or RFID tag assembled therein, thereby it can be simultaneously utilized as one for preventing any gate-type theft.
Next, referring to FIGS. 24A and 24B , there will be described a method for displaying information about the goods or the like at the end of a shelf when the items such as goods placed on the shelf portion are removed by a customer coming to a store or the like. FIG. 24A shows a state before goods 800 are removed from the shelf, in which general information or information about entire goods, for example, is displayed at an end 801 of the shelf. A RFID tag reader 802 is arranged at the upper surface of a shelf and an RFID tag is attached to the goods 800 . FIG. 24B shows a state just after the goods 800 is removed and what type of goods is removed is detected with RFID tag reader 802 . Individual information about the removed goods is displayed at the surface 803 of a shelf to enable detailed information about the goods removed by a customer coming to a store to be displayed.
Next, referring to FIG. 25 , this figure shows an example of letters to be displayed at the end of a shelf. Reference numeral 810 denotes information such as prices of the goods placed on the shelf that corresponds to the conventional price tags. Reference numerals 811 and 812 denote displays about an advertisement of the goods concerned. Reference numerals 813 , 814 , and 815 denote displays about a store promotion that indicate the number of points, recruitment of members and thanks messages for customers coming to the store or the like. Reference numeral 816 denotes a display for use in visually guiding a traffic line for a customer coming to a store. Reference numeral 817 denotes a display indicating the position of goods. Reference numeral 818 denotes a display for use in guiding a customer coming to a store to an escaping path at the time of emergency. Reference numerals 819 , 820 , 821 , and 822 denote examples for displaying information attracting the interest of a customer coming to a store, for example, weather forecast, news, horoscope and music played in the store or the like.
Sixth Embodiment
Next, there will be described a method enabling a customer to see an image at the end of a back of a shelf, i.e. the image from the end of a shelf under application of characteristic of total reflection through the transparent raw material such as acryl resin or glass or the shelf enclosed by mirrors at its upper and lower sides, separate from the aforesaid method for displaying an image at the end of a front of a shelf in its dispersed or light collected state. FIG. 26 shows its configuration. Nothing is arranged at the front of the transparent raw material 830 such as an acrylic block, a screen raw material 831 is attached to the acrylic block at the back of a shelf and there is provided a mirror 832 reflecting the image from below to the screen raw material and projecting it.
FIGS. 27A to 27D show side elevational views of shelves to show a positional relation between the back screen and a position of point of view. As shown in FIG. 27A , when the point of view is sufficiently far from a shelf and placed at the same height of the shelf, an image of the back screen 840 can be seen as it is. As shown in FIG. 27B , looking at a point of view 841 near to some extent shows that light is totally reflected at the upper part and lower part of the shelf, a part of the light can be seen in a correct opposite state and another part of the light can be seen under its upside down state. As shown in FIG. 27C , looking at a point of view 842 sufficiently near the end of the shelf, light is reflected by plural times at the upper and lower sides of the shelf, it is possible to see an image where plural images at the screen 843 are repeated like a kaleidoscope, for example. As shown in FIG. 27D , even in the case that the point of view 844 is seen at the height different from the shelf, light is reversed at the upper and lower sides of the shelf and the image can be seen.
FIGS. 28A and 28B are views taken from above the shelf and show a positional relation between the back screen and the position of point of view. It is possible to see the image projected to the back screen in response to a reflecting characteristic inside the shelf as well as in the case that the point of view 850 is placed at the front of the shelf as shown in FIG. 28A and in the case that the shelf is seen from the slant point of view 851 in the same manner as that of the side.
FIG. 29 shows an example in which the effect described in reference to FIGS. 27 and 28 is embodied under application of a display device such as a liquid crystal display or a plasma display in place of projecting an image at the end of the shelf by the projector and the mirror. The back of the shelf is provided with a display 860 and its front is provided with a shelf plate 861 of transparent raw material such as acryl or glass.
FIG. 30 shows an example using a rear projection system in place of the aforesaid display device. The back of the shelf is provided with a screen raw material 870 and its front is provided with a shelf 871 of transparent raw material such as acryl. The image projected from a projector 872 is projected by the mirror 873 to the screen 870 .
Different images are displayed at the end of the shelf and the back of the shelf as shown in FIG. 31A under application of the methods in FIG. 29 and FIG. 30 described above, it is possible to see the image 880 displayed on the end of the shelf as if it is floated up as shown in FIG. 31B .
It can be utilized as a shelf-like display machine capable of effectively transmitting information on goods to a store visiting customer at the store selling goods. | The prior art in this field had a display portion of electronic paper at a part of a shelf and showed a problem that the display portion and the goods were hardly co-related to each other in response to the arrangement of the goods. In view of the foregoing, plural images arranged in response to the number of stages of the shelves to be displayed are irradiated with a light source after each of the images is corrected in correspondence with the optical path length ranging from the light source to the end of each of the shelves, each of the images is guided to the end of each of the shelves by plural reflector members and then the images are displayed at the ends. In addition, each of the images is guided to the end of each of the shelves by plural reflector members and the images are displayed at the ends after plural images (either still images or animations) arranged in response to the number of stages of shelves to be displayed are irradiated by the light source and the optical path lengths ranging from the light source to the end of each of the shelves are set to be substantially the same to each other. | 6 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of application Ser. No. 10/351,495 filed Jan. 23, 2003 now U.S. Pat. No. 6,776,727 and claims the benefit thereof.
FIELD OF INVENTION
This invention relates to putters that can be used for practice and play, with either a right or left-handed stroke. Specifically, this invention is a putter rotatable from a first position to strike a golf ball with a practice face of a clubhead to a second position to strike a golf ball with a play face of the clubhead.
BACKGROUND
Golf is governed by The Rules of Golf as approved by the United States Golf Association and the Royal and Ancient Golf Club of St. Andrews, Scotland, referred to herein as the USGA Rules. The most current rules are available from www.USGA.org. A typical game of golf is played on a course having 18 holes and a golfer may carry up to 14 clubs with him during play. An average golfer uses over 80 strokes to complete the game, and typically half of those stokes are putts. Therefore, the putter is by far the most important of the regulation 14 golf clubs in a golfer's bag, and improved putting will improve a player's score more than improvement in any other stroke.
Consequently, thousands of devices and methods have been devised to help a golfer improve his putting, ranging from the practical to the absurd. Most of these devices do not conform to the design of clubs specified by the USGA Rules, however, and therefore are used during practice only. The golfer must switch putters to play a round of golf, thus changing the primary tool with which he perfected his stroke. As a result, the putt stokes during play are seldom as good as during practice. It would be advantageous, then, to provide a dual-purpose putter that conforms to the Rules of Golf so that the golfer can use the same putter in practice as in play.
Under the USGA Rules, the putter shall have a shaft and a head, fixed to form one unit. When the golf club is in its normal position to address the ball, the shaft shall be aligned so that the projection of the straight part of the shaft onto the vertical plane through the toe and heel shall diverge from the vertical by at least 10 degrees. Further, the projection of the straight part of the shaft onto the vertical plane along the intended line of play shall not diverge from the vertical by more than 20 degrees. The USGA Rules further require that the clubhead meet specific criteria. For example, the distance from the heel to the toe of a putter shall be greater than the distance from the play face to the back. These rules limit the orientation of the shaft to the clubhead, and therefore the balance of the putter, a major factor in aligning the ball and in putting consistently.
The penalty for playing a game of golf with a putter that does not conform to the USGA Rules is disqualification from the game. However, with the many rules pertaining to the design of putters, it is difficult to design a club that provides quality training features for practicing and yet can be used for play. It is desirable to provide a single putter that can be converted from a practice putter to a play putter that conforms to USGA Rules.
Therefore, it is an object of this invention to provide a putter that enables the golfer to determine which strokes are the best during practice so that he may practice those strokes repeatedly and learn to stroke the ball consistently in play. It is another object of this invention to provide a single putter that can be used for both practice and play. It is another object to provide a single putter that can be converted from a practice putter to a play putter that conforms to the USGA Rules. It is an object of this invention to provide a putter in which the shaft always diverges at least 10 degrees from the sole of the clubhead, regardless which orientation the golfer holds the putter when addressing the ball.
SUMMARY OF THE INVENTION
The present invention is an improved putter that combines several features to provide a balanced putter, which assists a player in perfecting a putt stroke during practice and repeating it with the same club during play. The shaft is attached to the clubhead such that it can swivel from a practice configuration to a play configuration. The clubhead has tapered top and bottom surfaces such that the angle of the shaft relative to the sole of the putter is no more than 80 degrees. The clubhead has a playing surface on one face that is parabolic and can be flat in the extreme. The clubhead has a practice surface on the other face that is curved, preferably elliptical, to assist the golfer in learning the proper stroke. The putter conforms to the Rules of Golf so that the player does not have to change clubs between practice and play. The club may be used for either a right- or left-handed stroke.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1( a ) is a perspective view of the practice face of the clubhead with the shaft in position for a right-handed golfer.
FIG. 1( b ) is a perspective view of the play face of the clubhead, with the shaft in position for a right-handed golfer.
FIG. 2( a ) is a top view of the clubhead.
FIG. 2( b ) is a bottom view of the clubhead.
FIG. 2( c ) is a cross-section view of the clubhead 11 along line c—c of FIG. 2( a ).
FIG. 2( d ) is an end view of the clubhead; each end is symmetric to the other.
FIG. 3 is an exploded, perspective view of the clubhead with a curved practice face and a flat play face.
FIG. 4 illustrates an exploded view of the clubhead, illustrating the hosel and its alignment with the receiving holes.
FIG. 5( a ) illustrates the angle of the shaft to the sole of the putter when the putter is standing upright.
FIG. 5( b ) illustrates the angle of the shaft to the sole of the putter for a right-handed stroke.
FIG. 5( c ) illustrates the angle of the shaft to the sole of the putter for a left-handed stroke.
FIG. 6 is a perspective schematic view of the clubhead, indicating the sides and faces of the preferred embodiment.
FIG. 7 illustrates the center of the clubhead aligned with the center of the golf ball at the instant the clubhead strikes the golf ball during a putt stroke.
FIG. 8( a ) is a plan view of the practice face of the preferred embodiment, having a convex practice insert.
FIG. 8( b ) is a plan view of the play face of the preferred embodiment, having a flat play insert.
FIG. 9( a ) is a plan view of the practice face of an alternate embodiment, having a convex practice insert.
FIG. 9( b ) is a plan view of the play face of an alternate embodiment having a parabolic, concave play insert.
FIG. 9( c ) is a side view of the alternate embodiment, showing a convex practice face and a concave play face.
FIG. 10( a ) illustrates a golfer playing a left-handed putt stroke with the play face.
FIG. 10( b ) illustrates a golfer practicing a left-handed putt stroke with the practice face.
DETAILED DESCRIPTION OF THE INVENTION
A clubhead 11 of an improved putter 10 is attached to a shaft 12 with a hosel 13 . The present device may be used with shafts of any length. The clubhead 11 has two faces, a practice face 14 and a play face 15 . Only the play face is used as a striking surface during play, thereby conforming with a USGA Rule that a clubhead have only one striking face. The shaft is attached to the clubhead in such a way that the clubhead can swivel from a practice position to a play position, keeping the shaft in the same position relative to the golfer. See FIG. 1 a which shows the clubhead in the practice position for a right handed golfer and FIG. 1 b which shows the clubhead after it has been swiveled into the play position.
In the preferred embodiment, the shaft is affixed to the hosel or integral with it. The hosel 13 is attached to a spring 9 that is biased to keep the hosel substantially flush with the top surface of the clubhead. See FIG. 2 c . The clubhead is switched from a practice position to a play position by pulling the shaft away from the clubhead, thereby extending the spring 9 . Once the hosel is free of its seated position in the clubhead, the clubhead is rotated 180 degrees relative to the shaft. The shaft is released, thereby allowing the hosel to be drawn back to the clubhead again as the spring 9 contracts. See FIG. 4 . The hosel is guided to its seated position and the playface is now facing the ball.
In the preferred embodiment, the hosel has two pins 7 that extend toward the clubhead that rest inside two receiving holes 8 . The hosel can be firmly seated in the clubhead in other ways, for example using a detente system having hemispherical projections and mated recesses.
The practice face 14 has a substantially circular insert, referred to as a practice insert 16 . The practice insert 16 is convex relative to the practice face 14 , as best illustrated in FIGS. 2 a–d , and the practice face shape ranges from elliptical to spherical. The curved shape limits the number of points at which the practice face can strike a golf ball in order for the golf ball to move in a straight line perpendicular to the practice face, referred to as the line of putt. Hitting the center of the golf ball with the center of the practice face will cause the golf ball to move on the perpendicular line. However, if the golfer hits the golf ball with any part of the practice face other than the center of the practice insert, the golf ball will veer off the perpendicular line. The farther away from the center of the practice insert, the worse the veer angle will be.
Preferably the practice insert 16 is an ellipse. With an elliptically curved practice insert, the veer is relatively small at short radii from its center, thereby being somewhat forgiving to a less-than-perfect stroke. This approximates the amount of forgiveness of putts in play, because slight deviations for a perfect line of putt will not prevent the golf ball from falling in the hole. However, as the veer angle grows increasingly larger farther away from the center of the practice face, the “penalty” for a bad stroke increases as the stokes become increasingly off-center. A spherical practice insert may also be used; it provides a less forgiving center, but a more forgiving perimeter, as the veer angle changes relatively less than at the perimeter of an elliptical practice insert. The “penalty” for a bad stroke is constant regardless of how off-center the stroke is. It is likely that a better golfer will use the spherical practice insert to fine tune his putt stroke.
In addition to the curvature of the practice insert, the present invention includes alignment apertures for assisting the golfer in visualizing a straight line to the ball or other desired point. Each alignment aperture is made in the clubhead 11 to receive a lightweight post 30 that extends substantially perpendicularly from the practice face 14 . A conventional drinking straw is suitable for the post, as is it extremely lightweight and most convenient to obtain at a golf course. Preferably, therefore, the diameter of each aperture is made to enable a drinking straw to be inserted and held in place snugly simply by friction. A post can be inserted in any one or more of the alignment apertures, in whichever placement the golfer finds it assists his alignment the best. In the preferred embodiment, the practice face 14 has two alignment apertures, 18 and 20 , however more are acceptable, as indicated by aperture 21 and the aperture into which post 30 is inserted.
The play face 15 also has a substantially circular insert, referred to as a play insert 17 . The play insert 17 is inwardly parabolic relative to the play face 15 , ranging from flat to concave. A flat striking face is required under USGA Rules, so a flat play insert should be used when playing a round of golf.
A parabolic-shaped play insert is self-correcting to some degree, because the curve of the insert will urge the golf ball to the center of the parabola before redirecting the ball away from the play face. A parabola is the set of all points in a plane equidistant from a fixed point (called the focus) and a fixed line (called the directrix). The formula for a parabola is generally:
y = x 2 4 p
Thus, when p is large, the curvature of the play insert is great and the ball is strongly urged to the center of the parabola. As the parabola flattens out, that is, as p becomes small, the play insert provides less assistance in getting the ball to travel on the putt line perpendicular to the play face. When the parabola is flat, that is, when y is constant, the striking face is flat, and the putter provides no self-correcting assistance to the golfer. Preferably, the play insert 17 is flat so that the putter conforms to USGA Rules.
FIG. 3 illustrates a preferred embodiment of the clubhead having a core 91 , curved practice insert 92 and flat play insert 93 . The top and the bottom of the clubhead are substantially v-shaped with flattened apexes, the tapered sides serving to position the shaft at an appropriate angle to the ground during practice and play, as described in more detail below. The clubhead is operable with sharp edges where the various faces meet, but preferably the edges are rounded. Preferably the clubhead 11 is manufactured as a core having apertures into which the hosel and shaft assembly, practice insert and play insert are inserted to form an integral unit. The inserts must be firmly fixed so that there is little likelihood of them working loose during a round of golf. The inserts may be integral with the core 91 of the clubhead 11 , or may be separate pieces that are attached to the core or face of the clubhead, with adhesive or friction fit. Preferably the practice inserts and play inserts are changeable to accommodate the needs of the golfer and preferably the insets are threaded to mate with a threaded aperture in the core 91 . They also may be attached in other ways, such as friction fit.
The core is made of any durable material, and preferably metal such as aluminum, brass or steel. The practice insert is also made of a durable material, but preferably a hard composite material such as a polymer that provides for a satisfying “thunk,” such as Surlyn® thermoplastic resin sold by the E.I. DuPont De Nemours and Company, which was the first and most durable cover material that revolutionized the construction of the golf ball when it was introduced in the 1980s. The play insert is made of durable materials, metal or composite, and preferably the same material as the practice insert so that the feel of the practice stroke is the same as the stroke during play.
For aligning the ball and for putting consistently, it is advantageous to have a puffer that is balanced in as many dimensions as possible. One USGA Rule requires that the projection of the straight part of the shaft onto the vertical plane through the toe and heel shall diverge from the vertical by at least 10 degrees. In other words, the angle between the shaft and the sole of the club must be less than 80 degrees. To achieve both a balanced clubhead and this angle, the bottom of the clubhead is tapered in a V, upward from the midpoint of the bottom to the toe and heel. When putting, one side of the bottom of the club will be resting on or parallel to the playing surface. This portion of the bottom becomes the sole of the club. Due to the taper and the shaft's orientation to the clubhead, the shaft is then atways tilted at least 10 degrees from vertical. The clubhead can be rotated to accommodate for either a right-handed or left-handed golfer. FIG. 5 illustrates the resultant effect, where α is the angle between the vertical and the shaft. In FIG. 5( a ), the putter is shown in its upright position with the shaft 12 perpendicular to the playing surface 60 . FIG. 5( b ) illustrates the putter in the position as a right-handed golfer addresses the ball. Note that α is at least 10 degrees, making the shaft 12 at least 10 degrees off vertical; in other words, the angle between the shaft and the sole 31 of the club is less than 80 degrees. FIG. 5( c ) illustrates the putter in the position as a left-handed golfer addresses the ball. Note again that the shaft 12 is at least 10 degrees off vertical, so that the angle between the shaft 12 and the sole 32 is less than 80 degrees. Since the clubhead is tapered by at least 10 degrees, the shaft will always diverge at least 10 degrees from the plane through the toe and heel, regardless of which orientation the golfer uses to address the ball. To maintain symmetry and weight balance in the clubhead, the top should be similarly tapered. That is, the top of the clubhead is tapered in a V, downward from the midpoint of the top to the toe and heel.
The clubhead 11 is a polyhedron. Preferably the perimeter of the practice face 16 and play face 17 are octagons as shown in FIG. 6 . The perimeter of the practice face has sides a, b, d, c, e, f, g and h. The perimeter of the play face has sides i, j, k, l, m, n, o and p. The practice face and play face are substantially parallel to each other, and connected to each other with a top and a bottom. The top of the polyhedron has three faces, P, Q and R that are attached to sides of the practice face a, b, c and the play face i, j, and k, respectively. The bottom has three faces, S, T and U that are attached to sides of the practice face e, f, g and play face m, n and o, respectively. The ends of the clubhead 11 are parallel to each other and perpendicular to face Q and face T of the bottom. The taper of the clubhead is the effect of the relationship of the sides to the top and bottom. In FIG. 6 , the taper is therefore indicated by angle β. The angles between sides a and b, b and c, d and e, e and f, are equal and no more than 170 degrees, and the angles between sides i and j, j and k, m and n, n and o, are equal and no more than 170 degrees.
To best control and eliminate spin on the golf ball, it is desirable to be able to strike the ball along the horizontal plane bisecting the center of the ball. FIG. 7 illustrates the centerline l—l of the play face 15 aligned with the center of a golf ball 79 upon impact with the golf ball. Consistent with good clubhead balance, preferably the practice and play faces are centered along the horizontal centerline of the clubhead 11 . For good visual alignment, the practice and play faces are preferably about the same size as a golf ball. Preferably, therefore, the practice and play faces are centered on the clubhead so that the center of the practice and play faces meet the centerline of the ball when it is struck. The actual dimensions of the clubhead can be customized to take into account various factors including the player's stroke, the lay of the ball on the putting surface, and the length of the nap of the grass.
Many combinations of the shapes of the clubhead, play and practice faces are possible while still achieving the objective of this invention, as illustrated in FIGS. 8 and 9 . FIG. 8 illustrates the preferred embodiment, wherein the practice face 50 ( FIG. 8( a )) and play face 51 ( FIG. 8( b )) are octagons and the taper angle α is about 10 degrees. The practice insert 52 is outwardly convex in an elliptical curve. The play insert 53 is flat. FIG. 9 illustrates an alternate embodiment, wherein the practice face 70 ( FIG. 9( a )) and play face 71 ( FIG. 9( b )) are octagons, but the taper angle α has been increased to about 20 degrees. The practice insert 72 is outwardly convex in a spherical curve and the play insert 73 is convex in a parabolic curve. FIG. 9( c ) is a side view illustrating a convex practice face and a concave play face.
FIG. 10( a ) illustrates a golfer 80 practicing a left-handed putt stroke into hole 83 . The golfer uses the practice face 81 to hit the ball and improve his aim. By rotating the putter 180 degrees in his hands, the golfer can use the same putter and the same stance to putt in play. FIG. 10( b ) illustrates the same golfer putting in play, using the play face 82 as the striking face.
While there has been illustrated and described what is at present considered to be the preferred embodiment of the present invention, it will be understood by those skilled in the art that various changes and modifications may be made and equivalents may be substituted for elements thereof without departing from the true scope of the invention. Therefore, it is intended that this invention not be limited to the particular embodiment disclosed, but that the invention will include all embodiments falling within the scope of the appended claims. | The present invention is an improved putter that combines several features to provide a balanced putter, which assists a player in perfecting a putt stroke during practice and repeating it with the same club during play. The shaft is attached to the clubhead such that it can swivel from a practice configuration to a play configuration. The clubhead has tapered top and bottom surfaces such that the angle of the shaft relative to the sole of the putter is no more than 80 degrees. The clubhead has a playing surface on one face that is parabolic and can be flat in the extreme. The clubhead has a practice surface on the other face that is curved, preferably elliptical, to assist the golfer in learning the proper stroke. The putter conforms to the Rules of Golf so that the player does not have to change clubs between practice and play. The club may be used for either a right- or left-handed stroke. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
Generally, the present disclosure relates to integrated circuits, and, more particularly, to the design of Built-In Self-Test (BIST) circuits for testing components of a microcircuit design.
2. Description of the Related Art
Built-in self-test (BIST) is a technique that allows integrated circuits to test their own operation functionally and/or parametrically. Like other Design-for-Test (DFT) techniques, it makes difficult-to-test circuits easier to test by adding test circuitry to a microcircuit design for such things as test pattern generation, timing analysis, mode selection, and go-/no-go diagnostic tests. BIST includes control circuits to initiate tests and to collect and report the results, even externally to the chip.
BIST circuits often connect to scan logic. Scan logic is another DFT technique that facilitates testing of a microcircuit chip by, for example, replacing traditional sequential elements, such as flip flops, with scannable sequential elements, called scan cells. A scan cell is a traditional latch or flip-flop with an additional input called the scan input and an additional output called the scan output. The portion of the scan cell that comprises the traditional latch or flip-flop remains part of the functional core logic. The scan output of one scan cell, however, connects to the scan input of the next scan cell to form a scan chain. The scan chain allows test patterns to be serially injected into the core logic so that they appear at the outputs of the latches, or flops. Testing is accomplished by shifting test patterns into the scan chains, cycling the system clock one or more times, and capturing the test results within the latches or flops. The results may then be shifted out through the scan chain for analysis by external test equipment or internal BIST logic.
BIST circuits also typically connect to boundary-scan elements. Boundary-Scan (also known as the Joint Test Action Group (JTAG) standard, or IEEE 1149.1) adds boundary-scan cells to each pin on a microcircuit device so that test and control data can be injected into the microcircuit device, tests initiated, and the results shifted out, even when the microcircuit is encased in a package. Boundary-scan test circuits are frequently used to initiate BIST and to report BIST results through, for example, a JTAG interface.
BIST logic does not come without a cost, however. The logic added to a microcircuit design for BIST testing typically intrudes into the critical timing paths of functional signals. BIST logic typically causes functional signals to propagate through additional gates that couple BIST test data onto the functional data paths, reducing the maximum speed of the microcircuit's operation and increasing its power consumption. While BIST makes device testing more efficient, it typically degrades device performance.
SUMMARY OF EMBODIMENTS OF THE INVENTION
The apparatuses, systems, and methods in accordance with the embodiments of the present invention improve device performance while maintaining the effectiveness of BIST. The apparatuses, systems, and methods described herein achieve improved performance by removing BIST intrusion logic from critical timing paths. Functional data, i.e., signals that propagate through the core logic of a microcircuit design, no longer need to pass through additional circuitry for BIST.
One apparatus in accordance with an exemplary embodiment of the invention comprises a plurality of scan cells connected into one or more scan chains, wherein a scan data input of at least one scan cell is configured to receive built-in test data during BIST testing and scan test data during scan testing. The test data may be supplied through a multiplexer that multiplexes the BIST test data and scan test data onto the scan data input pin of the scan cell. The apparatus may be microprocessor having a memory array, such as a cache memory, and an execution unit.
The apparatus may further comprise a memory array having at least one global bitline coupled to functional logic, the functional logic having a functional data input, a functional data output, and a test data input, wherein the test data input is coupled to the functional data output through a bypass circuit, the functional logic configured to cause a signal to propagate from the functional data input to the functional data output without passing through the bypass circuit.
The microprocessor may further comprise at least one execution unit having at least one multi-cycle ALU, at least one single-cycle ALU, at least one physical register file (PRF), and a multiplexer configured to couple test data onto the result path of the multi-cycle ALU. Test data may be written into the PRF through the execution of an opcode in one of the ALUs.
One method in accordance with an exemplary embodiment of the invention comprises multiplexing BIST data with scan test data on a scan data input circuit of a scan cell and selecting between the scan test data and the BIST data during testing of the microcircuit. The method may further comprise providing test data on a test data input of a bypass circuit coupled to functional logic, the functional logic having a functional data input and a functional data output, the test data input being coupled to the functional data output through the bypass circuit, wherein the functional logic is configured to allow a signal on the functional data input to propagate to the functional data output without passing through logic comprising the bypass circuit. The bypass circuit may comprise a multiplexer having one input coupled to the test data input and another input coupled to a feedback signal representing the functional data output. The method may further include injecting a test pattern into a physical register file (PRF) of an execution unit through the result path of a multi-cycle ALU and executing an operation that results in a known pattern being written into the PRF.
In other embodiments, the apparatuses described above may be formed on semiconductor material and configured to operate in the manner described above, or they may be designed using a hardware descriptive language and stored on a computer readable storage device encoded with data that, when implemented in a manufacturing facility, adapts the manufacturing facility to create the apparatuses. Though described in the context of a microprocessor design, the invention may be used in any type of integrated circuit and is not therefore limited to a microprocessors.
BRIEF DESCRIPTION OF THE FIGURES
The disclosed subject matter will hereafter be described with reference to the accompanying drawings, wherein like reference numerals denote like elements, and:
FIG. 1 is a simplified block diagram of a microprocessor design containing BIST and scan test elements in accordance with an exemplary embodiment of the invention.
FIG. 2 is a simplified block diagram of a portion of the microcircuit design shown in FIG. 1 in accordance with an exemplary embodiment of the invention.
FIG. 3 is a simplified schematic diagram illustrating BIST intrusion logic in the critical timing path of an address line supplied to a memory array typically found in the prior art.
FIG. 4 is a simplified schematic diagram of the circuit of FIG. 3 configured in accordance with an exemplary embodiment of the invention.
FIG. 5 is a simplified schematic diagram of a typical S-R latch having BIST intrusion logic located in a feedback path via a bypass circuit rather than the functional path in accordance with an exemplary embodiment of the invention.
FIG. 6 is a simplified block diagram of an execution unit having at least one multi-cycle ALU with BIST intrusion logic coupled to the result path of the ALU, in accordance with an exemplary embodiment of the invention.
While the disclosed subject matter is susceptible to various modifications and alternative forms, specific embodiments thereof have been shown by way of example in the drawings and are herein described in detail. It should be understood, however, that the description herein of specific embodiments is not intended to limit the disclosed subject matter to the particular forms disclosed, but on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the disclosed subject matter as defined by the appended claims.
DETAILED DESCRIPTION
FIG. 1 is a simplified block diagram of a general purpose microprocessor 10 in accordance with an exemplary embodiment of the invention. Microprocessor 10 performs basic arithmetic operations, moves data from one memory location to another, and makes decisions based on the quantity of certain values contained in registers or memory. To accomplish these tasks, microprocessor 10 incorporates a number of execution units 70 , such as a floating point unit or an integer execution unit, functional logic 50 , and control logic 15 . The functional logic 50 , control logic 15 , and execution units 70 may be designed, for example, using scannable sequential elements connected into one or more scan chains. Microprocessor 10 may also include one or more memory arrays 60 , such as a cache memory and/or a translation look-aside buffer, to facilitate operation of the device. Microprocessor 10 also includes a type of memory array typically found in an execution unit 70 , called a physical register file (PRF) 80 . A PRF stores the intermediate results of an executed instruction, such as a floating point operation, for later use or storage in main memory.
For testing, microprocessor 10 contains BIST & Scan Test Control 30 circuitry for generating test patterns and/or shifting test patterns through scan chains that may comprise part of the functional logic 50 , control logic 15 , execution units 70 , and memory arrays 60 . Microprocessor 10 may include a Test Interface 40 that comprises, for example, a JTAG interface containing boundary scan elements, and/or a scan test interface for receiving test patterns and control data from scan test equipment external to the device. Test Interface 40 connects to Power-Up Reset & Control 20 to reset, configure, control, and/or initiate BIST and/or scan testing. Test patterns may be generated internally to microprocessor 10 by BIST & Scan Test Control 30 for BIST testing and injected into the core logic by shifting through the scan chains. The results may be shifted out and compared to expected results within BIST & Scan Test Control 30 or externally through Test Interface 40 .
FIG. 2 is a simplified block diagram of a portion of the microcircuit design shown in FIG. 1 . As shown, BIST & Scan Test Control 30 includes a master control unit 120 that connects to one or more slave units 130 A, 130 B, and 130 N for communicating test patterns and/or control data, to initiate scan or BIST testing, and to collect and/or report the results. BIST & Scan Test Control 30 also connects to Power-Up Reset and Control 20 and Test Interface 40 to coordinate power-up reset testing, JTAG testing, and scan testing and report the test results, including, for example, to report a go/no-go diagnostic test result. Each slave unit controls the testing of one functional unit of microprocessor 10 . As shown, slave unit 130 A connects to memory array 60 , 130 B connects to functional logic 50 , and 130 N connects to execution unit 70 . Each is designed specifically for testing a particular unit or collection of units.
FIG. 3 is a simplified schematic diagram of a scan cell circuit comprising Mux-D flop 220 , as typically found in the prior art. As understood by one of ordinary skill in the art, Mux-D flop 220 has two data inputs, Scan_Data_In 260 and Read_Address_In 245 , and two data outputs, Read_Address_Out 290 and Scan_Data_Out 295 . The next state of Read_Address_Out 290 and Scan_Data_Out 295 is determined by one of the two inputs. For example, if Scan_Enable 270 is high on the next rising edge of clock 280 , Scan_Data_In 260 determines the next state of Read_Address_Out 290 and Scan_Data_Out 295 . If Scan_Enable 270 is low on the next rising edge of clock 280 , Read_Address_In 245 determines the next state of Read_Address_Out 290 and Scan_Data_Out 295 . Clock 280 may be a system clock supplied internally by microprocessor 10 during the functional operation of microprocessor 10 , a clock under the control of BIST & Scan Test Control 30 , or supplied through Test Interface 40 during BIST or scan testing, or a clock generated and/or controlled by all three, depending on the design and operational state of microprocessor 10 .
In a typical microprocessor design, there are many such scan cells connected into one or more scan chains. To form a scan chain, the scan output pin (SDO) of one scan cell is connected to the scan input pin (SDI) of the next. In the context of FIG. 3 , the Scan_Data_In 260 signal of Mux-D flop 220 is typically connected to the scan data output pin of the previous scan cell, and the Scan_Data_Out 295 pin of Mux-D flop 220 is typically connected to the scan data input pin of the next scan cell. Scan chains facilitate shifting test patterns into and out of the core functional logic. By activating the scan enable pin of each scan cell of the scan chain (i.e., Scan_Enable 270 , in the instant example) and cycling clock 280 until the entire test pattern has been serially shifted into the scan chain, the scan test pattern will appear on the outputs of the scan cells. Scan testing may then commence by deactivating the scan enable pin of each scan cell, enabling the functional data input pin of each scan cell to determine the next state of each scan cell's outputs, and cycling clock 280 the required number of times for the test. The results of the scan tests are captured inside the scan cells and may then be serially shifted out of the scan chain in the same manner the test pattern was serially shifted in. The test results may then be compared to expected results. In one embodiment, the comparisons for both scan and BIST testing may be done in slave units 130 A, 130 B, and 130 N and the results reported to master unit 120 . In other embodiments, the comparisons may be done in master unit 120 or in BIST & Scan Test Control 30 and report internally or externally, or shifted out through Test Interface 40 and compared externally to microprocessor 10 .
As shown in FIG. 3 , BIST data enters Mux-D flop 220 through multiplexer 210 . In normal operation of microprocessor 10 , both BIST_Read_Enable 230 and Scan_Enable 270 will remain inactive. This allows Read_Address line 240 to propagate through multiplexer 210 and determine the logical state of Read_Address_Out 290 on the next rising edge of clock 280 . Read_Address 240 is an address line supplied by the core functional logic of microprocessor 10 during a memory read access cycle of memory array 60 , for example. During Memory Built-In Self-Testing (MBIST), BIST Control 30 activates BIST_Read_Enable 230 , sources BIST_Read_Address 250 , and causes clock 280 to pulse one or more times. Multiplexer 210 acts as the insertion point for BIST data and constitutes BIST intrusion logic into the functional path of Read_Address 240 . When BIST intrusion logic is inserted into critical timing paths like this, the maximum clocking frequency of the circuit is degraded and the constant cycling of the intrusion logic during normal functional operation of the microcircuit design consumes additional power. Removing BIST intrusion logic from critical timing paths increases the maximum speed of the microcircuit design and reduces normal power consumption.
FIG. 4 is a simplified schematic diagram of the circuit of FIG. 3 configured in accordance with an exemplary embodiment of the invention. In FIG. 4 , multiplexer 210 multiplexes Scan_Data_In 260 with BIST_Read_Address 250 , Read_Address 240 connects directly to the functional data input pin of Mux-D flop 220 , and the output of multiplexer 210 connects to the scan input pin of the Mux-D flop 220 to select between scan test data and BIST data during testing of the microprocessor 10 . Both BIST_Read_Enable 230 and Scan_Enable 270 select between the scan data input and functional data input of Mux-D flop 220 through OR gate 315 . Because Read_Address 240 connects directly to Mux-D flop 220 , Read_Address 240 no longer propagates through or cycles the logic contained in multiplexer 210 during normal microprocessor 10 operation, making the critical timing path of Read_Address 240 faster and more efficient.
Though FIG. 3 and FIG. 4 illustrate the effect of BIST intrusion logic on read address lines, any data or control line could have been selected. For example, the circuits illustrated in FIG. 3 and FIG. 4 may be used for any data or control line in control logic 15 , functional logic 50 , memory array 60 , or execution unit 70 of microprocessor 10 where BIST and scan test data injection points are made. A read address line is shown for illustration purposes only.
FIG. 5 illustrates another example of avoiding BIST intrusion logic into the critical timing path of a functional data signal. In FIG. 5 , global bitline circuit 310 is coupled to SR latch 320 . Bitline circuit 310 may be any bitline circuit of memory array 60 , for example. Scan or MBIST test data enters latch 320 as Bypass_Data 410 through bypass circuit 330 and appears as Dout 460 of latch 320 , as described in more detail below. In the prior art, Dout 460 of latch 320 would be multiplexed with Bypass_Data 410 on the output side of inverter 414 , and the multiplexer that multiplexes Bypass_Data 410 with Dout 460 (not shown) would constitute intrusion logic along the critical path of Dout 460 .
In the exemplary embodiment of FIG. 5 , the signal path between Global_Bitline 404 and Dout 460 is not encumbered by BIST intrusion logic. During BIST testing, ArrBypassEn 408 is forced high, driving the output of NOR gate 470 low and allowing Bypass_Data 410 to appear on the output of Selector 420 . Selector 420 acts as a multiplexer that multiplexes between Dout* 461 and Bypass_Data 410 , based on the logic level of ArrBypassEn 408 . A logic low on the output of NOR gate 470 closes (turns on) transistor 442 , pulling Global_Bitline 403 high. A high on Global_Bitline 403 and a low on NOR gate 470 closes transistors 444 and 447 , respectively, and opens (turns off) transistor 445 , allowing the bypass data on the output of Selector 420 to determine the state of Dout* 461 by either closing transistor 446 when Bypass_Data 410 is high or transistor 448 when Bypass_Data 410 is low. Inverter 414 inverts Dout* 461 so that Bypass_Data 410 appears with the proper logic level on Dout 460 .
When ArrBypassEn 408 is low, Precharge 405 selects which circuit, i.e., the global bitline circuit 310 or bypass circuit 330 , determines the logic state of Dout* 461 . When Precharge 405 is high, bypass circuit 330 latches the current state of Dout* 461 . Specifically, when Precharge 405 is high, the output of NOR gate 470 is driven low, causing Global_Bitline 403 to be driven high through transistor 442 and closing transistor 447 in bypass circuit 330 . A high on Global_Bitline 403 , in turn, closes transistor 444 and opens transistor 443 . Because ArrBypassEn 408 is low during normal operation of microprocessor 10 , Dout* 461 controls the output of Selector 420 . When Dout* 461 is low, the output of Selector 420 is high, opening transistor 448 and closing transistor 446 . Because both transistor 444 and 446 are now closed, Dout* 461 is pulled low, its current state, and remains a logic low. When Dout* 461 is high, the output of Selector 420 is low, turning on transistor 448 . In this condition, both transistor 448 and 447 are turned on, which pulls Dout* 461 high. Thus, bypass circuit 330 holds the current state of Dout* 461 during a precharge state.
When Precharge 405 is low, global bitline circuit 310 determines the state of Dout* 461 . The output of NOR gate 470 is driven high, turning transistor 445 on and transistors 442 and 447 off. If both Local_Bitline 0 401 and Local_Bitline 1 402 are high, the output of gate 403 turns transistor 440 off and Global_Bitline 403 is driven high by the action of inverter 413 and transistor 441 . When Global_Bitline 403 is high, transistor 443 turns off and transistor 444 turns on. Because transistors 445 and 444 are both on, Dout* 461 is pulled low and Dout 460 assumes a logic high through inverter 414 . When either Local_Bitline 0 401 or Local_Bitline 1 402 is low, transistor 440 turns on and Global_Bitline 403 is pulled low, turning transistor 443 on and transistor 444 off. Because transistor 443 is turned on, Dout* 461 is pulled high and Dout 460 assumes a logic low through inverter 414 . The circuit of FIG. 5 allows Dout 460 to be controlled by either Bypass_Data 410 or bitline data 401 and 402 without the bitline data having to propagate through BIST intrusion logic.
FIG. 6 illustrates yet another example of how to avoid BIST intrusions in the critical timing paths of functional logic. FIG. 6 is a simplified block diagram of an execution unit 70 having two Arithmetic Logic Units (ALU) ( 510 and 512 ), two PRFs ( 570 and 571 ), and two Address Generation Logic Units (AGLUs) ( 511 and 513 ). ALU 0 510 is a multi-cycle ALU, while ALU 1 512 may be a single- or multi-cycle ALU. Each ALU and AGLU contains a result path (i.e., R 00 560 , R 01 561 , R 10 562 , and R 11 563 ) for writing the results of the respective operations into PRF 1 570 and/or PRF 2 571 . Execution Unit 70 contains execution control unit 530 for generating read and write addresses for PRF 1 570 and PRF 2 571 during normal microprocessor 10 operation, or BIST operation under the control of BIST Slave 30 . Note that execution control unit 530 comprises a single control unit, though it is shown in two places in FIG. 6 to facilitate description. Result path R 00 560 contains multiplexer 550 for multiplexing BIST data onto result path R 00 560 . Execution unit 500 also contains four bypass multiplexers ( 540 , 541 , 542 , and 543 ) for multiplexing result path data and source operand data (e.g., S 00 A and S 00 B to the respective logic units. BIST Slave unit 30 connects to execution control unit 530 and BIST Master 20 for BIST testing and control and to multiplexer 550 for injecting test patterns into PRF 1 570 and PRF 2 571 . In the prior art, there would be one multiplexer coupled to each result path (i.e., R 00 560 , R 01 561 , R 10 562 , and R 11 563 ) for multiplexing BIST data with result data and for writing the BIST data into each array. Test patterns and control data may be received by BIST Slave 30 from BIST Master 20 either serially or in parallel over 525 or developed internally to BIST Slave 30 in response to control information from BIST Master 20 . Test results may be received by BIST Slave 30 through ALU 0 510 from Bypass Multiplexer 540 , as described in more detail below, and compared internally to expected results or passed on to BIST Master 20 for comparison with expected results and/or further disposition.
BIST slave 30 writes test pattern data into each memory location of each PRF 570 and 571 by outputting BIST write data on R 00 560 through multiplexer 550 , which may be under the control of BIST Slave 30 or execution unit control 530 , and sending control information to execution control unit 530 , instructing it, for example, to execute an ADD operation, such as add zero to the BIST write data on R 00 560 , via ALU 1 512 . The ADD operation will cause execution control unit 530 to select R 00 560 data on bypass multiplexer BP 10 542 , thereby supplying the BIST write data to ALU 1 512 , to send the proper opcode 531 to ALU 1 512 to execute the ADD operation, and to write result data that would appear on R 10 562 back into PRF 1 570 , for example. As one of skill in the art will understand, BIST Slave 30 and execution control unit 530 may be designed and configured to cause any various types of opcodes 531 to be executed that result in known values being written into either PRF 1 570 or PRF 2 571 . The BIST write data may then be read out of either PRF 1 570 or PRF 2 571 by, for example, executing a second add operation to, for example, add zero to the previous result and to output the result through bypass multiplexer 540 to BIST Slave 30 through 580 and/or 581 for comparison to expected results in the manner described above. One advantage provided by the exemplary embodiment illustrated in FIG. 6 is allowing testing of an execution unit, including its PRFs, through a single BIST intrusion point, i.e., multiplexer 550 . Because the selected result path is a result path of a multi-cycle ALU rather than a single-cycle ALU, the described embodiment does not intrude on a critical timing path.
All elements described herein, including the functional logic 50 , functional control 15 , execution units 70 , memory arrays 60 , and scannable sequential elements, may be formed on a semiconductor material by any known means in the art. Forming can be done, for example, by growing or deposition, or by any other means known in the art. Different kinds of hardware descriptive languages (HDL) may be used in the process of designing and manufacturing microcircuit devices. Examples include VHDL and Verilog/Verilog-XL. In one embodiment, the HDL code (e.g., register transfer level (RTL) code/data) may be used to generate GDS data, GDSII data and the like. GDSII data, for example, is a descriptive file format and may be used in different embodiments to represent a three-dimensional model of a semiconductor product or device. Such models may be used by semiconductor manufacturing facilities to create semiconductor products and/or devices. The GDSII data may be stored as a database or other program storage structure. This data may also be stored on a computer readable storage device (e.g., data storage units, RAMs, compact discs, DVDs, solid state storage and the like) and, in one embodiment, may be used to configure a manufacturing facility (e.g., through the use of mask works) to create devices capable of embodying various aspects of the instant invention. As understood by one or ordinary skill in the art, it may be programmed into a computer, processor or controller, which may then control, in whole or part, the operation of a semiconductor manufacturing facility (or fab) to create semiconductor products and devices. These tools may be used to construct the embodiments of the invention described herein.
The particular embodiments disclosed above are illustrative only, as the disclosed subject matter may be modified and practiced in different but equivalent manners apparent to those skilled in the art having the benefit of the teachings herein. Furthermore, no limitations are intended to the details of construction or design herein shown, other than as described in the claims below. It is therefore evident that the particular embodiments disclosed above may be altered or modified and all such variations are considered within the scope and spirit of the disclosed subject matter. Accordingly, the protection sought herein is as set forth in the claims below. | Methods, systems, and apparatuses are presented that remove BIST intrusion logic from critical timing paths of a microcircuit design without significant impact on testing. In one embodiment, BIST data is multiplexed with scan test data and serially clocked in through scan test cells for BIST testing. In another embodiment, BIST data is injected into the feedback path of one or more data latches. In a third embodiment, BIST data is injected into the result data path of a multi-cycle ALU within an execution unit. In each embodiment, BIST circuitry is eliminated from critical timing paths. | 6 |
This is a continuation of application Ser. No. 08/422,662, now U.S. Pat. No. 5,575,777, filed Apr. 10, 1995 which is a continuation of application Ser. No. 08/152,401, now abandoned, filed Nov. 15, 1993.
BACKGROUND
1. Field of the Invention
This invention relates generally to medical appliances; and more particularly to a device for inserting into a patient's body a medical appliance such as a cannula, e.g., an intravascular cannula, or such as a guidewire used for emplacing catheters etc. The invention is for helping protect people from contracting diseases (particularly fatal diseases such as AIDS and hepatitis) through accidental puncture by needles that have been used in diseased patients.
2. Prior Art
U.S. Pat. No. 4,747,831 to Kulli sets forth the state of the pertinent art and is, in its entirety, incorporated herein by reference. Kulli teaches a safety device for use in inserting a cannula into a patient and for thereafter protecting people from contact with portions of the device that have been within the patient.
(For purposes of this document as in the Kulli patent, the term "cannula" means a catheter assembly consisting of primarily a hub and short tube--as pictured and described in the Kulli patent column 3, lines 25 through 37! and herein. As already mentioned the technology is not necessarily limited to use with cannulae directly but is useful as well in insertion of other medical appliances such as catheter guidewires.)
Kulli's device includes a needle for piercing a patient and for guiding and carrying a cannula or other appliance into place within such a patient; the needle has a shaft with at least one sharp end. His device also includes a hollow handle adapted to enclose at least the sharp end of the needle beyond reach of people's fingers.
In one major facet or aspect of preferred embodiments of Kulli's invention, the invention also includes some means (denominated the "securing means") for securing the shaft to the handle, with the sharp end projecting from the handle. It also includes some means (the "releasing means") for releasing the securing means and for substantially permanently retracting the sharp end of the needle into the handle and beyond reach of people's fingers. The releasing and retracting means are manually actuable by a simple unitary motion, of amplitude that is substantially shorter than the shaft of the needle.
In a second major aspect or facet, Kulli's invention also includes (in addition to the needle and hollow handle) a block fixed to and extending from the needle. The block is restrained within the handle with the sharp end of the needle projecting out of the handle through the aperture, and adapted for motion within the handle to withdraw the needle into the handle. The invention in this second major aspect further includes a trigger mechanism, which is actuable from outside the handle for releasing the block. The trigger mechanism also includes positive biasing means for forcibly moving the block within the handle to substantially permanently retract the sharp end of the needle into the handle and beyond reach of people's fingers.
Many other details of the Kulli invention are discussed at length in his '831 patent and for economy's sake will not be repeated directly here, though as already noted they are all incorporated into this document by reference.
In the course of very extensive efforts directed toward preparation of the Kulli invention for the marketplace, it has been confirmed that his invention is entirely operational and serviceable for all the purposes described. No criticism of the structure or function of Kulli's invention is intended by, and none should be inferred from, anything in the present document.
To enhance acceptance of such a device by the medical community and regulatory authorities, it has been found desirable to focus attention upon certain operating characteristics of the Kulli device--particularly as they relate to peripheral but very important matters. Such matters include (1) manufacturing economics, and possible resulting variations in operation, (2) variations in skill of--and consequently variations in handling by--operating personnel, and resulting perceptions of medical appliances by operating personnel, and (3) potential misuse of the device, due for example to prevailing societal conditions.
It will now be understood that none of these considerations can properly be regarded as in the nature of a defect or limitation of Kulli's invention. Rather they are in the nature of areas in which that invention leaves room for further refinement.
None of these considerations is, in substance, a part of the prior art; instead they have been adduced through work leading to the present invention, and are regarded as at least in part components of the creative and innovative processes of making the present invention. Accordingly in this document these considerations will be detailed in a later section, not addressed to the prior art.
For reference purposes, however, the present section will now describe the overall procedure for inserting a cannula or the like--whether using the Kulli device or essentially any other cannula insertion set--as this procedure itself is a part of the prior art and will be of interest in later discussion of the present invention. Typically a doctor, nurse, paramedic or other medical staff person first locates a target blood vessel chosen for catheter insertion, and then pierces the patient's skin and blood-vessel wall--inserting the pointed end of the needle and a portion of the catheter (see FIG. 16 of Kulli).
Next the practitioner almost always deliberately permits a small quantity of the patient's blood to flow through the hollow needle--impelled by the patient's own blood pressure--so that the small quantity of blood can be seen at the rear of the needle. The blood which thus flows from the needle enters some sort of chamber that is part of the cannula insertion set, and which ordinarily is made of transparent material to afford a view of the interior and thus of the blood therein.
This practice of allowing some blood to flow into a viewing chamber is known in jargon of the medical field as "flashing", and the blood that enters the chamber is sometimes called the "flash" quantity. The flashing step has the purpose of confirming that the catheter is indeed inserted into the blood vessel.
In the instance of Kulli's invention, the chamber is the hollow handle into which the needle will later be retracted, and which thus serves double duty as a viewing chamber.
In other types of cannula insertion sets too the chamber may be a hollow handle, but may take other forms. In such other types of sets, the chamber is generally configured in one way or another to permit the flash blood to enter the chamber--but then to retain that blood.
To permit entry of that blood into the solid chamber, some provision must be made for escape of air that is initially in the chamber; on the other hand, retention of the blood once it has entered the chamber requires that the chamber be to some extent fluid sealed. These two seemingly contradictory requirements can be and are satisfied in a variety of ways, including careful placement of breather holes or tubes to permit air escape--and so accommodate the slow passage of blood into the chamber--while presenting a relatively long, high-impedance path to obstruct liquid flow out of the chamber.
More often modernly these requirements are met by providing--for instance at the rear end of the handle--a relatively large orifice that is closed by a selective filter to pass air somewhat readily, at least at the flow rates typically associated with blood flow into the chamber, but block passage of blood out of the chamber. As will be understood such purposes may be best served by for example a hydrophilic filter; such filters are sometimes used.
Once a desired flash quantity of blood is observed, as mentioned in the Kulli patent the medical practitioner usually provides temporary stoppage of the blood flow by placing a finger or other hand portion upon the blood vessel to squeeze off the vessel. While maintaining this stoppage the practitioner carefully withdraws the needle, leaving the inserted end of the cannula or other appliance in place--and then secures an appropriate intravascular connecting tube, most typically a delivery tube, to the hub of the cannula etc.
Next the practitioner fixes the cannula or like appliance to the patient's body, usually employing a small piece of tape, and releases the manually applied closing pressure upon the vessel. Various liquids may then be introduced through the appliance into the patient's blood stream, the patient's blood pressure may be monitored, etc., all as well known.
Also part of the prior art are teachings of certain other Kulli patents, including U.S. Pat. Nos. 4,900,307, 4,904,242, 4,927,414 and 4,929,241--some of which disclose features related to deterrence of needle reuse, but in different contexts.
Important aspects of the technology used in the field of the invention are amenable to useful refinement.
SUMMARY OF THE DISCLOSURE
The present invention introduces such refinement. Before offering a relatively rigorous discussion of the present invention, some informal orientation will be provided here.
It is to be understood that these first comments are not intended as a statement of the invention. They are simply in the nature of insights that will be helpful in recognizing the underlying character of the special considerations alluded to above (such insights are considered to be a part of the inventive contribution associated with the present invention)--or in comprehending the underlying principles upon which the invention is based.
Flash leakage--Through extensive work with devices constructed according to Kulli's disclosure, it has been discovered for example that some personnel sometimes handle the devices in such a way that blood from a patient can leak rearward or forward from the handle of the device, or forward from the needle. Some of the procedures leading to such leakage are necessary parts of the usage of the device--detailed in the preceding section of this document--and others are in the nature of variations in operator skill, attentiveness or anticipation, and the like.
In any event, for success of a device to be used in very large numbers throughout the medical industry it is highly desirable to minimize the potentiality for blood leakage resulting from such handling variations. The portion of procedures that sometimes leads to blood leakage is the so-called flashing step already described in the previous section of this document.
At the outset it may be noted that the Kulli disclosure does not propose to position a filter over the rearward orifice 13 etc. of the hollow handle, or otherwise to provide for selective passage of air but not blood as in some other insertion devices. Kulli instead proposes that the rearward orifice 13 etc. may be preserved open and at substantially the same internal diameter as the cannula hub--thus making possible a temporary attachment of intravascular tubing through the handle, as is sometimes desired by some medical professionals, preparatory to shifting the attachment to the cannula hub.
In the present state of medical practice, however, such temporary attachments are disfavored and retention of the flash blood is regarded as more important. It might be supposed accordingly that the Kulli device should simply be fitted with a suitable filter at its rear orifice 13 etc.--or that the rear orifice should be eliminated by sealing the rearward end of the handle and some other provision (e.g., small vent holes or tubes) incorporated for escape of air to accommodate incoming flash blood.
In efforts toward resolving this consideration, however, it was learned with some surprise that such emplacement of a filter or a fine vent was not sufficient. The reason is that the retraction of Kulli's needle, or needle and block, into the hollow handle tends to displace a volume of flash blood collected in the handle. This displacement tends to expel blood abruptly out of the enclosure by whatever path is available.
One leakage path is forward through the needle and its carrier block. In other words, in such a device when the retraction button is operated blood can be squirted out of the front end of the needle--an unacceptable result, not merely because of the untidiness involved but more importantly on account of the exposure of people in the vicinity to the patient's blood. The latter is particularly troublesome since an important objective in providing a retracting needle is to minimize such exposure.
Another path--once the needle carrier block has retracted out of its initial or forward-locked rest position with minimal radial clearance--is forward around the needle and block. In this instance the blood leaks out of the assembly by issuing through the forward apertures of the Kulli handle or housing.
This path, utilizing only incidental clearances in the apparatus, tends to create smaller leakage than that through the needle--particularly with respect to the immediate, piston-driven expulsion of blood at the time of retraction. This second path, however, remains important because of a potential for somewhat slower but more protracted trickling of blood from the front of the chamber, sometimes occurring after use of the device is nominally complete and it has been laid down on a table or tray--so that personnel may no longer be attentive to the possibility of blood leakage.
Further, in the course of development, it was noted that the possibility of abrupt expulsion of blood through the needle was reduced very greatly through fabrication of the needle carrier block with relatively greater radial clearance--and by instructing medical personnel not to fill the handle more than about three-quarters full. These two provisions, coupled with the relatively high viscosity of blood in the needle, allowed enough mechanical volume for rearrangement of the blood within the chamber, upon retraction, and thereby nearly eliminated the squirting of blood through the needle.
In some cases, however, it is not possible to avoid filling the chamber beyond the three-quarters point; with patients who have large blood vessels and high blood pressure, for example, the chamber may be filled with flash blood very quickly. It was found that highly skilled and specially instructed personnel could reliably avoid overfilling, by anticipating rapid filling in appropriate cases, and by particularly dextrous manipulations; but in general use the volumetric suitability of the flash is simply outside the control of the insertion-set manufacturer.
Furthermore, providing a relatively high clearance around the needle block--while reducing the potentiality for abrupt expulsion of blood through the needle--has the undesirable effect of aggravating the potentiality for longer-term leakage of blood along the incidental clearances around the needle. Efforts to resolve the latter complication through incorporation of a specially sized resilient seal at the forward end of the device were operationally successful but objectionably expensive, and in particular also objectionably cumbersome in assembly--and as will be understood could not address the former matter of flash-volume control.
As can now be appreciated, the seemingly simple initial expedient of providing a substantially conventional flash-chamber enclosure for the Kulli device--as by placing a filter at the rear aperture of that unit, or by otherwise closing that orifice and incorporating vents--can lead to blood expulsion or leakage concerns of magnitude at least equal to the initial desire to enclose the flash.
Only after very extensive experimentation and trial-and-error efforts was it realized that the source of this concern is the implicit initial choice of enclosing or barring the flash blood at a point that is fixed relative to the handle. This choice in turn implies relative motion between that blood, in the handle, and the piston formed by the moving needle block.
It is this relative motion, particularly motion of the carrier block moving through the blood, which causes the primary concern over leakage--that is, the abrupt expulsion of blood forward through the needle. Accordingly a resolution of this concern can be sought in the alternative of enclosing or barring the flash blood at a point that is effectively fixed relative to, instead, the movable needle--thereby enabling elimination of effective relative motion between the blood and the moving needle block.
The words "effectively" and "effective" have been used above because, as will be seen, some configurations that prevent application of retraction forces to the flash blood involve pneumatic association of the blood enclosure with the moving needle even though the enclosure may be fixed to the handle.
As will be seen, this change of focus opens a variety of possibilities for allowing air to escape from the enclosure so that flash blood can flow from the rear of the needle--and for then holding the blood safely enclosed even during needle retraction. In particular, in such a configuration a filter or vent too can be associated with the moving needle.
That association yields the beneficial result that the limited airflow capacity of the filter or vent (relative to air moved by the piston effect during retraction) now works favorably toward leak-free operation. The limited-airflow filter or vent does so by isolating the flash blood in the chamber against the air-pressure increase developed in retraction.
Hence the moving needle, carrier block, chamber, filter or vent, and flash blood all together form and act as a composite piston upon the air in the hollow handle. Furthermore the handle itself no longer need be sealed by a filter or fine vent, and the air moved by the composite piston can be rapidly relieved to ambient.
Still another alternative for resolving leakage concerns can be found in the isolation of flash blood in the needle (as distinguished from the receiving chamber) from air-pressure increases developed in retraction. A check valve, for example, can be provided to perform this function.
Retraction speed--Retraction of the Kulli needle and block are, in some preferred embodiments, effectuated by a biasing means such as for example a coil spring. Whatever propulsion unit is used, the resulting retraction speed is subject to variations in biasing force--which are compounded by variations due to dimensional tolerances for the needle, block and handle; and particularly by highly variable lateral and torsional forces developed on the needle tip, as for example by the manual pressure mentioned earlier.
These factors together create a very large range of variation in the final resultant retraction speed. In consequence, if the various tolerances are chosen to be substantially certain of positive and prompt retraction when all factors tend toward minimum retraction force and speed, then objectionably high speed results when all factors tend toward maximum force and speed.
Retraction speed may be objectionably high even though the mechanism functions perfectly and poses no threat of injury or damage--either to itself or to anything else. The objectionability of high speed arises rather from the perceptions of some medical personnel, for whom unusually forcible or loud retraction may be startling or annoying, or simply may seem unprofessional.
It will be understood that a high range of variation in speeds--leading, as explained above, to quite high speed in some cases--can be avoided by constraining mechanical tolerances more closely. Such resort to tighter specifications, however, is itself objectionable on account of the associated higher cost.
As implied already, objectionably high speeds and consequent loud clicking or snapping sounds can be avoided by using lower spring pressure, closer clearances, etc.--but not without shifting the problem to the low-speed end of the overall range of variations, or in other words causing some needles to retract unreliably or too slowly.
Part of the present invention accordingly resides in recognition that retraction can be both (1) made reliable and (2) controlled in speed--but within a very economical device--by in essence assigning these two functions to two different mechanical elements respectively. More specifically, positive and prompt retraction can be assured by selecting a sufficiently strong spring or other biasing means; and it is possible to prevent or compensate for excessive retraction speed by incorporating a damping or other energy-absorbing provision.
A suitable energy-absorbing element can for instance take the form of a viscous lubricant interposed between the needle carrier block and the interior bore of the hollow handle; and means (such as a lubricating port) for facilitating placement of the lubricant. This type of energy-absorbing provision may not provide a resistive force that is consistent over the full travel of the needle; rather the consequent speed-limiting action appears to be concentrated at the beginning of the stroke and may result in part from thixotropic or stiction-like effects.
Such effects may include, for example, (1) a tendency of the lubricant to make spring coils stick together, and for the spring coils to break loose only gradually to begin the stroke, and similarly (2) a tendency for the lubricant to make the needle carrier block stick in place against the interior bore of the handle, and for the block to break loose from the bore surface only gradually at first. In any event, whether or not the operative mechanisms of the technique are fully understood at a physics or classical-mechanics level, this form of energy absorbing has been found very satisfactory.
This type of energy absorbing also offers an additional benefit of sealing the carrier block against the interior bore, before the needle is retracted. Under these conditions suction (e.g., from an external plunger), can be applied to the interior passage, and thereby to the flash chamber and needle lumen, to assist in drawing flash blood into the chamber. Such a suction boost is desirable to assist in the flashing procedure on some occasions, as when for instance the patient's blood pressure is very low.
Other energy-absorbing elements, however, are believed to be usable and within the scope of the invention. For example a separate mechanical element can be disposed within the hollow handle and biased laterally (e.g., radially) against the needle or carrier block to impose frictional force tending to retard the retraction; in such a system, biasing force and surface materials are selectable to obtain desired damping levels. In such a configuration the biasing force may preferably be varied along the stroke--as for example by using or exaggerating the draft generally employed in molding of hollow shapes such as a handle housing.
As another example, a dashpot device may be formed by separate or preferably existing elements within the hollow handle. In this case the energy-absorbing effect would appear to be more in the nature of true damping than the viscous-lubricant system, but may tend to be concentrated near the end of the retraction stroke, whereas in the case of the preferred viscous-lubricant technique the damping action tends to be concentrated near the beginning of the retraction stroke.
Risk of Abuse--Unfortunately in present-day society a widespread phenomenon is use of discarded medical needles by drug addicts to inject themselves with hallucinogenic drugs and the like. Apart from the social evils of addiction and resulting crime, such abuse of discarded medical equipment poses a risk of spreading disease from the blood of diseased patients.
Thus in addition to its primary function of deterring the inadvertent infection of medical personnel through accidental needle punctures, it is desirable that any disposable medical appliances which include needles be configured to deter or discourage later reuse.
Study of the '831 patent suggests that the needle and its carrier block might be reset forward within the handle by insertion of an elongated tool such as a screwdriver blade, to push against the rear end of the needle or block. While the block and needle are thus held in a forward position, they can once again be locked in that position by resetting the latch button outward.
Alternatively, even a relatively short tool may be used to start the sharp needle tip back through the forward end of the handle. A person may thereby be enabled to grasp the tip with fingers, pliers or the like and pull it forward to complete the forward-resetting motion.
In either of these ways a person may be able to fully or partially redeploy--and thereby prepare to abuse--potentially contaminated medical needles following their disposal by hospitals and other medical facilities.
Such abuses can be frustrated by configurations that obstruct or otherwise deter insertion of such tools. As will be understood, virtually nothing can be done to prevent a person from cutting open the rear end of the handle to gain unobstructed access to the needle within; short of such tactics, however, as will be seen a variety of abuse-frustrating configurations is within the scope of the invention.
Now with these preliminary observations in mind this discussion will proceed to a perhaps more-formal summary. The invention has several major aspects or facets.
In preferred embodiments of a first of these primary aspects, the present invention is a safety device for use in inserting a medical appliance such as a cannula into a patient and for thereafter protecting people from contact with portions of the device that have been within the patient--and from contact with the patient's blood. The device includes a hollow needle for piercing a patient and for guiding and carrying such an appliance into place within the patient; the needle has a shaft with at least one sharp end;
The device of the first aspect of the invention also includes a hollow handle adapted to enclose at least the sharp end of the needle beyond reach of such people's fingers; and some means for securing the shaft to the handle, with the sharp end projecting from the handle. These means, for purposes of breadth and generality in discussion of the invention, will be called the "securing means".
The device further includes some means for releasing the securing means and for substantially permanently retracting the sharp end of the needle into the handle and beyond the reach of such people's fingers. These means, again for generality and breadth, will be called the "releasing and retracting means"; they are manually actuable by a simple unitary motion, of amplitude that is substantially shorter than the shaft of the needle.
The device also includes some means for receiving blood from within the hollow needle and for reliably retaining that blood during and after retracting of the needle, notwithstanding forces developed by the retracting.
The foregoing may represent a description or definition of the first main facet of the invention in its broadest or most general form. (A considerable variety of different kinds of receiving and retaining means is introduced elsewhere in this document.)
Even in this form, however, this first aspect of the invention may be seen to provide the refinement needed to resolve concerns discussed earlier in this section of the present document. In particular, because the receiving and retaining means accept and hold the blood even in the face of retraction forces, they make possible avoidance of the flash expulsion sometimes observed upon fitting Kulli-type devices with a selective filter.
Nevertheless, for greatest enjoyment of the benefits of the invention, it is considered preferable to practice this first broad aspect of the invention in conjunction with certain other characteristics or features. It is particularly preferable to practice this first main facet of the invention in conjunction with the other principal aspects, to be introduced below; however, in addition to those major aspects there are several other preferable features or characteristics.
For example, the receiving and retaining means most preferably comprise a chamber fixed for motion with the needle; and some means for permitting viewing of received and retained blood by a user of the device. More specifically, it is preferred that the chamber be fixed to the needle, within the hollow handle.
It is also preferred that the receiving and retaining means further comprise some means for isolating the interior of the chamber from forces developed by said retracting. Several such isolating means are within the scope of the invention.
Among these are systems that include relatively high-impedance means for transmitting gas from the interior of the chamber. Such systems may for instance include means for permitting relatively slow escape of air from the interior of the chamber to enable entry of blood through the hollow needle; and means for deterring relatively rapid entry of air into the interior of the chamber to avoid expulsion of blood through the hollow needle by forces developed in retracting. Such high-impedance transmitting means may take the form of a selective filter, or a fine passage for venting air.
Alternatively, the receiving and retaining means preferably may include a chamber associated with the handle; and some means for transmitting blood from within the hollow needle into the chamber, substantially without transmitting into the chamber force developed during said retracting. For example blood-transmitting means may include a flexible tube communicating between the chamber and the interior of the hollow needle; or a frangible passage communicating between the interior of the chamber and the interior of the hollow needle (in which system the releasing and retracting means break the frangible passage); or a check valve disposed along a blood-flow path between the interior of the chamber and the interior of the hollow needle.
In preferred embodiments of a second major facet or aspect of the invention too, the invention is a safety device for use in inserting a medical appliance such as a cannula into a patient and for thereafter protecting people from contact with portions of the device that have been within the patient. This device too includes a hollow needle, hollow handle, securing means, and releasing and retracting means manually actuable by a simple unitary motion, of amplitude substantially shorter than the shaft of the needle--all substantially as set forth above.
In addition a device according to preferred embodiments of this second major facet of the invention also includes some means for absorbing some of the energy of the retracting--which will be denominated, for purposes mentioned earlier, "energy-absorbing means" or simply "absorbing means". (A variety of absorbing means may be employed, within the scope of the invention, as set forth elsewhere in this document.)
While the foregoing may represent a definition or discussion of the second aspect of the invention in its most general or broad form, once again this aspect too can be seen to resolve concerns discussed earlier in this section. In particular the energy-absorbing means enable the needle carriage to be amply powered for reliable retraction, since so powering the carriage no longer need produce objectionably loud, or startling retraction sounds--or objectionably forcible or jerky operation.
Nevertheless it is preferable, to maximize the benefits of the invention, that this second main facet of the invention too be practiced in conjunction with certain other features and characteristics that enhance its advantages. For example it is preferred that the device also include some biasing means for powering the retracting reliably, despite accumulated manufacturing tolerances tending against said retracting--or, in other words, that the possibility mentioned in the preceding paragraph be actualized by providing ample retraction force.
It is also preferred that the absorbing means include a viscous substance interposed between the needle and the hollow handle; and further that these means include a port defined in the hollow handle for placement of the viscous substance within the hollow handle.
Alternatively the absorbing means preferably include a surface that is fixed to one of (1) the needle and (2) an interior bore of the handle; and an element carried on the other of the needle and that interior bore, and bearing against said surface to develop friction during said retracting. Still further alternatively the absorbing means preferably include a dashpot element fixed for motion with the needle in said retracting.
In preferred embodiments of a third of its main facets or aspects, the invention is as before a safety device for use in inserting a medical appliance such as a cannula into a patient and thereafter protecting people from contact with portions that have been within the patient. This device includes as before a hollow needle, hollow handle, securing means, and manually actuable releasing and retracting means as characterized earlier.
In addition a device according to this third main facet of the invention includes some means--the "deterring means"--for deterring redeployment of the needle after said retracting. (A number of different forms of such means are described elsewhere herein.)
The foregoing may constitute a definition or description of this third aspect of the invention in its broadest or most general form. Even in this broad form, however, it may be seen to resolve needle-abuse concerns mentioned earlier in this section, as the deterring means will significantly reduce the risk of needle reuse by addicts and others, thereby correspondingly reducing the risk of disease propagation through such abuse.
Nevertheless this third facet of the invention, to optimize the benefits which it provides, is preferably practiced in conjunction with certain other features or characteristics. For example it is preferred that the deterring means deter access to the needle after said retracting. Also it is preferred that after the retracting the deterring means alternatively or additionally deter forward movement of the needle, or reengagement of the securing means, or both.
In preferred embodiments of a fourth major aspect of the invention, the invention is a catheter-insertion device with a retracting needle, and includes an elongated hollow needle having a piercing end and an interior end. The device also includes a handle defining an interior passage.
In addition this device includes a needle carriage, movably received within the interior passage, defining an interior chamber and supporting the needle so that the interior end of the needle communicates with the interior chamber and the piercing end of the needle extends outward. The device also includes some means for securing the needle and carriage with the piercing end of the needle outside the handle. In addition the device includes some means for releasing the securing means and retracting the needle and carriage inward with respect to the handle so that the piercing end of the needle is inside the handle.
The foregoing may represent a definition or description of the broadest or most general form of the fourth primary facet of the invention. Once again the invention in this form will be seen to resolve important concerns of abrupt leakage or squirting of blood, which arise upon fitting a Kulli device with a selective filter as described earlier in this section.
The invention as broadly couched in this fourth main aspect resolves such concerns by carrying the blood with the needle during retraction, rather than holding the blood in the handle--so that there is no relative motion between the blood and the needle. Under these conditions it remains only to deal with the compressive forces developed during retraction, to prevent application those forces to the blood that is carried with the needle; dealing with those forces can be accomplished by various means as indicated elsewhere in this document.
Nevertheless it remains preferable to practice this fourth major aspect of the invention in conjunction with other features or characteristics that lead to the most advantageous overall structure and function. For example it is preferred that the interior chamber include some means for making visible any contents of the interior chamber.
In addition preferably the interior chamber defines a first end sealingly attached to the interior end of the needle, and a second end. Preferably the needle carriage further includes means for permitting slow passage of air, and for deterring passage of blood, outward from the interior chamber into the interior passage of the handle; and for deterring rapid passage of air inward into the interior chamber from the interior passage of the handle.
These permitting-and-deterring means preferably comprise a filter covering the second end. Such a filter is preferably of a hydrophilic material.
Also preferably the handle defines an injection aperture for introducing a viscous substance into the interior passage of the handle; and the device further includes a viscous substance introduced through the injection aperture and disposed between the carriage and an interior surface of the handle. In addition preferably the device includes a grill secured across the interior passage of the handle.
As mentioned earlier it is preferred that all these major facets or aspects of the invention be practiced in conjunction with one another. They are all, however, to various extents capable of practice independently.
All of the foregoing operational principles and advantages of the present invention will be more fully appreciated upon consideration of the following detailed description, with reference to the appended drawings, of which:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a longitudinal section of a retracting-needle cannula-insertion device according to preferred embodiments of the invention--using for pressure isolation a flash chamber that moves with the needle, and for energy absorbing a viscous substance and a port for positioning the substance--shown together with a cannula that can be inserted using the device, and particularly showing the needle in its extended position; FIG. 1a is a partial like section, enlarged, showing an alternative, crushable energy absorber mounted to the chamber;
FIG. 2 is a like view of the FIG. 1 device but showing the needle retracted;
FIG. 3 is a cross-section of the same device taken along the lines 3--3 of FIG. 1 and so showing the needle extended;
FIG. 4 is a like view but taken along the lines 4--4 of FIG. 2 and so showing the needle retracted;
FIG. 5 is a cross-section of the same device taken along the lines 5--5 in either FIG. 1 or 2, and showing an embodiment of the invention that employs for abuse deterrence a grill supported across the interior of the hollow handle to render difficult any access to the needle for forward resetting;
FIG. 6 is a somewhat schematic partial longitudinal section of an alternative embodiment employing for pressure isolation a flexible interconnecting tube, and for abuse deterrence a generally complete obstruction of the interior of the hollow handle;
FIGS. 7 and 7a (taken along line 7a--7a in FIG. 7) represent a like schematic section of still another alternative embodiment--employing for pressure isolation an initially flattened, preferably transparent or translucent balloon fixed for liquid communication to the rear of the needle and for energy absorbing a separate laterally biased element, and for abuse deterrence a labyrinthine end cap that similarly provides essentially complete obstruction of the interior of the hollow handle;
FIG. 8 is a like schematic section of another alternative embodiment employing for pressure isolation a frangible passage and for abuse deterrence a laterally formed piston-pressure relief port that renders difficult any access to the needle for resetting; and
FIGS. 9 and 9a (greatly enlarged) are like schematic sections of yet another alternative embodiment--employing for pressure isolation a check valve, for energy absorbing a dashpot member that is integrated with the valve, and for abuse deterrence ratchet elements to prevent, respectively, forward motion of the needle and reengagement of the trigger to its locking position.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIGS. 1 and 3 show a preferred embodiment 10 of the invention, having an elongated generally cylindrical handle housing 20 with a cylindrical wall 21 and a cylindrical interior passage 24. The housing 20 also defines an end portion 22 with an increased-diameter end recess 23.
A cylindrical end plug 85 defines an air passage 87 and a grill 86, which may by way of example be cruciform as shown. This plug 85 is secured within the end recess 23 using a force or interference fit, together with other appropriate attachment provision such as, for instance, adhesive or sonic welding.
Formed in an outer surface of the handle housing 20 is a radially extending (or upward-extending, with the device oriented as drawn in FIG. 1) trigger guard 25, and a plurality of ribs 26 to facilitate positive grasping of the device by a user. Also formed in the handle housing, through the cylindrical wall 21 for communication with the cylindrical interior passage 24, is a generally circular grease port 27.
A frontal housing 30 is secured to the forward end of the handle housing 20--again by any appropriate means such as adhesive, sonic welding etc., but preferably by a snap fit--and defines a generally tapered forward-extending nose portion 40, with a needle-passing aperture 42 formed at the forwardmost tip, and a tapered passage 41 generally coextensive with the nose portion 40 and communicating between the interior cavity 33 of the frontal housing and the needle aperture 42.
Formed transversely through either the frontal housing 30 or the front end of the handle housing 20--but preferably through the latter--is a pair of opposed slots 31, 32. A lock slider or trigger 50 (to some extent better seen in FIGS. 3 and 4) defines an elongated generally planar lock member 52--preferably formed of a strong material such as metal, and slidably received through the opposed slots 31 and 32. Formed through the planar lock member 52 is a keyhole-shaped aperture or slot 53.
Movably and preferably slidably received within the cylindrical interior passage 24 of the handle is a carriage or carrier block 60. This carriage 60 in turn defines an interior flash chamber 61, and a reduced-diameter portion 63.
Extending through and secured within this latter portion 63 of the carriage 60 in a sealed attachment is an elongated hollow needle 70. An internal end 71 of the needle 70 is positioned in communication with and preferably within the interior flash chamber 61.
The remainder of the hollow needle 70 extends forward from the carriage 60--through the tapered passage 41 and aperture 42 in the nose portion 40 of the frontal housing 30, and beyond. The needle terminates in a piercing point formed by a beveled facet 74.
Thus flash blood passing from a patient into the device through the hollow needle 70 is introduced into the interior flash chamber 61 for viewing. The device includes some means for permitting viewing of the flash blood by a user of the device; such means may include a separately defined transparent window, but preferably they include transparent materials used in fabrication of the entire chamber 61, indeed the entire carriage 60--as well as the handle housing 20.
The needle carriage 60 also defines a front end 65, a circumferential, preferably circular groove 64, and a rear end that is spanned by a hydrophilic filter 62. (Hydrophobic/hydrophilic composite units are also potentially useful.) This filter provides liquid sealing of the flash chamber 61 while permitting outward air diffusion into the passage 24 of the handle.
A coil spring 80 encircles and receives the reduced diameter portion 63 of the needle carriage 60, and is captured between the needle carriage 60 and, for convenience, the lock slider 50. As will be clear, the spring 80 can as well seat against an internal feature of the handle.
A conventional catheter or cannula 11 includes a catheter housing 90, with an interior cavity 94 that receives the nose portion 40 of the frontal housing 30 in a conventional attachment such as preferably a snap fit. (Description of the invention here in conjunction with a cannula is only for definiteness of description; as mentioned earlier the invention is for emplacement of other medical appliances as well.) The cannula 11 also includes an elongated hollow catheter tube 91 with an end portion 92--and a needle passage 93 formed through the tube 91 and end portion 92.
The interior end of the catheter tube 91 is sealingly secured, as is conventional, within the interior cavity 94 of the catheter housing 90. In the assembled position of FIG. 1, the piercing point 73 and bevel 74 of the needle 70 extend slightly beyond the end 92 of the catheter tube 91 to facilitate the piercing action of the needle unit 10.
FIG. 1 represents the needle-extended condition of the device, in which the carriage 60 and needle 70 have been drawn forward against the force of the compressing spring 80--so that the groove 64 in the front end 65 of the carriage 60 is aligned with the keyhole aperture 53 in the slider/trigger 50--and are held in that forward position by the slider 50.
This forward positioning of the needle 70 and carriage 60 is accomplished while the trigger 50 is initially moved downward (as drawn) within the slots 31, 32 of the frontal housing 30 or handle 20, thereby aligning the larger-transverse-dimension, circular part 55 (better seen in FIG. 4) of the keyhole aperture 53 with the end portion 65 of the needle carriage 60. The end portion 65 has then been passed through the larger-transverse-dimension circular part 55 of the keyhole, just enough to align the circumferential groove 64 in the carriage 60 with the planar trigger plate 50.
With the carriage 60 thus longitudinally aligned, the lock slider 50 has been raised (as drawn) to the position shown in FIGS. 1 and 3 so that the narrower portion 56 of its keyhole-shaped aperture 53 is fitted into the carriage groove 64, capturing and holding the carriage 60 and needle 70 in their forward positions--against the force of the spring 80. At this stage, the device 10 with associated cannula 11 is ready for use.
Now in proper use a medical professional manipulates the device 10, holding it by the handle housing 20, to pierce the patient's skin and target-vessel wall--and thereby insert the piercing point 73 and cannula tip 90 into the target vessel. Once this occurs, a small volume of the patient's blood, the flash blood, is forced through the passage of the hollow needle 70 by the patient's blood pressure and flows into the flash chamber 61--readily expelling before it from the chamber a like volume of air, through the filter 62.
The blood itself, however, is substantially obstructed by the filter and so is substantially completely confined within the chamber 61, where the blood may be readily observed to confirm proper insertion of the needle and catheter. Once the flash blood has been observed, the medical practitioner then withdraws the needle 70 from the patient's body while maintaining the cannula 11 in place.
At this juncture the device 10 contains a quantity of the patient's blood within the flash chamber 61, and the needle 70--both externally and within its hollow passage--is contaminated with a small quantity of the patient's blood. Thus in accordance with preferred safety practice the device 10 should be discarded with due care for the possibility of infecting people with that blood.
As in use of the Kulli device, the practitioner is able to retract the needle 70 to a safety or retracted position such as shown in FIGS. 2 and 4 by operating the trigger 50--that is to say, by forcing the lock slider/trigger 50 downward (as drawn) to bring the circular, larger-transverse-dimension portion 55 of the keyhole aperture 52 once again into alignment with the front end 65 of the needle carriage 60 as shown in FIG. 4. (The trigger guard 25 helps avoid inadvertent premature operation of the trigger.)
The larger-dimension portion 55 of the aperture 52, as noted earlier, is big enough for passage therethrough of the front end 65 of the carriage 60; therefore in this juxtaposition of the parts the locking action of the slider 50 upon the carriage 60 is released, no longer opposing the restoring force of the spring 80. In consequence the spring accelerates the needle carriage 60 rearward through the passage 24 of the handle housing 20--to the position shown in FIG. 2.
In that position the entirety of the needle 70, including the piercing point 73, is withdrawn into the interior of the frontal housing 30 and thus is no longer able to puncture the skin of the practitioner or anyone else. The end plug 85 blocks movement of the carriage 60 through the aperture at the rear end 22 of the handle housing 20 and so keeps the carriage 60 and needle 70 within the handle.
Importantly with respect to the present invention, the retracting rearward flight of the needle moves air quickly through the passage 24 of the hollow handle 20. By virtue of openings in the grill 86 and the air-leakage path forward around the needle carrier block, however, retraction develops relatively little air pressure increase within the passage 24.
To the extent that retraction may produce a brief pressure pulse in the passage 24, the filter acts essentially as an air-impermeable wall or piston tending to isolate the interior of the flash chamber 61 from such pressure. In consequence any piston-effect pressure developed during retraction is not applied to the blood in the flash chamber 61, and that blood is not expelled forward and outward through the hollow needle but rather is safely retained within the chamber.
The small lateral port 27 through the cylindrical wall 21 of the handle housing 20 facilitates introduction of a small quantity of viscous material, such as lubricant, into the interior of the passage 24. This viscous material provides the desired energy absorption mentioned earlier.
By virtue of this energy absorbing, a relatively strong spring 80 or other biasing element may be employed for reliable retraction--but without incurring undesirably loud or violent operation in some production units whose manufacturing tolerances aggregate toward maximum retraction speed. In this regard it has been found particularly satisfactory to use a spring that exercises a force in the range of 33 to 40 Newtons per meter (3 to 3.6 ounces per inch) of compression from its relaxed position.
A nominal or ideal value is roughly 37 N/m (3.3 oz/in)--amounting to a nominal 2.2N (8 oz) at 6.1 cm (2.4 inch) compression. The viscous material may be a lubricant such as "High Vacuum Grease" available from the Dow Corning Company.
Merely for purposes of placing these values within the environment of a practical device, and not to limit the scope of the invention as claimed, it is preferred to use these dimensions:
8.6 cm (3.4 inch) length from the rear end of the handle to forward surface of the frontal housing;
5.1 cm (2.0 inch) length from the forward surface of the frontal housing to the tip of the needle;
1.1 cm (0.42 inch) outside diameter of the frontal housing;
0.8 cm (0.30 inch) outside diameter of the handle grip surface;
0.46 cm (0.18 inch) inside diameter of the handle bore near the trigger, with fabrication tolerance of ±0.005 cm (±0.002 inch);
3.0 cm (1.18 inch) overall length of the carrier block;
0.94 cm (0.37 inch) effective length of the segment of the carrier block over which the spring is coiled;
0.33 cm (0.13 inch) outside diameter of that same segment of the carrier block, with fabrication tolerance of ±0.0025 cm (±0.001 inch);
1.8 cm (0.72 inch) length of the remainder of the carrier block--that is, the exterior length of the flash-chamber segment;
1.7 cm (0.67 inch) interior length of the flash chamber;
0.44 cm (0.175 inch) outside diameter of the flash chamber;
0.32 cm (0.125 inch) inside diameter of the flash chamber; and
0.22 cm (0.085 inch) inside diameter of the lubrication port.
For satisfactory operation it is also important to avoid underfilling, overfilling or misfilling the device. Underfilling tends to lead to inadequate energy-absorbing effect, and overfilling tends to make the effect excessive--or, in other words, to render retraction unreliable or possibly, in extreme cases, even to consistently prevent retraction.
To avoid such adverse phenomena the lubricant introduction techniques should be carefully developed to ensure that the lubricant is reasonably well distributed about the needle carrier block and in particular fills the region of the spring coils--but does not extend much rearward along the flash chamber 61. Grease must be kept away from the open rearward end of the needle lumen.
It has not been attempted to measure the speed of retraction or the jerk applied to the handle (and thereby to the hand of the operator) with vs. without the lubricant. Rather, the criteria used for success of the lubricant energy-absorbing technique of the invention have been the satisfaction with and acceptance of the operation by medical personnel.
By those criteria this energy-absorbing technique of the invention has been found to be a total success. In particular it has been found that the invention not only avoids startling or annoying operators, but goes further to convey an operational perception, sensation or so-called "feel" that is very solid, positive and professional--and accordingly enhances significantly the acceptance of the device in the field. Furthermore, no significant variation in at least these perceptions was noted as among different production units.
A grill 86 supported within the end plug 85 is provided to frustrate attempts to redeploy the needle 70 (as by inserting a screwdriver, paperclip or like tool to push the needle forward) for reuse. The grill 86 may be cruciform as illustrated, but other adequately strong grill patterns that significantly deter insertion of such tools will serve equally well.
Some prospective reusers may be so determined that they use cutting tools or breaking techniques for access to the needle; accordingly, complete prevention of discarded-device abuse may not be physically possible. Some device configurations, however, such as the grill 86 illustrated, do protect at least against more ordinary efforts such as insertion of pushing tools.
Although it is preferable to use as the receiving and retaining means a movable interior chamber 61 and associated filter 62 as in FIG. 1, alternative means as mentioned earlier may be employed instead. For example, flash blood may be received from within the hollow needle 170 (FIG. 6) and reliably retained, during and after retracting of the needle, in a chamber 161 that is associated with, fixed to, or even integral with the handle housing 120.
In such a configuration it is appropriate to provide some means for transmitting blood from within the hollow needle into the chamber, substantially without transmitting into the chamber the compressive force that is developed in the course of retraction. Such a transmitting means may take the form of a flexible tube 163 that interconnects for fluid communication the interior of the flash chamber 161 with the needle lumen.
During retraction the forward end 163f of the flexible tube 163 moves with the needle while the rearward end 163r of the same tube 163 remains fixed to a tubular extension 161f at the front end of the chamber 161 and thus to the handle housing 120. The intervening long segment 163i of the tube 163 takes up the differential motion by bodily deformation.
To facilitate this operation the intervening portion 163i of the tube may if desired be coiled slightly as shown, to facilitate an orderly arrangement of that portion 163i during retraction. This may help avoid its obstructing the advancing needle carriage 160--as for example by tangling, or catching between the advancing needle carriage 160 and the interior bore of the cylindrical handle wall 121. A slightly longer handle 121 is preferred to accommodate the coiled tube 163 after retraction. During flash acquisition, air is exhausted at the rear of the assembly through, for example, a lateral port 162 as in other fixed-flash-chamber devices.
Conceptually somewhat related to the receiving and retaining system of FIG. 6 is a likewise flexible element 262 (FIG. 7) that operates by resilient deformation to take up dimensional differences--but here these are differences between pre- and postflash dimensions, rather than pre- and postretraction dimensions. In this case the flexible element is a translucent or transparent balloon 262 that serves as the flash chamber.
The balloon chamber 262 is initially flattened, thus enclosing very little air, and expands with introduction of flash blood through the needle 270--thereby eliminating the need for a selective filter, vent system or the like for exhaust of displaced air and retention of blood. Upon retraction the balloon chamber 262 is protected against potentially compressive forces within the handle 220 by a relatively stiffer plastic sleeve 261.
As can be seen, this FIG. 7 embodiment is also to an extent conceptually related to that of FIGS. 1 through 5, in that the balloon chamber 262 and sleeve 261 during retraction move with the needle. Other forms of receiving and retaining means within the scope of our invention may be seen as related instead to the system of FIG. 6 in that a chamber is associated with the handle housing rather than with the needle--and a filter or vent system accommodates air exhaust ahead of the flash--but no flexible member is used to accommodate dimensional changes.
For example, one of such other forms employs instead a frangible duct 363 (FIG. 8) for directing flash blood from the needle 370 lumen to a flash chamber 361 fixed to or integral with the handle 320--as for example an annularly arranged chamber 361. In retraction the breakaway duct 363 is left loose within the handle 320.
Another of such forms employs a pivoted flapper-style valve 463 connected to the needle-carriage 460 (FIG. 9) for admitting flash blood from the needle 470 lumen directly to the interior of the passage 424 within the hollow handle 420--and for blocking return passage of that blood from the passage 424 into the lumen in retraction.
Other forms of energy-absorbing means too are, analogously, within the scope of the invention. For instance a crushable element--such as a crushable type of filter 62' (FIG. 1a)--at the rear of the flash chamber may be substituted for the hydrophilic or like filter discussed earlier. The crushable filter may be for instance a sintered plastic unit commercially available from the Porex Company. Alternatively a crushable element in the form of fine molded vanes or the like may be used instead.
Another usable energy absorber is a separate bearing element 227 (FIGS. 7, 7a) may be fixed to the needle--preferably carried in the needle carriage 260--and biased laterally (e.g., radially outward) as by a crescent spring 227s against the interior cylindrical surface 221 of the hollow handle housing 220.
Also available is the converse system--that is to say, a separate bearing element (not illustrated) carried in the inner cylindrical surface 221 of the housing 220 and bearing against a surface fixed to the needle--preferably carried on the carriage 260. Either of these biased-element systems is believed to provide drag or damping as desired.
Yet another form of energy-absorbing means is a dashpot piston 427 (FIG. 9) fixed at the end of the needle for developing damping, during retraction, through friction with liquid--and more specifically the flash blood--inside the hollow handle 420. For manufacturing convenience this dashpot element 427 is advantageously integrated with the check valve 463 discussed earlier.
Other forms of redeployment-deterring means too are within the scope of the invention. For example the two end walls of a flash chamber 161 (FIG. 6) that is firmly fixed to the rear of the hollow handle 120 also form a complete obstruction of the hollow handle 120--thus deterring insertion of a tool through that rear portion of the handle to redeploy the needle 170. This would remain essentially true even if a puncturable filter, forming the rear of the chamber, were provided in place of the lateral port 162--as the forward wall of the chamber would still provide a near-complete barrier.
As another example, a labyrinthine end plug 286 (FIG. 7) can serve to exhaust air from the internal passage 221 of the handle housing 220, while entirely blocking insertion of a tool into the housing 220 to redeploy the needle. Alternatively air exhaust can be effected through relief ports 362 (FIG. 8) formed laterally, e.g., radially, through the cylindrical wall 321 of the handle housing 320--rather than longitudinally at the end of the housing 320--thereby permitting use of an entirely solid endcap 285 to obstruct tool insertion.
Still further, abuse-deterring means may take the form of a ratchet element 486a (FIG. 9), cooperating with the narrow portion 56 (FIG. 4) of the keyhole aperture in the lock slider/trigger 450, to prevent resetting of the trigger 450 after the assembly has been first made ready for use. As will be understood the mechanism must permit resetting of the trigger 450 one initial time, since this is the procedure by which the needle is deployed initially for its intended use.
Analogously, further abuse-deterring means may take the form of a ratchet-like element 486c which upon retraction falls in front of the needle 470 piercing end, to block subsequent forward movement of the needle.
It will be understood that the foregoing disclosure is intended to be merely exemplary, and not to limit the scope of the invention--which is to be determined by reference to the appended claims. | Leakage of blood from the insertion set, during and after safety-needle retraction, is suppressed by components that receive and retain flash blood for viewing--notwithstanding forces developed within the device in retraction. One preferred such system includes a flash chamber that moves with the retracting needle, within a hollow handle, carrying a relatively high flow-impedance element which allows air exhaust from the chamber into the handle to admit flash blood--but isolates blood in the chamber from retraction-generated increase in air pressure in the handle. Energy-absorbing components control or compensate for retraction speed, to provide quiet smooth retraction--while yet enabling use of ample retraction force to make retraction reliable. Among several energy absorbing systems disclosed is a preferred one that includes a viscous material introduced within the hollow handle to damp the retracting motion; and an injection port to facilitate introduction of the viscous material. Needle reuse, and concomitant risk of spreading disease, are avoided through components that deter needle redeployment--by deterring access to or forward motion of the needle, or trigger reengagement. | 0 |
CROSS REFERENCE TO RELATED APPLICATIONS
The present application claims the benefit of Great Britain Patent Application No. 1121818.7, filed Dec. 19, 2011, and Great Britain Patent Application No. 1204224.8, filed Mar. 9, 2012, and Great Britain Patent Application No. 1210908.8, filed Jun. 20, 2012, and Great Britain Patent Application No. 1220993.8, filed Nov. 22, 2012, the disclosure of each of which is hereby incorporated by reference.
RELATED ART
1. Field of the Invention
The present invention relates to a thermal window for an electronic control box containing at least one electronic component. The at least one electronic component is typically partially or completely enclosed in the electronic control box, the thermal window providing for diagnostic inspection of the at least one electronic component therein. The thermal window can be fitted to the electronic control box when it is manufactured or retrofitted to an existing electronic control box. The present invention also relates to a method of monitoring the thermal behaviour of the at least one electronic component.
2. Brief Discussion of Related Art
In-situ monitoring of the performance and behaviour of engineering equipment, and in particular of control electronics and electronic components, is generally desirable to maintain optimal performance of the electronic components, to diagnose potential problems at an early stage, and thus to reduce or avoid major system problems and breakdowns. It is particularly desirable if diagnostic procedures can be carried out in-situ whilst the electronic components are functioning, to avoid expensive periods of down time.
Manufacturers, hotels and leisure facility providers in particular reply upon lighting, heating and/or system automation that all use electricity. The equipment used should be monitored to ensure it is safe because electricity is potentially harmful. Death by electrocution caused by direct contact with a live conductor or via an arc-flash explosion due to the catastrophic failure of the equipment is a daily risk to all users of the equipment.
Monitoring the thermal behaviour of electronic components and systems is known as an effective diagnostic tool for the evaluation of performance and the early identification of potential problems. Producing and analysing thermal images of such systems by means of suitable thermal imaging equipment can be a valuable aid in this regard. However, problems arise where the electronic components or systems are wholly or partially enclosed within the overall apparatus, for example behind a control panel and/or within a control box, and as a result are not readily accessible and/or visible for such analysis.
To carry out an evaluation of such electronic components it is commonly necessary first to shut down the apparatus, then to open the box or other enclosure of the control electronics, trip any safety device which is likely to be in place to prevent operation of the apparatus in such a state, and subsequently to restart the apparatus to perform the analysis. This is likely to lead to long periods of down time, may have safety implications since the apparatus is being operated in a fundamentally unsafe state, and in relation to certain apparatus and processes may not be possible.
In such circumstances, the fitment of thermally transparent windows within the walls of the control panel, box or other enclosure has been proposed to enable the thermal monitoring of electronic components and systems there within. Such windows may be provided at the time of manufacture of the apparatus or can be retrofitted.
INTRODUCTION TO THE INVENTION
In accordance with a first aspect of the present invention there is provided a thermal window comprising: (a) a thermally transparent window member, (b) a window frame for receiving the thermally transparent window member, (c) at least one transmitter configured to transmit electromagnetic radiation with a frequency from 3 Hz to 300 GHz, and (d) a cover for protecting the thermally transparent window member, wherein optionally the cover is mounted to the window frame by a spring loaded hinge.
The at least one transmitter may be configured to transmit electromagnetic radiation with a frequency from 433 to 435 MHz, normally from 433.050 to 434.790 MHz, typically 433 MHz. The electromagnetic radiation with a frequency from 433.050 to 434.790 MHz, from 433 to 435 MHz, or 433 MHz may be a Wi-Fi™ signal. The at least one transmitter may be configured to transmit the Wi-Fi™ signal. The at least one transmitter may be referred to as a Wi-Fi™ transmitter.
The at least one transmitter may be configured to transmit electromagnetic radiation with a frequency from 300 MHz to 300 GHz. The electromagnetic radiation with a frequency from 300 MHz to 300 GHz may be microwave radiation. The electromagnetic radiation with a frequency from 300 MHz to 300 GHz may be a Wi-Fi™ signal.
The at least one transmitter may be configured to transmit electromagnetic radiation with a frequency from 2.4 GHz to 2.5 GHz, normally from 2.400 GHz to 2.500 GHz. The electromagnetic radiation with a frequency from 2.400 GHz to 2.500 GHz or from 2.4 GHz to 2.5 GHz may be a Wi-Fi™ signal.
The Wi-Fi™ signal may be an Industrial, Scientific and Medical (ISM) radio band signal. The power of the Wi-Fi™ signal may be low and/or may be less than or equal to 0 dBm. The range of the Wi-Fi™ signal may be short and/or may be less than or equal to 20 m, normally less than or equal to 2 m, typically less than or equal to 1 m.
The at least one transmitter may transmit information and thereby enable a suitably enabled thermal imager or thermal imaging camera to receive information about the thermal window. The information from the at least one transmitter may be up-to-date, that is current and/or not historical.
The information from the at least one transmitter may include the temperature of the thermal window. The information from the at least one transmitter may include the temperature of the thermally transparent window member. The temperature may be the optic temperature.
The temperature may be measured by a thermometer that is in contact with the thermal window or thermally transparent window member and connected to or in communication with the at least on transmitter. The thermometer may be able to detect temperatures of −10C to +60° C. The thermometer may have an accuracy of ±5%.
The temperature may be measured by a thermocouple and/or resistance temperature detector (RTD) that is in contact with the thermal window or thermally transparent window member and connected to or in communication with the at least one transmitter. The thermocouple and/or resistance temperature detector (RTD) may be able to detect temperatures from −10C to +60° C. The thermocouple and/or resistance temperature detector (RTD) may have an accuracy of ±5%.
The information from the at least one transmitter may include usage statistics for the thermal window. The usage statistics may be one or more of a unique identification number or code for a particular thermal window; the current date and/or time; the date and/or time of an earlier inspection of electronic components using the thermal window; and the charge status of a battery used to power the at least one transmitter.
The thermal window may comprise at least one transponder. The at least one transponder may be configured to transmit electromagnetic radiation with a frequency from 3 Hz to 300 GHz, typically from 13 to 14 MHz in response to an interrogating received electromagnetic signal. The electromagnetic signal may be a magnetic field and/or electromagnetic induction.
The at least one transponder may transmit electromagnetic radiation with a frequency from 13.553 to 13.567 MHz and typically 13.5 MHz. The at least one transponder may be a radio-frequency identification (RFID) device, also referred to as an RFID tag. The RFID device may be a high frequency RFID tag.
The RFID tag may comprise a radio-frequency electromagnetic field coil configured to modulate an external electromagnetic field and thereby transfer a coded identification number when queried by a reader device. The reader device may transmit the external electromagnetic field or interrogating received electromagnetic signal and may be an RFID enabled device, for example thermal imaging equipment such as a thermal imaging camera.
The at least one transponder may be configured to transmit a radio-frequency identification signal with a high frequency, that is frequency from 10 to 15 MHz, typically 13.5 MHz. Using high frequency reduces the likelihood of interference with an identification signal transmitted by nearby or adjacent electronic equipment.
The at least one transmitter and/or at least one transponder may be in the window frame and/or cover and may be encased in the window frame and/or cover. In an alternative embodiment the at least one transmitter and/or at least one transponder may be positioned adjacent to the window frame.
The RFID device may be capable of transmitting information about the particular window being monitored. The information may for example be about the location of the thermal window and the transmission characteristics of the corresponding thermally transparent window member. Such information can be linked to the infrared image taken so that the operator can more easily catalogue and store images for historical analysis and trending. The transmission characteristics may enable the user to correct for any attenuation caused by the thermally transparent window member either manually or automatically within a thermal imaging camera, thus providing fast and accurate measurement of internal components
The RFID device may enable an RFID enabled thermal imager or thermal imaging camera to communicate with the thermal window and as such correct the reading taken by the thermal imager or thermal imaging camera for any error due to the crystal optics of the thermally transparent window member.
The RFID device may be programmable either at the factory or in the field and may include information about the type of thermal window, its transmission characteristics, location and other information about its manufacture.
In an alternative embodiment the thermal window may include a barcode or serial number. In a further alternative embodiment the barcode or serial number may be positioned adjacent to the window frame. The barcode or serial number may perform a similar function to the RFID device.
The RFID device, barcode and/or serial number may provide the thermal imaging equipment, for example a thermal imaging camera, with information about the location of the thermal window and/or the transmission characteristics of the corresponding thermally transparent window member.
In use, the thermal window serves to provide a physical barrier between electronic equipment inside a control box and the operator of for example thermal imaging equipment used to collect information about the thermal behaviour of the electronic equipment. It will be understood that there are a number of reasons why this might be desirable, including physical protection of the equipment and the safety of the operator. The electronic equipment may be referred to as switchgear.
Information from the at least one transmitter and/or at least one transponder may include data about the electronic equipment. The data may relate to the operation of the electronic equipment. The data may relate to the current and/or voltage ratings of the electronic equipment.
The at least one transmitter may be powered by a battery. The battery is typically replaceable. The battery is normally a button cell battery.
The Wi-Fi™ transmitter and RFID tag typically use electromagnetic radiation as a means to communicate information but may operate and/or function differently. The Wi-Fi™ transmitter may be powered by, for example, a battery. The battery may provide the Wi-Fi™ transmitter with power to transmit a signal, in the form of electromagnetic radiation, and thereby provide two-way communication between the Wi-Fi™ transmitter and another Wi-Fi™ enabled device, for example thermal imaging equipment such as a thermal imaging camera. The two-way communication typically means that the Wi-Fi™ transmitter both listens for and responds to a signal from the thermal imaging equipment. The Wi-Fi™ transmitter typically sends an electromagnetic signal for detection by another Wi-Fi™ enabled device, able to receive that signal, for example thermal imaging equipment such as a thermal imaging camera.
In contrast, an RFID tag is typically not powered. An RFID tag typically provides one-way communication with another RFID enabled device, for example thermal imaging equipment such as a thermal imaging camera. An electromagnetic signal sent by an RFID enabled device is typically only reflected by the RFID tag.
The Wi-Fi™ transmitter may have an electronic memory for the storage and transmission of information. The RFID tag may not have any electronic memory.
The window frame may have a first surface with a recess to receive the thermally transparent window member. The thermally transparent window member may be engageable within the recess such that at least an edge portion of a first face of the thermally transparent window member contacts the first surface of the window frame.
The thermal window may include a securing seal engageable with the first surface of the window frame and so configured to hold the thermally transparent window member in the recess.
The cover may be engageable with a second surface of the window frame.
In accordance with a second aspect of the present invention there is provided a thermal window comprising: (a) a window frame having a first surface with a recess to receive a thermally transparent window member, the thermally transparent window member being engageable within the recess such that at least an edge portion of a first face of the thermally transparent window member contacts the first surface of the window frame, (b) a securing seal engageable with the first surface of the window frame and so configured to hold the thermally transparent window member in the recess, (c) at least one transmitter configured to transmit electromagnetic radiation with a frequency from 3 Hz to 300 GHz, and (d) a cover to protect the thermally transparent window member, the cover being engageable with a second surface of the window frame and wherein optionally, the cover is mounted to the window frame by a spring loaded hinge.
The at least one transmitter may be configured to transmit electromagnetic radiation with a frequency from 433 to 435 MHz, normally from 433.050 to 434.790 MHz, typically 433 MHz. The electromagnetic radiation with a frequency from 433.050 to 434.790 MHz, from 433 to 435 MHz, or 433 MHz may be a Wi-Fi™ signal. The at least one transmitter may be configured to transmit the Wi-Fi™ signal. The at least one transmitter may be referred to as a Wi-Fi™ transmitter.
The at least one transmitter may be configured to transmit electromagnetic radiation with a frequency from 300 MHz to 300 GHz. The electromagnetic radiation with a frequency from 300 MHz to 300 GHz may be microwave radiation. The electromagnetic radiation with a frequency from 300 MHz to 300 GHz may be a Wi-Fi™ signal.
The at least one transmitter may be configured to transmit electromagnetic radiation with a frequency from 2.4 GHz to 2.5 GHz, normally from 2.400 GHz to 2.500 GHz. The electromagnetic radiation with a frequency from 2.400 GHz to 2.500 GHz or from 2.4 GHz to 2.5 GHz may be a Wi-Fi™ signal.
The thermal window may comprise at least one transponder. The at least one transponder may be configured to transmit electromagnetic radiation with a frequency from 3 Hz to 300 GHz, typically from 13 to 14 MHz, optionally from 13.553 to 13.567 MHz and typically 13.5 MHz. The at least one transponder may be a radio-frequency identification (RFID) device, also referred to as an RFID tag. The RFID device may be a high frequency RFID tag.
The cover may protect the first face of the thermally transparent window member.
The cover may be moveable from a first position in which it protects the thermally transparent window member to a second position in which the thermally transparent window member is exposed and accessible to for example thermal imaging equipment such as a thermal imaging camera.
The cover may be partially or completely transparent or opaque. The cover may be partially or completely made of poly (methyl methacrylate) or PMMA, also referred to as acrylic glass, Plexiglas™, Lucite or Perspex™. Alternatively the cover may be partially or completely made of polycarbonate or PC, also referred to as Lexan™.
The cover is typically attached to the window frame and therefore captive. This has the advantage that it increases the speed at which an operator can open or remove the cover from over the thermally transparent window member, take a reading and replace the cover.
When the cover is mounted or attached to the window frame by the spring loaded hinge, then in use the cover is not disconnected from the window frame and this mitigates the risk of the cover being misplaced.
The spring loaded hinge may be biased to hold the cover in the second, open position in which the thermally transparent window member is exposed. The spring loaded hinge means the thermal window can be attached to a control box in any orientation. Even if the hinge is at an uppermost edge of the window frame, the cover will still be biased towards the second, open position in which the thermally transparent window member is exposed. This is important because it allows the thermal window to be positioned on the control box so the thermal window is most accessible and the cover of the thermal window is least likely to obstruct other control means, including emergency control buttons.
The thermally transparent window member may be made of a material that is transparent to infrared radiation and a material therefore that infrared radiation is able to pass through. The material may be a glass or plastic or a crystalline material. The thermally transparent window member maybe made from calcium fluoride, sapphire glass, PoIyIR™ polymer or any other suitable material or combination of materials that allows infrared transmission in the wavelength range of from 0.5 μm to 14 μm.
The thermal imaging equipment may communicate with a data server. The data server may be remotely located. Information held on the data server may also be available to the thermal imaging equipment. Data communication between the thermal imaging equipment and the data server may be two-way. The data server may provide the thermal imaging equipment with information about the infrared transmission of the thermally transparent window. This may allow for real-time adjustment of any image obtained by the thermal imaging equipment to correct for the particular infrared transmission of the particular thermally transparent window.
Information about the infrared transmission of the thermally transparent window may be uploaded to the data server when the thermal window is manufactured or may be uploaded later.
The thermal imaging equipment may communicate directly with the data server or via for example, a computer or PDA (Personal Digital Assistant) onto which data from the thermal imaging equipment has been downloaded. The thermal imaging equipment, computer or PDA and data server may be used in combination to create a schedule of the monitoring required and/or maintenance of the electronic components.
Data collected by the thermal imaging apparatus may be saved in a database on the data server and indexed to a particular thermal window so that an operator of the electronic equipment can monitor or track potential problems or low-level faults.
The at least one transmitter may be configured to transmit information that is unique to the particular thermal window.
The cover may be secured to the window frame by a locking mechanism including a fastener or locking screw. The fastener may be captive and therefore remain attached to the window frame or cover when the cover is in both the first and second positions.
The fastener may comprise a lock and socket. The lock may be attached to the cover and the socket attached to or part of the window frame. The lock and socket may be a quarter-turn locking mechanism that requires the lock to be rotated by about 90 degrees or a quarter-turn to move the lock in the socket from a locked position to an unlocked position. In the locked position the lock engages with the socket to hold the cover in the first, closed position against the window frame. In the unlocked position the lock is movable in the socket such that the cover can be moved or can move by action of the spring loaded hinge from the first closed position to the second open position.
The quarter-turn lock means that an operator can quickly remove or move the cover to expose the thermally transparent window member, take the necessary reading and replace the cover. In use the lock may remain attached to the cover and this mitigates the risk of the lock being misplaced.
The locking mechanism may be a push-to-release catch. The operator may push the cover towards the window frame to release the cover from the frame and thereby move the cover to the second open position. The operator may push the cover towards the window frame to latch the cover to the window frame and thereby move the cover to the first closed position.
There may be a first seal, optionally an o-ring seal between the window frame and the control box. The o-ring may provide a seal that engages a surface around a suitable aperture in the control box so as to seal the window frame (and so also the thermally transparent window member) in position over the aperture in the casing of the electronic control system. There may be a second seal between the thermally transparent window member and the window frame.
The first and/or second seal may provide a moisture-tight seal between inside and outside of the control box. The first and/or second seal may be made of a silicone-based material. For many applications it will be desirable for the thermal window to co-operate with casing of the control box to create a closed, controlled environment for the equipment in the control box (for example to prevent ingress of dust, moisture, or the like).
The thermal window may be attached to the control box by securing means. The securing means may comprise mechanical fixings. The securing means may be one or more screw(s) or nut(s) and bolt(s) and may fit into one or more apertures in the window frame. The securing means may comprise one or more spring clip(s) attached to the thermal window and typically attached to the window frame. Each spring clip may have a leg that, when the thermal window is being installed, is pushed through a suitable aperture in the control box and engages an inner surface of the control box to hold the thermal window against an outer surface of the control box. The spring clip may be prevented from being pulled back through the aperture in the control box by a locking pin that passes through a portion of the spring clip to lock the leg in position against the inner surface of the control box.
There may be a gasket between the cover and the window frame. The gasket may be between the cover and the second surface of the window frame.
The gasket may be attached to the cover. When the gasket is attached to the cover and the cover is in the second position, the thermally transparent window member is exposed and the securing means of the window frame are also exposed, allowing relatively easy removal and/or subsequent replacement of the thermal window.
The gasket attached to the cover may comprise a face-seal. The gasket may include at least one protrusion, that when the cover is in the second closed position, penetrates into the one or more apertures in the window frame. When the cover is in the second closed position, the gasket and protrusions from the gasket may reduce the chance of fluid such as water penetrating the cover and coming into contact with the thermally transparent window member providing an additional seal against water penetration into the control box.
Attaching the gasket to the cover and not the window frame reduces the time required to install the thermal window on the control box because there is no need for the installer to fit the gasket, rather the gasket has been fitted to the cover during manufacture of the thermal window.
Monitoring the thermal behaviour of electronic components and systems provides for the detection of low-level faults that are power hungry or cause an increase in the power consumption of the particular electronic component. These low-level faults generate heat. This heat contributes to the electrical inefficiency of the electrical component but the heat generated may not be sufficient to raise an alarm such as fire alarm. If the low-level faults can be quickly and/or routinely identified then the energy efficiency of the electronic component can be maximised, thereby reducing the carbon foot-print of the electronic component and improving its eco-credentials.
It will be understood that one purpose of the thermally transparent window member is to afford a degree of protection to the electronic equipment in the control box whilst enabling observation thereof by suitable thermal imaging means. Accordingly the thermally transparent window member must afford a degree of effective thermal transparency. In many circumstances, particularly where an environmentally sealed unit is desirable, this will most readily be achievable by use of a thermal window comprising an integral thermally transparent window member fabricated of material exhibiting reasonable infra-red transparency. Nevertheless, the invention is not so restricted, and it might be envisaged, particularly in circumstances where a high degree of environmental protection was not required, that the window member could constitute a mesh-like element, achieving the required degree of effective transparency by virtue of the apertures within the mesh.
The window member may be fabricated from a material exhibiting inherently high thermal transparency at the infra-red frequencies to be investigated. Suitable materials will be known to those skilled in the art, and will include specialist glasses and single crystal materials.
The optional features of the first aspect of the present invention can be incorporated into the second aspect of the present invention and vice versa.
In accordance with a third aspect of the present invention there is provided a method of monitoring the thermal behaviour of at least one electronic component, the at least one electronic component being at least partially enclosed, the method comprising the steps of: (a) providing a thermal window as described herein; (b) turning the fastener to release the cover, allowing the cover to move from the first closed position to the second open position; (c) monitoring the thermal behaviour of the at least one electronic component through the thermally transparent window member; (d) moving the cover from the second open position to the first closed position; and (e) turning the fastener to secure the cover to the window frame.
Turning the fastener may involve turning it by between 70 and 110 degrees. Preferably the fastener is turned by between 80 and 100 degrees, normally 90 degrees. The fastener may be rotated by a quarter-turn.
Monitoring the thermal behaviour of the at least one electronic component may be achieved using the thermal imaging equipment.
The thermal window may include at least one transmitter configured to transmit electromagnetic radiation with a frequency from 3 Hz to 300 GHz, typically from 433 to 435 MHz. The at least one transmitter may be configured to transmit a Wi-Fi™ signal. The at least one transmitter may be referred to as a Wi-Fi™ transmitter. The method may further include the step of scanning the at least one transmitter to read the information transmitted by the at least one transmitter.
The thermal window may comprise at least one transponder. The at least one transponder may be configured to transmit electromagnetic radiation with a frequency from 3 Hz to 300 GHz, typically from 13 to 14 MHz. The at least one transponder may be a radio-frequency identification (RFID) device, also referred to as an RFID tag. The RFID device may be a high frequency RFID tag. The method may further include the step of scanning the at least one transponder to collect the information stored by the at least one transponder.
The thermal window may include the Wi-Fi™ transmitter and RFID device. In an alternative embodiment the Wi-Fi™ transmitter and/or RFID device may be positioned adjacent to the window frame. The Wi-Fi™ transmitter and/or RFID device may be in the window frame and/or cover and may be encased in the window frame and/or cover. The Wi-Fi™ transmitter and/or RFID device may be capable of transmitting information about the particular thermal window being monitored. The information may include data pertaining to the location and/or physical characteristics of the thermal window. The information may be transmitted to thermal imaging equipment such as a thermal imaging camera.
The at least one electronic component may be at least partially or totally enclosed in a control box.
The method may further include the step of communicating data between a data server and the thermal imaging equipment. The data transmitted may provide the user of the thermal imaging equipment with a route for monitoring and/or the maintenance required on the at least one electronic component. The user of the thermal imaging equipment may be provided with a schedule of the monitoring and/or maintenance required.
The optional features of the first and second aspects of the present invention can be incorporated into the third aspect of the present invention and vice versa.
In accordance with a fourth aspect of the present invention there is provided a method of monitoring the thermal behaviour of at least one electronic component through a thermal window, the method comprising the steps of: (a) providing the thermal window comprising at least one transmitter configured to transmit electromagnetic radiation with a frequency from 3 Hz to 300 GHz and a thermally transparent window member with a cover for protecting the thermally transparent window member, wherein optionally, the cover is mounted to the thermal window by a spring loaded hinge, the spring loaded hinge acting against the cover; (b) operating a locking mechanism to release the cover, allowing the cover to move from a first closed position in which it protects the thermally transparent window member to a second open position; (c) monitoring the thermal behaviour of the at least one electronic component; and (d) scanning the at least one transmitter.
The at least one transmitter may be configured to transmit electromagnetic radiation with a frequency from 433 to 435 MHz.
The optional features of the first, second and/or third aspects of the present invention can be incorporated into the fourth aspect of the present invention and vice versa.
BRIEF DESCRIPTION OF THE DRAWINGS
An embodiment of the invention will now be described by way of example only and with reference to the accompanying drawings.
FIG. 1 is an exploded view of the thermal window in accordance with an aspect of the present invention;
FIG. 2 a is a side view of the assembled thermal window of FIG. 1 when the cover is in a first, closed position;
FIG. 2 b is a plan view of the cover of the thermal window of FIG. 1 in the first, closed position;
FIG. 2 c is a perspective view of the thermal window of FIG. 1 in the first, closed position;
FIG. 3 a is side view of the thermal window of FIG. 1 when the cover is in a second, open position;
FIG. 3 b is a plan view of the thermal window of FIG. 1 when the cover is in the second, open position;
FIG. 3 c is a top view of the thermal window of FIG. 1 when the cover is in the second, open position; and
FIG. 3 d is a perspective view of the thermal window of FIG. 1 when the cover is in the second, open position.
DETAILED DESCRIPTION
The exemplary embodiments of the present disclosure are described and illustrated below to encompass thermal window for an electronic control box containing at least one electronic component. Of course, it will be apparent to those of ordinary skill in the art that the embodiments discussed below are exemplary in nature and may be reconfigured without departing from the scope and spirit of the present disclosure. However, for clarity and precision, the exemplary embodiments as discussed below may include optional steps, methods, and features that one of ordinary skill should recognize as not being a requisite to fall within the scope of the present disclosure.
FIG. 1 shows the thermal window 10 , including a cover 14 , window frame 18 , thermally transparent window member 22 and securing seal 26 . FIG. 1 is an exploded, disassembled view of the thermal window 10 . The cover 14 has a transparent centre portion 15 , first hinge portion 16 and aperture 17 for receiving a fastener 30 .
FIG. 1 shows the forward facing surfaces of the various components of the thermal window 10 . The skilled reader will appreciate each of the components also has a corresponding rearward facing surface that is not shown in FIG. 1 .
In this embodiment an RFID tag 40 is located in the cover 14 . The RFID tag 40 fits into a hollow (not shown) in the rearward facing surface of the cover 14 . A gasket 19 is attached to and extends over the rearward facing surface of the cover 14 and RFID tag 40 . When assembled the outermost rearward facing surface of the RFID tag 40 is flush with the rearward facing surface of the cover 14 to which the gasket 19 is attached.
In this embodiment a Wi-Fi™ transmitter 44 is located in the cover 14 . The Wi-Fi™ transmitter 44 fits into a hollow (not shown) in the rearward facing surface of the cover 14 . A gasket 19 is attached to and extends over the rearward facing surface of the cover 14 and Wi-Fi™ transmitter 44 . When assembled the outermost rearward facing surface of the Wi-Fi™ transmitter 44 is flush with the rearward facing surface of the cover 14 to which the gasket 19 is attached.
The gasket 19 has an aperture 20 corresponding to the transparent centre portion 15 of the cover 14 and another aperture 21 in which the fastener 30 and a retainer 31 are located.
The window frame 18 has an aperture 23 corresponding to the aperture 20 of the gasket 19 and transparent centre portion 15 of the cover 14 . The window frame 18 also has screw holes 24 into which screws 25 can be located to hold the window frame and other parts of the thermal window to the control panel (not shown). The window frame 18 also has a socket 32 that cooperates with the fastener 30 .
In use the cover 14 is moved into a first position in which it covers and protects the thermally transparent window member 22 . The operator holds the cover 14 against the window frame 18 and turns the fastener 30 through 90 degrees or a quarter-turn so that the lugs 33 on the fastener 30 engage with and are retained in the socket 32 .
The window frame 18 has a second hinge portion 27 that cooperates with the first hinge portion 16 of the cover 14 . A pin 28 passes through holes 59 in the first hinge portion 16 and holes 58 a , 58 b in the second hinge portion 27 to secure the two portions together. The pin 28 passes through a spring 35 , the ends 36 , 37 of the spring 35 acting against the window frame 18 and the cover 14 , when the window frame 18 and cover 14 are connected together. The spring 35 is biased to move the cover 14 into the second, open position in which the thermally transparent window member is exposed, as shown in FIGS. 3 a to 3 d . The pin 28 has a flange 48 at one end and a threaded portion 49 at the other end. The threaded portion 49 cooperates with a threaded surface (not shown) inside hole 58 b of the second hinge portion 27 .
An o-ring 38 is located between the window frame 18 and thermally transparent window member 22 to provide a seal between the two components and prevent direct contact of the thermally transparent window member 22 and a recessed surface 39 of the window frame 18 . The o-ring 38 also reduces the likelihood of damage to the thermally transparent window member 22 due to its contact with the recessed surface 39 . The thermally transparent window member 22 is secured in the recess 39 of the window frame 18 by the securing seal 26 .
The securing seal 26 has a raised lip 29 . The raised lip 29 is part of the securing seal 26 and is compressed against the rearward face of the thermally transparent window member 22 when the thermal window 10 is attached to the control panel (not shown).
The raised lip 29 is outside the pitch circle diameter of the holes 43 to prevent moisture entering the control panel (not shown) via the holes 43 . The raised lip 29 may create a better seal between the securing seal 26 and thermally transparent window member 22 compared to a conventional o-ring.
The securing seal 26 has locating bars 41 that cooperate with slots 42 in the recessed surface 39 of the window frame 18 , to orientate the securing seal 26 and window frame 18 so that the screw holes 24 in the window frame 18 line up With the holes 43 in the securing seal 26 .
The thermal window 10 is attached to the control panel (not shown) using screws 25 . The screws 25 are pushed through the screw holes 24 in the window frame 18 and holes 43 in the securing seal 26 . The screws 25 are self-tapping screws and are turned so that they grip the outer edge of a corresponding pilot hole (not shown) that has been pre-drilled in the control panel (not shown).
The thermally transparent window member 22 is typically made of glass, transparent to infrared radiation. The thermally transparent window member 22 may comprise a single crystal or other suitable material exhibiting high transparency to infrared wavelengths. The window frame 18 and/or securing seal 26 and/or cover 14 is made of aluminium. The securing seal 26 is made of silicone, the silicone may be the type KSIL60. In an alternative embodiment the securing seal 26 is made of a nitrile-based material and in a further alternative embodiment it is made of a fluorocarbon-based material. The gasket 19 is a silicone gasket. The cover 14 is made of Plexiglas™. In alternative embodiments the cover may be made of any suitable transparent material including a suitable metallic material. The cover may be made of Lexan™.
The thermal window 10 is fitted in position over an aperture in a control panel (not shown) containing electronic equipment in accordance with the invention. The thermal window 10 allows examination of the electronic equipment (not shown) from a suitable external position using thermal imaging means (not shown).
FIGS. 2 a , 2 b and 2 c show a side, plan and perspective view respectively of the assembled thermal window 10 of FIG. 1 when the cover 14 is in a first, closed position. FIGS. 2 a and c show the cover 14 with first hinge portion 16 and fastener 30 . It also shows the window frame 18 with second hinge portion 27 and the securing seal 26 . FIG. 2 b shows the cover 14 with transparent centre portion 15 , first hinge portion 16 and fastener 30 .
FIGS. 3 a , 3 b , 3 c and 3 d show a side, plan, top and perspective view respectively of the thermal window of FIG. 1 when the cover 14 is in the second, open position.
FIG. 3 a shows the cover 14 and window frame 18 parallel or at 180 degrees to one another. FIG. 3 a also shows the fastener 30 and protrusions 47 from the gasket 19 and securing seal 26 .
FIGS. 3 b and d show the cover 14 , fastener 30 and gasket 19 . They also show the aperture 21 in the gasket 19 through which the fastener 30 passes. The gasket 19 has castellations 45 located between raised locating edges 46 of the cover 14 . The castellations 45 ensure that the gasket 19 is located correctly on the cover 14 such that the protrusions 47 from the gasket 19 are located in the screw holes 24 when the cover 14 is in the first, closed position. FIGS. 3 b and d also show the cover 14 with first hinge portion 16 and window frame 18 with second hinge portion 27 . The spring 35 is shown between the hinge portions 16 , 27 .
FIG. 3 c shows the cover 14 and fastener 30 .
There is also herein described a method of monitoring the thermal behaviour of an electronic component (not shown) enclosed in a control panel (not shown). The method uses a thermal window 10 as described herein.
First the operator turns the fastener 30 to release the cover 14 , allowing the cover 14 to move from the first closed position (as shown in FIGS. 2 a to c ) to the second open position (as shown in FIGS. 3 a to d ). The operator can then monitor the thermal behaviour of the electronic component through the thermally transparent window member 22 . Because the cover 14 is held in the second open position (as shown in FIGS. 3 a to d ) by the spring 35 acting between the hinge portions 16 , 27 , the operator does not need to hold the cover 14 away from the thermally transparent window member 22 .
The relative orientation of the thermal window 10 on the control box (not shown) does not affect the ability of the spring 35 loaded hinge 16 , 27 to hold the cover 14 in the second open position (as shown in FIGS. 3 a to d ).
When the operator has collected the data, the operator moves the cover 14 from the second open position (as shown in FIGS. 3 a to d ) to the first closed position (as shown in FIGS. 2 a to c ). The operator turns the fastener 30 to secure the cover 14 to the window frame 18 . In this embodiment the operator turns the fastener 30 by 90 degrees or a quarter-turn to secure the cover 14 to the window frame 18 and seal the thermally transparent window member 22 from external sources of dirt, dust and moisture.
The quarter-turn of the fastener 30 moves the lugs 33 on the fastener 30 relative to engaging surfaces (not shown) in the socket 32 between an engaged and disengaged position. In the engaged position the cover 14 is held against the window frame 18 ; in the disengaged position the cover 14 moves from the first closed position (as shown in FIGS. 2 a to c ) to the second open position (as shown in FIGS. 3 a to d ) under the bias of the spring 35 .
Following from the above description and invention summaries, it should be apparent to those of ordinary skill in the art that, while the methods and apparatuses herein described constitute exemplary embodiments of the present invention, the invention is not limited to the foregoing and changes may be made to such embodiments without departing from the scope of the invention as defined by the claims. Additionally, it is to be understood that the invention is defined by the claims and it is not intended that any limitations or elements describing the exemplary embodiments set forth herein are to be incorporated into the interpretation of any claim element unless such limitation or element is explicitly stated. Likewise, it is to be understood that it is not necessary to meet any or all of the identified advantages or objects of the invention disclosed herein in order to fall within the scope of any claims, since the invention is defined by the claims and since inherent and/or unforeseen advantages of the present invention may exist even though they may not have been explicitly discussed herein. | A thermal window comprising a thermally transparent window member, a window frame for receiving the thermally transparent window member, and at least one transmitter configured to transmit electromagnetic radiation with a frequency from 3 Hz to 300 GHz. The thermal window also has a cover for protecting the thermally transparent window member, wherein the cover may be mounted to the window frame by a spring loaded hinge. | 4 |
FIELD OF THE INVENTION
[0001] The invention relates to a method for transferring signal and more particularly, relates to a method for transferring single ended signal with interference-resistance and a device used for inputting and outputting single ended signal with interference-resistance.
BACKGROUND OF THE INVENTION
[0002] Single ended signal is a commonly used signal form due to its simple processing circuitry. This signal however, is susceptible to interference during transferring process and consequently, where signal transmission system needs rigid requirement for anti-interference, differential signal transmission is normally employed. However, utilization of differential signal system increases complexity of hardware and results in limited application range. Thus, it is desired to provide a method of single ended signal transferring with interference-resistance.
[0003] Single ended signal may be easily influenced by interference during transmission. Due to lack of knowledge about reasons of occurrence of interference, it is high costly for normal method of reducing interference. Method for decreasing interference currently used is reducing interference source, as well as impedance of the connections at reference terminal as soon as possible. Thus, it is desired to provide an improved method of signal transferring capable of resisting high interference.
[0004] The follow is analysis of generation of interference.
[0005] FIG. 1 is an equivalent circuit of a single ended signal transferring circuit, wherein
[0006] G: reference ground
[0007] Goe: signal output device ground
[0008] Gie: signal input device ground
[0009] Vs: voltage source of output signal
[0010] Rs: internal resistance of output signal
[0011] Ri: internal resistance of signal input side
[0012] Cs: the sum of body capacitance and capacitance of induced capacitor of the signal output device ground relative to the reference ground G
[0013] Vns: induced interference voltage of the signal output device ground relative to the reference ground G
[0014] Ci: the sum of body capacitance and capacitance of induced capacitor of the signal input device ground relative to the reference ground G
[0015] Vni: induced interference voltage of the signal input device ground relative to the reference ground G
[0016] Rr: impedance of wiring between the reference terminal of signal input and output side
[0017] Vnl: induced interference voltage on the wiring between the reference terminal of signal input and output side
[0018] Vnr: interference voltage resulted from interference current generated at Rr by all the interference source existing in a system
[0019] Vn: the sum of Vnl and Vnr, i.e., equivalent interference voltage at the signal input side
[0020] The single ended signal has a signal terminal and a reference terminal, the later being commonly referred as a signal ground. The reference terminal has its potential constant, whereas potential at the signal terminal varies. It can be considered that interference mostly coming from wiring of the reference terminal and interference coming from the signal terminal is very little during transmission of the single ended signal. The interference voltage results from the following three sources: the first source is induced interference voltage at wiring between the reference terminal of receiving side and transmitting side, whose equivalent voltage to input signal is represented by Vnl in the figure; the second source is potential difference at the impedance Rr of wiring of the reference terminal, the potential difference resulting from interference current generated by unbalanced inducing voltage between the reference terminal of receiving and transmitting sides, the equivalent interference voltage to the input signal is shown in the figure by Vnr, and in addition, Cs, Vns, Ci and Vni are equivalent circuits of the interference source; and finally, the third source is multi-ground wire loop interference which may occur depending upon connection of the ground wires. Now, detailed analysis of influence of these interferences is provided.
[0021] Induced interference at the wiring between the reference terminal of receiving and transmitting sides is explained as follows.
[0022] Vnl shown in FIG. 1 is the interference voltage induced by this interference source. Single ended signal is generally transferred by unbalanced shielded wire. As the reference terminal of the signal is connected by an outer shielded layer of the shielded wire, it will easily generate induced voltage. The interference source may be equivalent to a voltage source with a high internal resistance. This interference voltage can be reduced by reducing impedance of load between its two terminals. The load impedance is impedance between Goe and Gie with the connection wiring of the reference terminal removed, and consisted of two impedances in parallel. One impedance is combination of Rs and Ri in series and the other is combination of Cs and Ci in series. Vnl in the figure is the interference voltage with the load impedance between the two terminals being calculated. In the equivalent circuit shown in FIG. 1 , since the signal reference terminal and device ground are the same, and since Cs and Ci are large enough, Vnl is not large and therefore, Vnl has less impact on entire input interference voltage. It should be noted that thickening of the conductor will reduce the internal resistance of the interference source thereof and increase the induced interference signal, hence resulting in increase of Vnl.
[0023] The receiving and transmitting terminal employ shielded inner conductor as their connection wiring and accordingly, less interference signal will be induced on the wire. However, in case where the load impedance become large due to large input impedance of the receiving terminal, or where the shielded wire produces less effective shielding function, induced interference influence from connection wiring between the receiving and transmitting terminals will increase.
[0024] If the single ended signal is transferred via balanced shielded wire, that is, both the signal terminal and reference terminal use shielded wire incorporating inner conductor therein, the induced interference potential at the connection wiring can be regarded as very small and consequently, less influence will be applied to Vnl.
[0025] Next, impedance of the connection wiring at the reference terminal resulted from interference current passing through the connection wiring is explained, wherein the interference current is induced by unbalancing induced voltage between the reference terminal of receiving and transmitting sides.
[0026] Cs, Vns, Ci, and Vni shown in FIG. 1 are the equivalent circuit of the interference source. The interference source includes induced interference and interference resulted from power and grounding system. Cs is the totality of body capacitance and induced capacitance of the device ground of transmitting side, Vns is induced voltage interference on the device ground of the transmitting side, Ci is the totality of body capacitance and induced capacitance of the device ground of receiving end, while Vni is induced voltage interference on the device ground of the receiving side. When induced potential difference occurs between Vns and Vni, induced current will be generated, and accordingly, interference voltage Vnr is generated on Rr.
[0027] In FIG. 1 , as the receiving and transmitting signal reference terminals directly couple with the device grounds, both Cs and Ci are very large and therefore, induced interference voltage will also be very large. In case where the device ground is still coupled to an external ground system, Cs or Ci thereof will still increase. Consequently, interference current flowing through Rr will also be increased if induced potential difference exists between the reference terminals of receiving and the transmitting sides, thus resulting in larger interference voltage.
[0028] Multi-ground wire loop interference is explained as follows.
[0029] During transmission of single ended signal, there may also be multi-ground wire loop interference. If the devices at both sides are connected by more than one ground wires, a loop circuit will be defined between every two ground wires. Interference potential will be produced in the loop, once varying flux passes through the area defined by the loop. The interference current resulted from the interference potential will generate interference voltage on signal ground wire Rr. In actual applications, this situation may occur frequently. For example, when both the device themselves have its power and are connected with the signal ground wires, one power will be connected with the ground wire in case where the two device are powered by the same power. Further, since another signal ground wire is needed for transmission of the single ended signal, there will accordingly be two ground wires. However, in conventional single ended signal transmission system, the device ground and signal ground are usually connected with each other directly. Once ground wire loop interference occurs, much experience will be required to eliminate the interference and thus, handling of the ground wire will become complicated.
[0030] In scheme of the invention, as isolation impedance is disposed in the loop composed of the signal ground and device ground, and since the impedance is sufficiently larger than impedance of the signal ground, ground wire loop interference voltage will mainly apply on the isolation impedance and will have little impact on the signal ground.
SUMMARY OF THE INVENTION
[0031] One object of the invention is to provide a method for transferring single ended signal, which holds high interference resistance and results in low cost.
[0032] Another object of the invention is to provide an output device for transmission of single ended signal capable of resisting interference, holding high interference resistance and bearing low cost.
[0033] The objects of the invention are obtained by the following technical scheme.
[0034] A method of transferring single ended signal with interference-resistance is disclosed. The transmission of the single ended signal includes an input device and an output device. The output device has its signal output terminal connected with a signal input terminal of the input device. A signal floating isolation circuit SFS is connected with the signal output terminal of the output device and/or signal input terminal of the input device. The output signal or input signal is output or input via this floating isolation circuit. The isolation reference terminal of the output signal is coupled to ground of the output device through the isolation impedance, and/or the isolation reference terminal of the input signal is coupled to the ground of the input device through the isolation impedance. The signal output reference terminal of the output device and the signal input reference terminal of the input device are connected with each other.
[0035] The device ground of the output device may be connected with the device ground of the input device, and lower impedance of connection wiring between the device grounds can enhance interference-resistance performance of the system. In the scheme of the invention, as isolation impedance is disposed in the loop formed by the signal ground and device ground, and the isolation impedance is greater sufficiently than the impedance of the signal ground wire, interference voltage presented on the ground wire loop will mostly act on the isolation impedance, and will have little effect on the signal ground wire. If there are several connection wires used for the device ground, ground wire loop interference will be rendered on the device ground wires. However, the ground wire loop interference presents little effect on the signal ground wire; in other words, signal transmission will not be affected. Therefore, multiple device ground wire connections may be presented in the system and this brings great convenience for actual application. Namely, we can increase number of low impedance connection wirings used for the device ground conveniently without fearing that whether ground wire loop interference will be introduced due to existing device ground connections.
[0036] When transmission and receipt of the single ended signal run between several devices, for example, when several input devices receive the same signal, the floating isolation port method of the invention may be used to these devices. That is, one or more signal input terminals or output terminals can connect with the floating isolation circuit SFS so as to sufficiently decrease interference. Preferably, when at most only one device doesn't use the floating isolation port method of the invention, little interference will exist on connection wiring between every two reference terminals.
[0037] The output device of the invention used to transfer a single ended signal with interference-resistance comprises floating isolation circuit and isolation impedance. The single ended signal is output through the floating isolation circuit, thereby establishing an isolation reference terminal for the output signal relative to the device ground of the output device used for transmission of the single ended signal with interference-resistance. The isolation reference terminal of the output signal connects to the device ground of the output device by the isolation impedance. In the invention, during interference resistance transmission, the device ground of the output device connects with the device ground of other input device
[0038] In the invention, an input device for transmitting single ended signal with interference-resistance is provided which comprises floating isolation circuit and isolation impedance. The single ended signal is input through the floating isolation circuit, thereby establishing an isolation reference terminal for the input signal relative to the device ground of the input device used for transmission of the single ended signal with interference-resistance. The isolation reference terminal of the input signal connects to the device ground of the input device by the isolation impedance. In the invention, during interference resistance transmission, the device ground of the input device connects with the device ground of other output device.
[0039] By improving interface circuit design between signal receiving and transmitting ends, interference signals entered into the signal channels are clearly reduced, thereby achieving transmission of single ended signal with interference-resistance.
[0040] The invention is described in greater detail below in conjunction with drawings and embodiments thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
[0041] FIG. 1 shows an equivalent circuit of single ended signal transmission interference.
[0042] FIG. 2 shows an equivalent circuit of single ended signal transmission interference at floating isolated output terminal according to an embodiment of the invention.
[0043] FIG. 3 shows an equivalent circuit of single ended signal transmission interference at floating isolated input terminal according to another embodiment of the invention.
[0044] FIG. 4 shows an equivalent circuit of single ended signal transmission interference at floating isolated output and input terminals according to yet another embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0045] Reference is made to the equivalent circuit of single ended signal transmission interference shown in FIG. 1 and to the following reference numerals.
[0046] G: reference ground
[0047] Goe: signal output device ground
[0048] Gos: isolation reference terminal of the output signal of the signal output device
[0049] Gie: signal input device ground
[0050] Gis: isolation reference terminal of the input signal of the signal input device
[0051] Vs: voltage source of output signal
[0052] Rs: internal output resistance of signal side
[0053] Ri: internal input resistance of signal side
[0054] Ros: isolation impedance between the Goe and Gos at signal output side
[0055] Ris: isolation impedance between Gie and Gir at signal input side
[0056] Cs: the sum of body capacitance and capacitance of induced capacitor of the signal output device ground relative to the reference ground G
[0057] Vns: induced interference voltage of the signal output device ground relative to the reference ground G
[0058] Ci: the sum of body capacitance and capacitance of induced capacitor of the signal input device ground relative to the reference ground G
[0059] Vni: induced interference voltage of the signal input device ground relative to the reference ground G
[0060] Rr: impedance of connection wiring between the signal input reference terminal and output reference terminal
[0061] Vnl: induced interference voltage at the wiring between the signal input reference terminal and output reference terminal
[0062] Vnr: interference voltage resulted from interference current generated at Rr by all the interference source existing in a system
[0063] Vn: the sum of Vnl and Vnr, i.e., equivalent interference voltage on the signal input
[0064] Rg: impedance of the wiring between the signal input device ground and signal output device ground.
[0065] SFS: signal floating isolation circuit, wherein
[0066] The SFS signal floating isolation circuit is a functional unit circuit having four ports represented in the description as A, B, C and D. Ports A and B are input ports, while ports C and D are output ports. The circuit enables the input signal and output signal to turn into a floating status with respect to each other, that is, reference terminal potential of the input signal has no relation with the reference terminal of the output signal, but varies following outer condition. In other words, both the input signal and output signal can build their own reference terminals potential with respect to each other. Isolation transformer and optoelectronic coupled device are typical devices which provide this function. Differential input amplification circuit constructed by operational amplifier can also provide this function and gain good linearity. For differential input amplification circuit built by operational amplifier, this is an application in which input impedance is unbalanced. Making input impedance of the amplification circuit higher enough than inner resistance of the input signal can improve ability of resisting common mode interference and therefore, utilization of operational amplification circuit is a cost effective solution.
[0067] In the equivalent circuit of single ended signal transmission shown in FIG. 1 , it is necessary to reduce both Vns and Vni at the same time or make them consistent with each other so as to reduce induced potential difference. As Rr is smaller substantially than Rs and Ri in series, induced current formed between Goe and Gie mostly flows through Rr. The induced current flows a loop defined by Cs, Ci and Rr. It is possible to increase impedance of the loop by reducing Cs, Ci or the both. This can reduce the induced current in the loop. While reduce Cs and Ci, Vns and Vni will reduce as well, even low induced current in the loop will be.
[0068] Generally, body capacitance and induced capacitance of both the receiving signal terminals and transmitting signal terminals are very small, and induced voltage thereof maintains low and loop impedance thereof are kept high. These two factors cause decreasing of interference current in the loop and as a result, there gets no influence for unbalanced inductance between the receiving and transmitting terminals. As for induced interference between the receiving and transmitting signal terminals, they can be reduced by utilization of shielded wire with good shielding effect and proper selection of impedance of the input terminals.
[0069] From the above analysis, it is apparent that interference in a single ended signal transmission system mainly comes from induced interference of receiving and transmitting reference terminals and connection wiring there between, while interference introduced by the receiving and transmitting signal terminals and connection wiring is small. Interference coming from connection wiring between the receiving and transmitting reference terminals is related to the device ground and capacitance thereof. It is necessary lowering the interference voltage at both the receiving and transmitting sides to reduce interference by decreasing unbalanced induced voltage. The interference caused by unbalanced induced voltage may be reduced by reducing Rr of the reference terminal connection wiring, and the interference caused by unbalanced induced voltage may also be lowered by reducing capacitance of either reference terminal of the receiving side and transmitting side.
[0070] Following is detailed embodiments of the invention of method for transmitting single ended signal with interference-resistance.
Embodiment 1
[0071] Referring to FIG. 2 , there is shown a method for transmitting single ended signal in which output side is isolated floatingly. Compared to the equivalent circuit shown in FIG. 1 , the circuit shown in FIG. 2 has modified circuit construction at its signal output side. This modification is made such as the output signal is output through a floating isolation circuit SFS, thereby establishing an isolation reference terminal for the output signal relative to the device ground of the output capable of transferring single ended signal with interference-resistance. The isolation reference terminal Gos of the output signal is connected with the output device ground Goe by isolation impedance Ros. In addition, a connection wire for connecting the device ground of the receiving and transmitting sides is added and has an impedance of Rg. Only an additional connection wire is provided for the signal input side for connecting the device ground of both the receiving and transmitting sides. If both the receiving and transmitting sides have been connected to the same ground by power cable, dedicated connection wire may be omitted here from. Because the isolation reference terminal Gos is not connected with the device ground directly, the body capacitance and induced capacitance may be very small. Rg is impedance of the connection wire that connects the two device grounds, and may have the same value as Rr. The value of Ros should be determined as follows:
[0000] Ros >>Rr and Ros >>Rg
[0072] Induced interference of the connection wire between the receiving and transmitting reference terminals is explained below.
[0073] In situation where induced interference potential on the transmission wires is large, this may happen when single ended signal is transferred via unbalanced shielded wire or over a long transmission distance, impedance between Gos and Gie should be lowered. This impedance is constructed by three impedance in parallel. The three impedance are Rs connected with Ri in series, Cs connected with Ci in series and Ros connected with Rg also in series. Ros is a major factor that has great effect on the impedance. The larger Ros is, the bigger the equivalent voltage Vnl is. In most application systems, Ros less than 1000 ohm is enough to eliminate the interference on the connection wire to a substantial extent.
[0074] In case where induced potential on the connection wiring of the reference terminal is low, this may happen when single ended signal is transferred across balanced shielded wire and both the signal terminal and reference terminal use shielded inner conductor, or when transmission distance is short, isolation impedance Ros between Gos and Gie may be high. or infinitely high, whereas the influence of interference Vnl may still not so big.
[0075] Another situation is explained, in which interference current flows through impedance Rr of the connection wiring at the reference terminal, the interference current being caused by unbalanced induced voltage between the receiving and transmitting sides.
[0076] As body capacitance and induced capacitance of Gos are very low, interference current caused by unbalanced induced voltage between Gos and Gie is also low; and therefore, the equivalent interference source of this interference is not presented in the equivalent circuit shown in FIG. 2 .
[0077] The interference source caused by unbalanced voltage between Goe and Gie is the same with that shown in FIG. 1 . Due to presence of Ros, interference current passing through Rr becomes reduced largely, and large portion thereof passes through Rg. Smaller value of Rg and bigger value of Ros can reduce the interference current passing through Rr and Vnr also can be small. When Rg equals Rr, ratio of current passing through Rr and Rg respectively equals ratio of Rg and Ros. Because Rg is resistor of the connection wire, impedance thereof can be regarded as less than 1 ohm. When Ros has a value of 100 ohm, interference current passing through Rr is 100 times smaller than that passing through Rg and accordingly, when compared to the equivalent circuit illustrated in FIG. 1 , Vnl will also be 100 times smaller than its original value. It is thus known that Vnr can be reduced effectively due to presence of Rg and Ros.
[0078] The totality of Vnl and Vnr is equivalent interference voltage at the signal input end. In the equivalent circuit shown in FIG. 2 , Vnl increases with the increasing of Ros, Vnr increases with the decreasing of Ros and decreases with decreasing of Rg and Rr. Suitable selection of Ros with the aim of minimizing the sum of Vnl and Vnr can optimize capability of the signal transmission system in interference resistance. In case where induced potential on the connection wire of the reference terminal is high, this may happen when the single ended signal is transmitted across unbalanced shielded wire or over a long transmission distance, the impedance of Ros should be lower so as to reduce Vnl. In case where induced potential on the connection wire of the reference terminal is low, this may happen when the single ended signal is directed by balanced shielded wire and both the reference terminal and signal terminal use inner conductor in the shielded wire as their connection wires or when transmission distance is short, the impedance of Ros can be larger. In this situation, Ros can be large or infinitely large, and Vnl may be still not too large, so Vnr can be small. In determining the value of Ros, another factor should be considered. That is, larger value of Ros will result in smaller ground loop interference caused by multi ground connections.
[0079] If the connection wiring between the signal input device ground and signal output device ground is not connected, this will mean that value of Rg is infinitely large, thus having no impact on transmission of signal. However, this results in worse interference-resistance performance of the transmission system. Especially great common mode interference will be generated at the input if Ros is large enough.
[0080] If there are several connection wires which connect the signal input device ground and the signal output device ground, wire loop interference will arise at the device ground wire. This wire loop interference in device ground has little influence on signal ground wire, that is, it will not interfere with transmission of the signal. Accordingly, there may be multiple device ground wires being connected.
Embodiment 2
[0081] Referring to FIG. 3 , there has been shown a method of transferring single ended signal with input side being floatingly isolated. Compared to the equivalent circuit shown in FIG. 1 , the circuit shown in FIG. 3 has modified circuit construction at its signal input side. This modification is made such that the input signal is input through a floating isolation circuit SFS, thereby establishing an isolation reference terminal for the input signal relative to the device ground of the input side capable of transferring single ended signal with interference-resistance. The isolation reference terminal Gis of the input signal is connected with the device ground Gie of the input device by isolation impedance Ris. In addition, a connection wire for connecting the device ground of the receiving and transmitting sides is added and has an impedance of Rg. Only an additional connection wire is provided for the signal output side for connecting the device ground of both the receiving and transmitting sides. If both the receiving and transmitting devices have been connected to the same ground by power cable, this dedicated connection wire may be omitted. Because the isolation reference terminal Gis is not connected with the device ground directly, the body capacitance and induced capacitance may be very small. Rg is impedance of the connection wire that connects the two device grounds, and may have the same value as Rr. The value of Ris should be determined same as that of Ros shown in FIG. 2 .
[0082] It is known from what has been described above that embodiment 2 differs from embodiment 1 only in that it applies similar circuit modification on the receiving side or transmitting side respectively. The analysis of anti-interference of embodiment 2 and corresponding result there from are similar to those of embodiment 1.
Embodiment 3
[0083] Referring to FIG. 4 , there is shown a method for transmitting single ended signal with both input and output ends being isolated floatingly. The equivalent circuit thereof is the combination of that shown in FIG. 2 and that shown in FIG. 3 . In this circuit, both the signal input side and output side employ floating isolation circuit SFS and corresponding isolation impedance Ros and Ris. Because both the input reference terminal and output reference terminal are of isolation reference terminal, induced interference between the reference terminals can be further reduced, and this interference accounts for little portion of the entire interference. In calculation of unbalanced induced voltage interference between the receiving end and transmitting end, Ros or Ris may be replaced by Ros plus Ris. It is found from above overall analysis that the equivalent circuit of FIG. 4 produces same anti-interference effect as the equivalent circuit shown in FIG. 2 or FIG. 3 .
[0084] It can be obtained from conclusions of embodiments 1, 2 and 3 that the same interference resistance effect for the single ended signal transmission system can be attained by using method of floatingly isolating port of the invention either at signal input device or at signal output device.
[0085] When receipt and transmission of the single ended signal occurs among multiple devices, for example when several input devices receive the same signal, the floating isolation port method of the invention may be used to these devices. That is, one or more signal input terminals or output terminals can connect with the floating isolation circuit SFS so as to sufficiently decrease interference. Preferably, when at most only one device doesn't use the floating isolation port method of the invention, little interference will exist on connection wiring between every two reference terminals.
[0086] Compared to conventional single ended signal transmitting method, the invention can greatly improve anti-interference performance during transmission of single ended signal. The implementation of the invention needs lower cost and can realize objects only by applies the invention on either device at receiving end or transmitting end. In addition, no problem of compatible with conventional device arises and thereby, the invention may be easily implemented. | The invention provides a method of transferring single ended signal with interference-resistance. The transmission of the single ended signal includes an input device and an output device. The output device has its signal output terminal connected with a signal input terminal of the input device. A signal floating isolation circuit is connected with the signal output terminal of the output device and/or signal input terminal of the input device. The output signal or input signal is output or input via this floating isolation circuit. The isolation reference terminal of the output signal is coupled to ground of the output device through the isolation impedance, and/or the isolation reference terminal of the input signal is coupled to the ground of the input device. The signal output reference terminal of the output device and the signal input reference terminal of the input device are connected with each other. The invention also provides an input device and an output device both of which are used to transfer single ended signal with interference-resistance. By improving interface circuit design between the signals receiving side and transmitting side, interference signal entered into the signal channels are reduced, and the cost of implementation of the invention are also low. | 7 |
CROSS-REFERENCE TO RELATED APPLICATION
This application claims, under 35 U.S.C. §109, priority to and the benefit of Korean Patent Application No. 10-2006-0126877 filed on Dec. 13, 2006, the entire contents of which are incorporated herein by reference.
BACKGROUND
(a) Technical Field
The present invention relates to a system for maintaining the temperature of a vehicle audio and/or audio-video deck, and more particularly to a system for maintaining the temperature of a vehicle audio and/or audio-video deck, which can selectively supply cooled or heated air so as to maintain the temperature of the deck at a target temperature or range.
(b) Background Art
Vehicles have a deck for holding an audio unit for replaying a cassette tape or a CD or for a radio, an audio-video (AV) unit for broadcasting or a navigator, or the like.
The deck is composed of various parts. A great amount of heat can be accumulated in the deck, which causes the temperature of the deck to become high. Typically, if a cassette tape or a CD is replayed for a long time, the deck temperature may become seriously high.
To resolve this problem of temperature rise, some technologies have been proposed. One example of such technologies provides a system that stops the operation of the deck when its temperature becomes higher than a certain temperature. This system, however, has drawbacks in that the operation of the deck can be frequently stopped in summer, which causes inconvenience to passengers.
Another proposed system uses a cooling fan to reduce the temperature, as shown in FIG. 1 . This system also has drawbacks in that although a deck 1 can be cooled by a cooling fan 3 , overall cooling efficiency is not good for some reasons. First, the size of the cooling fan 3 is not large enough to achieve a desired cooling efficiency. Second, positioning the cooling fan 3 is limited. As a result, it is difficult to cool the entire deck 1 and it takes a long time to do so.
There is thus a need for a new system that can solve the above-described problems associated with prior art.
The above information disclosed in this Background section is only for enhancement of understanding of the background of the invention and therefore it may contain information that does not form the prior art that is already known in this country to a person of ordinary skill in the art.
SUMMARY OF THE INVENTION
The present invention has been made in an effort to provide systems for maintaining the temperature of a vehicle audio and/or AV deck, in which cooled or heated air can be selectively introduce to the deck so as to maintain the temperature of the deck at a target temperature or range.
A preferred embodiment of the present invention provides a system comprising: an air duct positioned on both sides of the deck for supplying cooled or heated air to the vehicle cabin, a side part of the air duct defining therein a plurality of through holes through which cooled or heated air can be supplied to the deck; a sensor disposed inside the deck for detecting the temperature inside the deck; a side panel provided in the deck, which defines therein a penetration part for introducing cooled or heated air supplied through the through holes into the deck; a guide rail formed to the side panel; a sliding panel guided by the guide rail so as to open or close the penetration part; a driving motor coupled to the deck for moving the sliding panel along the guild rail; and a controller coupled to the deck for driving the driving motor in response to the temperature detected by the sensor so as to open or close the sliding panel, thereby maintaining the temperature of the deck at a target temperature or range.
In this embodiment, the controller may be a full automatic temperature control device. Also, the controller may regulate the temperature of the deck in response to the manipulation of a switch by a user.
Another preferred embodiment of the present invention provides a system comprising: an air duct positioned on both sides of the deck for supplying cooled or heated air to the vehicle cabin: a sensor disposed inside the deck for detecting the temperature inside the deck; a side panel provided in the deck, which defines therein a plurality of communication holes for supplying cooled or heated air to the deck; a panel guide rail formed to the side panel; an opening/closing device including a gear device and a flow panel that defines therein a plurality of opening/closing holes the shape and position of which are corresponding to those of the communication holes, wherein the flow panel is moved by the gear device along the panel guide rail so as to open or close the communication holes; and a controller coupled to the deck for driving the opening/closing device in response to the temperature detected by the sensor so as to open or close the communication holes, thereby maintaining the temperature of the deck at a target temperature or range.
Likewise, in this embodiment, the controller may be a full automatic temperature control device. It also may regulate the temperature of the deck in response to the manipulation of a switch by a user.
Preferably, in this embodiment, the flow panel may further comprise a gear that has a plurality of gear teeth formed along an end part thereof in a length direction and is operatively connected to the gear device. In this case, the gear device may further comprise: a main body; at least one rotating gear inside the main body, the rotating gear having a plurality of gear teeth that can engage with the gear teeth of the flow panel so as to raise and lower the flow panel; an operating part inside the main body, the operating part having a plurality of gear teeth that can engage with the gear teeth of the rotating gear so as to rotate the rotating gear in a clockwise or counter-clockwise direction; a damping member provided to the operating part for dampening an operating impact; and a supporter which is disposed at a lower part of the operating part and is provided with a receiving part at an inside thereof to receive and support the operating part.
Suitably, the rotating gear may comprise: a main rotating gear having a plurality of gear teeth that can engage with the gear teeth of the operating part and the gear teeth of the flow panel; and a sub rotating gear having a plurality of gear teeth that can engage with the gear teeth of the main rotating gear at a lower part of the main rotating gear. In this case, preferably, the main rotating gear has a diameter greater than that of the sub rotating gear.
The above information disclosed in this Background section is only for enhancement of understanding of the background of the invention and therefore it may contain information that does not form the prior art that is already known in this country to a person of ordinary skill in the art.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a conventional deck which is provided with a cooling fan.
FIG. 2 is a perspective view of an air duct and a deck according to a first exemplary embodiment of the present invention.
FIG. 3 is a perspective view of the air duct of FIG. 2 .
FIG. 4 is a perspective view of the deck of FIG. 2 .
FIG. 5 is a perspective view of an air duct and a deck according to a second exemplary embodiment of the present invention.
FIG. 6 is a schematic view of the communication hole opening/closing device shown in FIG. 5 .
FIG. 7 is a drawing showing how the communication hole of FIG. 5 operates.
FIG. 8 is another drawing showing how the communication hole of FIG. 5 operates.
Reference numerals set forth in the Drawings includes reference to the following elements as further discussed below:
10:
vehicle cabin
20:
crash panel
60:
air duct
620:
communication hole
64:
opening/closing device
640:
flow panel
660:
gear device
664:
rotation gear
666:
operating part
666a:
piston
666b:
damping member
668:
supporter
50:
controller
70:
deck
76:
sensor
DETAILED DESCRIPTION
Exemplary embodiments of the present invention will hereinafter be described in detail with reference to the accompanying drawings. The same reference numeral will be used for the same elements throughout the specification.
Referring to FIG. 2 to FIG. 4 , a system for maintaining the temperature of a vehicle audio and/or AV deck according to a first exemplary embodiment of the present invention will be explained.
As shown in FIG. 2 , a vehicle cabin 10 is provided with a crash panel 20 . A plurality of air ducts 30 is installed to the crash panel 20 for introducing air into the vehicle cabin 10 . The introduced air can be heated or cooled by an air conditioner. A deck 40 is disposed between the air ducts 30 .
As shown in FIG. 3 , each of the air ducts 30 includes a plurality of through holes 33 formed in a side part 32 thereof, which are disposed to face the deck 40 . Heated or cooled air is introduced to the air duct 30 , and then to the neighboring deck 40 via the through holes 33 .
As shown in FIG. 4 , an audio unit 42 and an AV unit 43 are provided to the deck 40 . Within the deck 40 is provided a sensor 41 for detecting the temperature inside the deck 40 .
A side panel 44 is provided in the deck 40 . At least one penetration part 45 is formed to the side panel 44 for introducing into the deck 40 heated or cooled air that has passed the through holes 33 .
The penetration part 45 can be perforated in a length direction or, as shown in FIG. 4 , in a width direction of the side panel 44 . Preferably, the penetration part 45 is formed at a position corresponding to the position of the through holes 33 .
A guide rail 46 is formed in the side panel 44 . The guide rail 46 receives a sliding panel 47 and support it so as to be slidable.
An end part in a length direction of the sliding panel 47 is inserted into the guide rail 46 . It can slidably move so as to be able to open or close the penetration part 45 . The size and the shape of the sliding panel 47 may vary according to the size and the number of the penetration part 45 .
A driving motor 48 operates the sliding panel 47 to open or close the penetration part 45 . A controller 50 drives the driving motor 48 on the basis of temperature data detected by the sensor 41 so as to maintain the temperature of the deck 40 at a constant temperature.
Preferably, the controller 50 can be provided as a separate device. Also preferably, it can be realized by a full automatic temperature control (FATC) unit.
In case that it is necessary to cool an overheated deck 40 , the controller 50 (or the FATC unit) operates an air conditioner to supply cooled air. The cooled air is supplied to the deck 40 via the through holes 33 and the penetration part 45 . Meanwhile, the driving motor 48 moves the sliding panel 47 , thereby opening the penetration part 45 .
Similarly, in case that it is necessary to warm an overcooled the deck 40 , the controller 50 (or the FATC unit) operates an air conditioner to supply heated air. The heated air is supplied to the deck 40 via the through holes 33 and the penetration part 45 . Meanwhile, the driving motor 48 moves the sliding panel 47 , thereby opening the penetration part 45 .
These operations can be either automatically performed by the FATC unit or the controller 50 or manually performed by operation of a switch by a user. In case of manual operation, preferably, a separate switch is provided at an instrument panel or a deck. Also preferably, a switch may be added to the FATC unit.
Referring to FIG. 5 to FIG. 8 , a system for maintaining the temperature of a vehicle audio and/or AV deck according to a second exemplary embodiment of the present invention will be explained.
A plurality of air ducts 60 for introducing heated or cooled air into the vehicle cabin 10 is installed to the crash panel 20 within the vehicle cabin 10 , and a deck 70 is disposed between the air ducts 60 (see FIG. 2 ).
As shown in FIG. 5 and FIG. 6 , each of the air ducts 60 includes a plurality of communication holes 620 which are formed in a side panel 62 . In addition, a panel guide rail 622 for guiding a flow panel 640 to slidably move is formed in a length direction on an outside of the side panel 62 .
The communication holes 620 have a shape of an ellipse. Cooled or heated air produced by an air conditioner is sent to the air duct 60 and then to the neighboring deck 70 via the communication holes 620 .
Preferably, the communication holes 620 may be formed on the side panel 62 . Also preferably, the communication holes 620 may be formed on a separate panel and the panel may be fixed to the side panel 62 by welding or the like. In this case, the side panel 62 includes a cut part in response to the separate panel. The communication holes 620 are opened or closed by an opening/closing device 64 .
The opening/closing device 64 includes the flow panel 640 which opens or closes the communication holes 620 . The device 64 also includes a gear device 660 which drives the flow panel 640 .
The flow panel 640 is a separate panel corresponding to a part to which the communication holes 620 are formed. The panel 640 has a plurality of opening/closing holes 642 having a size and a shape corresponding to those of the communication holes 620 . The panel 640 further includes a gear 644 which operates to be linked with the gear device 660 .
The gear 644 includes a plurality of gear teeth P, and is formed at an end part in a length direction of the flow panel 640 . The gear teeth P of the gear 644 are engaged with the gear teeth P formed to a rotating gear 664 of the gear device 660 so as to cause the flow panel 640 to move up and down along a length direction.
If the flow panel 640 moves up and down by the gear device 660 , the opening/closing holes 642 are overlapped by or deviated from the communication holes 620 so that the communication holes 620 can be opened or closed.
The gear device 660 includes a main body 662 in a shape of a box, a rotating gear 664 rotatably disposed within the main body 662 , an operating part 666 which drives the rotating gear 664 , and a supporter 668 which supports the operating part 666 .
As shown in FIGS. 7 and 8 , a plurality of gear teeth P are formed on an outer surface of the rotating gear 664 . The gear teeth P are engaged with the gear teeth P formed on the operating part 666 and the gear 644 of the flow panel 640 so as to rotate the rotating gear 664 .
There is no specific limitation on the number of the rotating gear 664 . Preferably, one rotating gear can be used. Also preferably, two rotating gears can be used. For example, the rotating gear 664 may include a main rotating gear 664 a and a sub rotating gear 664 b. The main rotating gear 664 a may be engaged with the gear teeth P formed to the operating part 666 and the gear 644 . The sub rotating gear 664 b rotates by engagement with the main rotating gear 664 a and is engaged with the supporter 668 . In order to drive the flow panel 640 , only the main rotating gear 664 a should be engaged with the gear 644 and the sub rotating gear 664 b should not contact the gear 644 , so it is preferable that the diameter of the main rotating gear 664 a is greater than the diameter of the sub rotating gear 664 b.
The operating part 666 is provided with the gear tooth P engaging with the rotating gear 664 , and moves along a length direction of the main body 662 so as to rotate the rotating gear 664 . A lower end of the operating part 666 to which the gear teeth P is extended is provided with a piston 666 a.
The piston 666 a is received by the supporter 668 , and an end thereof is formed to be wider than an inlet of a receiving part 668 a formed to the supporter 668 so as not to be arbitrarily separated from the supporter 668 . A damping member 666 b is inserted into an end of the piston 666 a.
The damping member 666 b serves to reduce operation noise which is generated by collision of an end of the piston 666 a with the supporter 668 during the operation of the operating part 666 . The damping member 666 b may be realized by any one of coil spring, hydraulic cylinder, pneumatic cylinder, and so forth. In case that the damping member 666 b is realized by hydraulic cylinder or pneumatic cylinder, the damping member 666 b may preferably be integrated with the piston 666 a, and the supporter 668 may be omitted (only the coil spring is shown in the drawing for convenience).
The receiving part 668 a is formed to the supporter 668 so as to receive the piston 666 a. If two rotating gears 664 are used, gear teeth are formed on a side surface to support the sub rotating gear 664 b.
The operating part 666 can be connected to an alternating current (A/C) electric power source of the FATC unit so as to obtain driving force.
FIG. 5 shows a system including an audio unit 72 and an AV unit 74 provided to the deck 70 . A sensor 76 is provided inside the deck 70 for detecting the temperature inside the deck 70 .
In response to the temperature inside the deck 70 is detected by the sensor 76 , the controller 50 operates the opening/closing device 64 to open or close the communication holes 620 which are formed to the side panel 62 . Accordingly, the temperature of the deck 70 may be maintained at a temperature or within a range to ensure normal operation of the deck 70 .
In case of a vehicle which is provided with a FATC unit, the controller 50 can be realized by the FATC unit. In a vehicle without the FATC unit, the controller 50 is provided as a separate device to regulate the temperature of the deck 70 .
These processes will be explained in more detailed hereinafter.
As shown in FIG. 7 , if the deck 70 is overheated, communication holes 620 should become opened.
In order to open the communication hole 620 , the controller 50 or FATC unit operates the opening/closing device 64 . While the operating part 666 connected to the controller 50 moves down, the gear teeth P are engaged with one another so as to rotate the rotating gear 664 in the direction of the arrow shown in FIG. 7 .
While the rotating gear 664 rotates in the direction of the arrow, the gear 644 engaged with the gear teeth P moves in the direction opposite to the rotation direction of the rotating gear 664 , and the flow panel 640 moves up.
At this time, the piston 666 a of the operating part 666 moves down to a bottom surface of the receiving part 668 a of the supporter 668 , and the damping member 666 b is extended to slowly lower the piston 666 a.
As such, if the flow panel 640 moves up so that the opening/closing holes 642 overlap the communication holes 620 , the communication holes 620 become opened. The cooled air produced by an air conditioner is sent to the deck 70 via the communication holes 620 so that the deck 70 is cooled.
On the other hand, in case that the temperature of the deck 70 is too low, the communication holes 620 can be opened in the similar way, and heated air will be supplied to the deck 70 .
As shown in FIG. 8 , if the temperature of the deck 70 reaches a target temperature or range thereof, the communication holes 620 become closed and supplying of cooled or heated air will be stopped.
In order to close the communication holes 620 , the controller 50 or FATC unit operates the opening/closing device 64 .
While the operating part 666 connected to the controller 50 moves up, the gear teeth P are engaged with one another so as to rotate the rotating gear 664 in the direction of the arrow shown in FIG. 8 .
While the rotating gear 664 rotates in the direction of the arrow, the gear 644 engaged with the gear teeth P moves in the direction opposite to the rotation direction of the rotating gear 664 , and the flow panel 640 moves down.
At this time, the piston 666 a of the operating part 666 moves up to the position of an inlet of the receiving part 668 a of the supporter 668 . While the damping member 666 b is compressed, the piston 666 a is prevented from colliding with the receiving part 668 a.
As such, if the flow panel 640 moves down so that the opening/closing holes 642 are deviated from the communication holes 620 , the communication holes 620 become closed. Accordingly, supply of cooled or heated air to the deck 70 through the communication hole 620 is cut off.
For this, the sizes and shapes of the opening/closing holes 642 and the communication holes 620 should be similar or identical. Preferably, the rotation distance of the rotating gear 664 , the operation distance of the operating part 666 , and the operation distance of the flow panel 640 are formed to be slightly greater than the length (longitudinal diameter) of the communication hole 620 .
With these embodiments of the present invention as described above, the temperature of a vehicle audio and/or AV deck can be maintained at a target temperature or range that ensures normal operation of the deck, credibility of the product, and user convenience.
While this invention has been described in connection with what is presently considered to be practical exemplary embodiments, it is to be understood that the invention is not limited to the disclosed embodiments, but, on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims. | A system for maintaining the temperature of a vehicle audio and/or audio-video deck provided in a vehicle cabin is provided, comprising: an air duct positioned on both sides of the deck for supplying cooled or heated air to the vehicle cabin, a side part of the air duct defining therein a plurality of through holes through which cooled or heated air can be supplied to the deck; a sensor disposed inside the deck for detecting the temperature inside the deck; a side panel provided in the deck, which defines therein a penetration part for introducing cooled or heated air supplied through the through holes into the deck; a guide rail formed to the side panel; a sliding panel guided by the guide rail so as to open or close the penetration part; a driving motor coupled to the deck for moving the sliding panel along the guild rail; and a controller coupled to the deck for driving the driving motor in response to the temperature detected by the sensor so as to open or close the sliding panel, thereby maintaining the temperature of the deck at a target temperature or range. | 1 |
BACKGROUND OF THE INVENTION
This invention relates to apparatus for opening the conditioning rolls of a mower conditioner when the header is raised to the transport position. The mower conditioner in which the crop conditioning rolls and the roll opening apparatus is incorporated is of the type having a wheel mounted frame to which is attached a laterally disposed header. The front edge of the header includes a sickle for cutting the crop material as well as means for delivering the harvested material to the nip of the conditioning rolls.
Prior art mower conditioners for use in harvesting hay are disclosed in: Cicci et al, U.S. Pat. No. 4,174,600; Johnson et al, U.S. Pat. No. 3,397,520; and Hurlburt et al, U.S. Pat. No. 3,599,405. In the Hurlbert et al machine there is a wheel supported frame, a header having crop-treating elements thereon pivotally mounted on the frame, link means operatively connecting the header to the frame, and lift means on the frame for pivoting the frame about a horizontal axis. In the machine of Johnson et al, the conditioning rolls are automatically raised by a linkage whenever the header is raised to the transport position. The hay harvesting machine of Cicci et al includes a header which is vertically movable relative to the carrying frame. There is a conditioning roll opening device consisting of a linkage which not only separates the rolls but also serves to stabilize the header when it is in the transport position.
The present invention differs from the prior art in that the rolls are opened by a pair of hydraulic cylinders. The conditioning rolls are separated during the last part of the header lift cycle to allow the machine operator to unplug the mower conditioner without having to leave the tractor seat.
SUMMARY OF THE INVENTION
This invention pertains to apparatus that forms a part of a hay harvesting machine of the type wherein a header is vertically movable relative to a wheel supported carrying frame. The main carrying frame includes a laterally extending horizontal beam on each end of which there is a vertically disposed strut-like member supported by a wheel rotatably mounted on a spindle. The center of the horizontal beam has pivotally attached thereto a forwardly extending tongue which connects to the rear end of a tractor. The crop harvesting header, spanning a width of 12 ft. or more, mounts to the frame by pivotal linkage which includes upper and lower links with the lower links being adjacent the wheel spindles. These linkages permit movement of the header between operating and transport positions.
A haycutting sickle spans the forward edge of the header. A conventional rotary reel is rotatably mounted above the sickle and serves to sweep crop cuttings rearward from the sickle across a platform to an auger. The flights of the auger and the positioning of the auger itself are arranged to deliver crop cuttings to the nip of a pair of laterally extending upper and lower conditioning rolls. The lower conditioning roll is rotatably mounted on a fixed axis while the upper roll is rotatably mounted at each end on lever arms pivotally attached to the header. The lever arms are biased by springs to make the upper roll operate closely adjacent the lower roll. The roll opening structure utilizes a pair of hydraulic cylinders. The base end of each cylinder is pivotally mounted to the header. The piston rod end of the first cylinder is pivotally attached to the lever arm on the left end of the upper conditioning roll. Similarly, the piston rod end of the second cylinder is pivotally attached to the lever arm on the right end of the upper conditioning roll. Hydraulic fluid is supplied to both cylinders in parallel causing the pistons thereof to extend simultaneously and thereby raise the upper conditioning roll against the force of the tensioning springs.
The header itself is raised and lowered by means of a pair of hydraulic lift cylinders, one in each vertically disposed strut. Each lift cylinder functions in combination with the upper and lower linkage arms that tie the header to the frame. The two lift cylinders and the two roll opening cylinders are plumbed so that hydraulic fluid is supplied to all four in parallel. The header lift cylinders are sized so that a fluid pressure between 850-1200 psi will raise the header to the transport condition. The conditioning rolls, on the other hand, are preloaded by two springs, one on each lever arm, so that almost 1500 psi of fluid pressure must be applied before the rolls begin to separate. For full separation 2000 psi of pressure is required.
In operation, the header is raised until the header lift cylinders are fully extended, then the roll opening hydraulic cylinders begin to separate the rolls by raising the upper roll. On lowering the machine the spring load on the roll causes the roll opening cylinders to collapse while the weight of the header causes the header lift cylinders to collapse. The roll closing is almost instantaneous with opening of the valve spool of the hydraulic fluid pressure source. The header requires 3 to 4 seconds to lower.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an isometric view of the right side of a mower conditioner containing the invention.
FIG. 2 is a plan view of the mower conditioner shown in FIG. 1.
FIG. 3 is an isometric view, partially exploded, showing the relative position and drive system arrangement for the conditioning rolls.
FIG. 4 shows the lever arm mounting arrangement for the upper conditioning roll.
FIG. 5 is an end view of the left end upper roll lever arm showing the placement of the hydraulic lifting cylinder and roll tensioning spring.
FIG. 6 shows a schematic of the hydraulic system with the header lifting cylinders being connected in parallel with the roll opening cylinders.
FIG. 7 is a cutaway left side view of the mower conditioner showing the placement of one of the header lift cylinders.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
There is shown in FIGS. 1 and 2 a mower conditioner 10 which includes a mobile carrying frame comprising a horizontal main beam 12, left and right vertical frame members 14 and 16 having ground wheels 24 rotatably mounted on spindles 17. The vertical frame members 14 and 16 are of inverted L-shape and are hollow to receive a portion of the lifting and floatation mechanism for the crop harvesting header assembly 18. A short post 26 extending upward from the center of main beam 12 provides a pivotal attachment point for a forwardly extending tongue 28, thereby allowing connection to a tractor.
Header assembly 18 comprises a laterally elongated platform 25 extending twelve or more feet between side sheets. A conventional rotary reel 20 is mounted above the platform and between the side sheets. Reel 20 includes a core tube 21 and a multiplicity of tines 22 arranged to extend outwardly from several reel tine bars 23. Cutter bar 27 extends across the front edge of the header. Reel 20 sweeps crop cuttings rearwardly from cutter bar 27 across platform 25. As depicted in FIG. 3 but not shown in FIG. 2, there is an auger 30 along the entire rear edge of platform 25. The flights of auger 30 are counter wound as shown and operate to centrally bunch crop cuttings swept therein by the rotational action of reel 20. As a result auger 30 delivers crop cuttings into the nip of a pair of upper and lower crop conditioning rolls 32 and 34 respectively.
Conditioning rolls 32 and 34 do not extend the full width of the platform (See FIG. 3). Use of auger 30 makes it possible to use shorter conditioning rolls and the flexible mounting arrangement depicted in FIGS. 3 and 4. Upper conditioning roll 32 is mounted on lever arms 36 and 38. These two lever arms are pivotally mounted to the subframe of header 18. Lower conditioning roll 34 is fixedly mounted for rotation on the subframe of the header. Both upper and lower conditioning rolls have serrated edges (See FIG. 5). The rolls are oriented one to the other so that the two rolls mesh with the upper roll turning counterclockwise (see arrows 40 and 42). To allow for coordinated operation of the conditioning rolls, the sprocket and chain drive arrangement shown in FIG. 3 was incorporated. Chain 44 passes over idler sprocket 46, around lower conditioning roll sprocket 48, in a reverse direction around upper conditioning roll sprocket 50 and thence around sprocket 52. The pair of conditioning rolls may then be driven either by means of shaft 54 or by means of a motor (not shown) attached to sprocket 52. The use of a pair of universal joints 56 and 58 allows the upper conditioning roll to move up and down by means of lever arms 36 and 38. In the unit reduced to practice, a tensioning force of approximately 700 lbs. was applied between rolls. For this reason, it was found to be operationally prudent to include universal joints 60 and 62 immediately adjacent the ends of lower conditioning roll 34 to accommodate flexing at the bearing supports.
As shown in mcre detail in FIG. 5, the left end of upper conditioning roll 32 is rotatably mounted to lever arm 38. The pivotal end of lever arm 38 is rotatably mounted to header subframe 64 by means of stub shaft 63. Tension to hold the upper roll 32 against the lower conditioning roll is provided by spring 66. Spring 66 is anchored to header subframe 64 by means of eyebolt 68. The other end of tension spring 66 has attached thereto a cable 70 which passes over a direction reversing pulley 72 to an attachment point 74 on the lower edge of lever arm 38. Tension in spring 66 and its companion on the right hand end of upper conditioning roll 32 serves to hold the upper roll against the lower roll 34 which is shown in phantom in FIG. 5. When it is desired to separate the upper and lower conditioning rolls 32 and 34, hydraulic fluid is applied to cylinder 76. The base end of cylinder 76 is attached by bolt means 78 to header subframe 64. The piston end of cylinder 76 is rotatably attached by pin 80 to the lower edge of lever arm 38. Application of hydraulic fluid pressure will thus force the upper roll to separate from contact with the lower conditioning roll 34 provided that the fluid pressure in the cylinder is sufficient to overcome the force applied by tensioning spring 66.
FIG. 7 shows the lifting and floatation means provided for raising and lowering the header 18 relative to the carrying frame and for counterbalancing a large portion of the weight of the header 18 to allow it to follow the ground in a more responsive fashion. To this end, a lifting strap 80 is pivotally connected as by pin 81 to the lower link 79 midway between its ends which are pivotally hinged at the forward end by pin 77 to header 18 and at the rear end to the bottom of vertical frame member 14 by pin 99. At the bottom of link 79 below pivot pin 99, strap 80 extends upwardly to a spring anchor 82 attached thereto as by welding and extending laterally outwardly on either side thereof. The lower ends of a pair of floatation tension springs 84 are hooked on the respective spring anchors 82 and extend upwardly inside the frame member 14 to end retaining collars 85 which are threaded on adjusting screws 86 extending through the vertical frame members 14. Thus, by turning screws 86, a proper amount of tension may be placed on the floatation springs 84. The lifting strap 80 extends beyond the floatation spring anchors 82 to a slotted upper end inside the vertical frame member 14. Lifting strap 80 slides vertically in slot 97 which is secured to frame member 14. The slot 87 in the upper end of the lifting strap 80 is engaged by a pin 89 on a lifting lever 90 pivotally connected to the frame member 14 as by transverse pin 91. The lifting lever 90 extends radially outward from pin 91 passed lifting strap 80 to a pivotal connection at pin 92 with the rod end of a hydraulic cylinder 94 pivotally anchored as at 95 to a gusset within the vertical frame member 14.
It will be understood that a similar lift and float mechanism is attached to the right swing link and extends into the right vertical frame member 16. Thus, when the header 18 is in operating position, the floatation springs 84 and 98 (See FIG. 1) acting on the lower swing links through the short portion of the lifting strap 80 counterbalance the header 18 while the lost motion connections between the slot 87 and the lifting lever 90 prevents the hydraulic cylinders 94 from being pumped during floatation in normal operation. It will be seen that since the connection 81 of the lifting strap is at the bottom of the link 79 and below the pivot 99, the lever arm through which the floatation springs 84 and 98 (See FIG. 1) act, increases as the header 18 floats upwardly. Thus, although the springs 84 become weaker, the increased lever arm prevents the counterbalancing effect from being reduced accordingly. Extending the hydraulic cylinder 94 and its companion on the right side takes up the lost motion at slot 87 and acting on the lower swing links through the lifting strap 80, raises the header to the transport or uppermost position.
FIG. 6 shows the hydraulic lines which deliver operating fluid to both the roll opening cylinders 76 and 77 and the header lift cylinders 94 and 96. In the system reduced to practice, pressurized hydraulic fluid was supplied by the tractor used to tow the mower conditioner. This fluid was delivered via hydraulic lines installed onto tongue 28 (See FIG. 1). Flexible hose 100 spanned the region between the pivotal tongue 28 and the main frame 12 of the mower-conditioner. Similar flexible high pressure hose (not shown) spanned the distance from the main frame to the header.
In FIG. 6, hydraulic line 102 is positioned on the header subframe and connects with the hydraulic hose bringing fluid from the mower conditioner tongue to the main frame. Bulkhead branch tee 104 divides the output of line 102 into two parts. One flows along high pressure hose 106 to the roll opening cylinders 76 and 77. The other part flows along high pressure hose 107 to header lift cylinders 94 and 96. Since the header moves with respect to the positioning of the lift cylinders 94 and 96, due to their location in the vertical frame members (See FIG. 7) it is necessary to use flexible high pressure lines 108 and 109 to make connection with the header lift cylinders. Lines 110 and 111 can be plumbed using rigid tubing since the bases of roll opening cylinders 76 and 77 remain fixed with respect to the header subframe.
With both the roll opening and header lift cylinders plumbed as shown in FIG. 6, oil pressure applied at line 102 will simultaneously act on all four cylinders. In the system reduced to practice the cylinders were sized and biased so that the header raising and roll opening actions were sequential. The header lift cylinders 94 and 96 were sized so that working in conjunction with springs 84 and 98 (See FIGS. 7 and 1) application of hydraulic pressure in an amount between 850 and 1200 psi fully raises the header to the transport position.
The upper conditioning roll (See FIG. 5) is held against the lower roll both by its own weight and the force exerted by the two tension springs, one (spring 66) pulling down on the left lever arm 38, the other pulling down on right lever arm 36. As a result, in the system reduced to practice, approximately 700 lbs of force was required to bring about initial separation of the upper and lower conditioning rolls. Spring 66 and its mate on the other end of the upper conditioning roll are sized so that the spring force increases by approximately 300 lbs for each inch of roll separation. This means that a force of about 1300 lbs is required to raise the upper roll 32 (See FIG. 4) to achieve a two inch spacing between rolls. The roll opening cylinders are sized so that about 1500 psi of hydraulic pressure is needed to initiate separation. For full separation 2000 psi of hydraulic pressure is required.
This means that in operation, the header rises to the transport position with the header lift cylinders fully extended before the conditioning rolls begin to separate. Thus, if the tractor operator sees a plug forming at the nip of the conditioning rolls, he activates the hydraulic valve to apply pressure to the lift cylinders. The header rises, stopping the cutting of additional crop material, then the conditioning rolls begin to separate allowing passage of the slug of wadded up crop material rearward between the rolls and out the back of the machine.
Once the slug of crop material is passed, the operator releases hydraulic pressure by opening the valve spool at the tractor. With hydraulic pressure released at hydraulic line 102 (See FIG. 6) the upper conditioning roll 32 (See FIG. 5) quickly closes onto roll 34 due to the force applied by tension spring 66 and its companion at the right hand end of the roll. The header 18 (See FIGS. 1 and 7) drops more slowly when hydraulic line pressure is removed since the header weight is partially counterbalanced by springs 84 and 98. In the unit reduced to practice, lowering the header took between three and four seconds.
In summary, a header for a mower conditioner is disclosed wherein a sickle bar crop cutting apparatus is disposed laterally across the front lower edge. A conventional rotary reel, rotatably mounted above the cutting apparatus, serves to sweep crop cuttings rearward across a platform and into a transversely mounted rotating auger. The flights of the auger are counter wound, one end with respect to the other, so that crop cuttings are moved transversely inward toward a central region. Immediately behind and above the auger is a pair of crop conditioning rolls mounted one above the other. The rolls are transversely mounted but only about 70 percent as long as the auger. The lower conditioning roll is rotatably mounted on a fixed axis and the upper roll is mounted at each end to lever arms which are pivotally mounted to the header to allow swinging movement of the upper roll toward and away from the upper roll. Spring tension is maintained at each of the two lever arms to press the upper roll against the lower. The drive for the rolls is timed so that the spirals which are cut into the surface of each roll makes them run centered within its mated companion.
In combination, the rotating auger and reel deliver crop material to the nip of upper and lower conditioning rolls. The crop material passes between the conditioning rolls with the stems being bent and split open at short intervals. The conditioned crop material is ejected rearwardly and upwardly by conditioning rolls 32 and 34 (See FIG. 3) in the form of a stream which strikes windrow forming hood 96 (See FIGS. 1 and 7). Within windrow forming hood 96, the crop material is further consolidated and then deposited in a neat windrow on the ground behind the machine.
Thus, there has been disclosed roll opening apparatus which operates sequentially with the header lifting mechanism. While the invention has been described in conjunction with a specific embodiment, it is evident that many modifications will be apparent to those skilled in the art. Accordingly, it is intended to embrace such alternatives within the scope of this invention.
For example, not all mower conditioners have augers. In practice it has been found that headers which are less than 12 feet wide do not require the use of an auger. Without an auger, the reel will convey the crop cuttings directly from the cutter bar into the nip of the rollers.
For some implementations the crop cutting apparatus will comprise something other than a sickle bar. At least two other cutting means are known in the art. U.S. Pat. No. 4,085,570 to Joray et al and assigned to the same assignee as this application discloses a flail type forage harvester. As described at column 4, lines 40 et seq of U.S. Pat. No. 4,085,570 a flail type cutting apparatus includes a rotatable rotor carrying a plurality of flails or knives. The knives are secured to the rotor in four rows defined by a plurality of four rods spaced 90 degrees apart. Each rod extends through openings in a set of knives mounted serially at spaced intervals thereon. Each knife in each row overlaps the knives of alternate rows by a small amount to produce an even and complete cutting action when the rotor assembly is turned. With the flail type cutting apparatus a reel assembly is not needed as the flails will convey crop cuttings directly to the rear of the header.
Another crop cutting apparatus which does not utilize a sickle bar is the rotating disk subassembly. In this implementation a multiplicity of rotatable disks span the lower front edge of the header. Each disk is between 1 and 2 feet in diameter and mounted so as to be rotatably driven in a generally horizontal plane. The disks are driven so as to rotate in synchronism. One or more small knife blades are attached to the periphery of each disk serving to sever crop stems as the header advances. With this type cutting apparatus a reel assembly is usually not required since the rotating disks convey crop cuttings rearward as the material falls onto the top surface of the multiplicity of spinning disks.
Finally, our invention will accomplish the roll opening task for implementations wherein the conditioning rolls are mounted in the main frame structure and not in the movable header structure. In this implementation, the lower conditioning roll is fixedly mounted for rotation on the main frame while the upper conditioning roll is pivotally mounted to the main frame. The drive for the conditioning rolls and the roll opening action is the same as earlier disclosed for the preferred embodiment. The header will include only the crop cutting apparatus, the means for conveying crop material to the nip of the conditioning rolls and the header raising and lowering mechanism which enables both an operating and a transport mode. | Roll opening apparatus for separating the crop conditioning rolls of a mower conditioner is presented. The mower conditioner is of the type wherein a wheel supported main frame has mounted thereto by pivotal linkage a transversely disposed header having a sickle spanning its forward edge, a rotary reel for rearwardly sweeping the crop cuttings across a platform, and an auger at the rear of the platform for delivering the crop cuttings to the nip of a pair of laterally extending upper and lower crop conditioning rolls. The lower conditioning roll is rotatably mounted to the header on a fixed axis. The upper conditioning roll is mounted on lever arms pivoted to the header and biased by tension springs to an operating position adjacent the lower roll. Each lever arm is fitted with a hydraulic cylinder mounted so that extension of its piston causes the upper conditioning roll to open against the force of the tension springs. The two roll lift cylinders are plumbed in parallel with a pair of hydraulic cylinders which raise the header to its transport position. All four hydraulic cylinders work from the same source of pressurized fluid. The component parameters are chosen such that on application of gradually increasing fluid pressure, the header will be fully raised to its transport position before roll separation commences. | 8 |
BACKGROUND
[0001] The present invention relates to a method to mitigate and reduce the volatile compound emissions (Volatile Organic Compounds (VOC) and other volatile compounds) of a Steam Methane Reformer (SMR) plant by routing the contaminated streams to the furnace and by using the heat of the furnace to destroy the organic compounds. Steam Methane Reformers are used to produce Synthesis Gas (syngas) from Methane and Steam and can be adjusted to produce pure hydrogen, methanol or other products. These endothermic reactions occur at high pressure and temperature releasing a lot of heat. Part of this heat is used to produce steam required by the process in one or more boilers.
[0002] To produce steam, the boiler will need high quality water which is usually mixed with condensates from the process and sent to a deaerator to remove oxygen, dissolved CO2 and other impurities. The process condensates will sometimes contain volatile organic and volatile inorganic compounds coming from the plant process, which might have been absorbed by the water during condensing. Typically those volatile compounds such as, but not limited to, methanol or ammonia would be stripped from the water and vented to the atmosphere by the deaerator. Other vent streams containing volatile compounds (e.g. vent stream from boiler blowdown drum, process condensate stripper) can be treated similarly.
[0003] In order to protect our environment, more and more states and countries have new legislation limiting and reducing atmospheric rejects by industrial plants. The first regulations were focusing on sulfuric acid or nitric oxides but today regulations are now implemented on volatile compound emissions (VOC & Other). The proposed invention describes how the heat from the furnace of an SMR could be used to destroy those pollutants and reduce the environmental impact of the plant.
SUMMARY
[0004] The present invention is a method for Volatile Compound (VC, which includes VOC and other volatile compounds) mitigation in a syngas production process. This method includes providing a hydrocarbon reforming syngas production plant, this plant includes a reformer system comprising a primary fuel and oxidant stream, where part of this system is at low pressure, a steam inlet stream, and a primary combustion system for providing heat to said reformer system and producing a reformer flue gas stream, and a gaseous vent stream mainly composed of water and containing VC. This method also includes introducing at least a portion of said vent stream into one or more of the following: said primary fuel or oxidant stream; said steam inlet stream; said reformer box; said reformer flue gas stream.
BRIEF DESCRIPTION OF THE FIGURES
[0005] FIG. 1 is a schematic representation of one embodiment of the present invention, indicating the VC containing stream being injected into the convective section of the heat recovery device.
[0006] FIG. 2 is a schematic representation of one embodiment of the present invention, indicating the VC containing stream being injected into the radiant section of the reformer unit.
[0007] FIG. 3 is a schematic representation of one embodiment of the present invention, indicating the VC containing stream is combined with an ambient air stream, introduced into convection section where it is preheated, then combined with a fuel stream, and then introduced into the reformer through burners, where it is combusted.
[0008] FIG. 4 is a schematic representation indicating a vertical VC containing stream injection manifold, in accordance with one embodiment of the present invention.
[0009] FIG. 5 is a schematic representation indicating a horizontal VC containing stream injection manifold, in accordance with one embodiment of the present invention.
[0010] FIG. 6 is a schematic representation indicating the blow down from the heat recovery device, in accordance with one embodiment of the present invention.
DESCRIPTION OF PREFERRED EMBODIMENTS
[0011] The invention provides a number of technical solutions for using the heat of the reformer to destroy the volatile compounds (VC), which can be implemented in order to destroy the volatile compounds without a dedicated thermal or catalytic oxidizer.
[0012] As defined in this document, volatile compounds (VC), includes, but is not limited to, regulated volatile organic compounds, and other volatile compounds both organic and inorganic. This also includes, but is not limited to, ammonia and amines.
[0013] One solution is to route the VC-containing stream, composed mostly of water and VC, to the convection section (also called waste heat recovery section) of the plant. In order to ensure the full destruction of the VC, the higher the flue gas temperature at the injection point, the better. A preferred embodiment of this solution would be to inject the contaminated stream into the flue gas duct between the exit of the furnace and the first coil of the waste heat recovery section. In order to ensure high destruction efficiency the flue gas temperature should be above 750° C. and preferably above 850° C. The injection system could be designed with an injection grid located horizontally or vertically, co-current or counter current of the flue gas flow. The preferred solution would be to have a counter flow injection to minimize the impact on the downstream coils in the waste heat section. Additionally the invention could include the mixing of the vent with steam to avoid any condensation in the lines prior to and at the injection point.
[0014] In another embodiment of the solution, the contaminated stream would be injected in the bottom of the furnace in one or more places in the flue gas tunnels. Temperature at the injection point should be in the range of 1000° C. to 1060° C. In order to ensure the full destruction of the VC, beside the high temperature a sufficient residence time is important. The preferred distance to allow the maximum destruction of the VC would be ⅔ rd of the furnace length away from the flue gas exit. This would provide enough residence time to ensure destruction efficiency over 99%. The injection point should be carefully designed to avoid any impact on the refractory bricks of the flue gas tunnel and should ensure no liquid carry-over into the firebox.
[0015] In another embodiment, the contaminated stream may be injected on one or several side of the furnace at one or several locations. In the preferred solution the vent would be injected low enough not to disturb the burners flames but high enough to allow enough residency in the box and destruction of the VC. Tube protections would have to be engineered to avoid spraying the vent directly on the tubes and therefore cooling down the tubes, reducing the efficiency of the process reactions and leading to potential tube damage due to the water.
[0016] In another embodiment, the contaminated stream could be injected from the top of the furnace either in the fuel system of the burners or in a separate injection point. If injected in the fuel system a protection system would have to be put in place to ensure that no liquid water is sent to the burners.
[0017] The invention provides a number of technical solutions that could be implemented in order to destroy the volatile compounds without a dedicated thermal or catalytic oxidizer.
[0018] Turning now to FIG. 1 , hydrocarbon reforming syngas production plant 100 is presented. Reformer feed stream 101 and steam stream (steam inlet stream) 103 are introduced into the catalyst tubes of reformer unit 104 . Reformer unit 104 may be a Steam Methane Reformer (SMR) or an Autothermal Reformer (ATR). Hydrocarbon fuel (primary fuel) and oxidant stream 102 is introduced into the primary combustion system 114 in the shell side of reformer 104 , where they are combusted thereby providing the temperature and heat required for the reforming process. The products of this combustion exit the shell side of reformer 104 as SMR flue gas stream 106 .
[0019] Reformer feed stream 101 and steam stream (steam inlet stream) 103 are converted into syngas stream 105 , which exits reformer 104 and proceeds to downstream cleanup, cooling and utilization (not shown). The SMR flue gas stream 106 then enters heat recovery device 107 , where it indirectly exchanges heat with boiler feed water stream 112 , thereby producing steam stream 103 , and with the SMR flue gas stream exiting as cool flue gas stream 110 . The two major sections of system 100 comprise a radiant section 108 , and a convection section 109 , with the convection section primarily comprised of heat exchange tubes.
[0020] Most of the dissolved oxygen, as well as other non-condensable gases, in boiler feed water stream 112 are removed in deaerator 111 . The dissolved oxygen stream also contains volatile compounds (VC) which exit deaerator 111 in VC containing stream (gaseous vent stream) 113 . In one embodiment, VC containing stream 113 is introduced into convective section 109 of heat recovery section 107 . The idea would be to introduce the VCs into a section of the system wherein the pressure is relatively low and wherein the temperature and residence time are sufficiently high to destroy the VCs. By relatively low, it is understood that the pressure should be less than 2 bar, preferably less than 1.5 bar and could even be below atmospheric pressure.
[0021] Turning now to FIG. 2 , hydrocarbon reforming syngas production plant 200 is presented. Reformer feed stream 201 and steam stream (steam inlet stream) 203 are introduced into the catalyst tubes of reformer unit 204 . Reformer unit 204 may be a Steam Methane Reformer (SMR) or an Autothermal Reformer (ATR). Hydrocarbon (primary fuel) fuel and oxidant stream 202 is introduced into the primary combustion system 214 in the shell side of reformer 204 , where they are combusted thereby providing the temperature and heat required for the reforming process. The products of this combustion exit the shell side of reformer 204 as SMR flue gas stream 206 .
[0022] Reformer feed stream 201 and steam stream (steam inlet stream) 203 are converted into syngas stream 205 , which exits reformer 204 and proceeds to downstream cleanup, cooling and utilization. The SMR flue gas stream 206 then enters heat recovery device 207 , where it indirectly exchanges heat with boiler feed water stream 212 , thereby producing steam stream 203 , and with the SMR flue gas stream exiting as cool flue gas stream 210 . The two major sections of system 200 comprise a radiant section 208 , and a convection section 209 , with the convection section primarily comprised of heat exchange tubes.
[0023] Most of the dissolved oxygen, as well as other non-condensable gases, in boiler feed water stream 212 are removed in deaerator 211 . The dissolved oxygen stream also contains volatile compounds (VC) which exit deaerator 211 in VC containing stream 213 . In one embodiment, VC containing stream 213 is introduced into the radiant section of reformer unit 204 . The idea would be to introduce the VCs into a section of the system wherein the pressure is relatively low and wherein the temperature and residence time are sufficiently high to destroy the VCs. By relatively low, it is understood that the pressure should be less than 2 bar, preferably less than 1.5 bar and could even be below atmospheric pressure.
[0024] Turning now to FIG. 3 , hydrocarbon reforming syngas production plant 300 is presented. Reformer feed stream 301 and steam stream (steam inlet stream) 303 are introduced into the catalyst tubes of reformer unit 304 . Reformer unit 304 may be a Steam Methane Reformer (SMR) or an Autothermal Reformer (ATR).
[0025] Reformer feed stream 301 and steam stream (steam inlet stream) 303 are converted into syngas stream 305 , which exits reformer 304 and proceeds to downstream cleanup, cooling and utilization. The SMR flue gas stream 306 then enters heat recovery device 307 . The two major sections of system 300 comprise a radiant section 308 , and a convection section 309 , with the convection section primarily comprised of heat exchange tubes. Within heat recovery device 307 , the combined stream indirectly exchanges heat the above combined ambient air stream 302 A and VC containing stream 313 , and with boiler feed water stream 312 , thereby producing steam stream 303 , and with the SMR flue gas stream exiting as cool flue gas stream 310 .
[0026] Most of the dissolved oxygen, as well as other non-condensable gases, in boiler feed water stream 312 are removed in deaerator 311 . The dissolved oxygen stream also contains volatile compounds (VC) which exit deaerator 311 in VC containing stream 313 . A deaerator will typically operate at between 0.4 bar and 0.7 bar, so stream 313 will be at an equivalent low pressure. VC containing stream 313 is combined with ambient air stream 302 A, and the combined stream is introduced into radiant section 308 . In radiant section 308 , the combined stream is in indirect heat exchange with hot flue gas stream 306 , thereby producing preheated oxidant stream 302 A. Preheated oxidant stream 302 A is combined with fuel stream 302 C, which are then introduced into the shell side of reformer 304 , where they are combusted thereby providing the temperature and heat required for the reforming process. The products of this combustion exit the shell side of reformer 304 as SMR flue gas stream 306 .
[0027] The idea would be to introduce the VCs into a section of the system wherein the pressure is relatively low and wherein the temperature and residence time are sufficiently high to destroy the VCs. By relatively low, it is understood that the pressure should be less than 2 bar, preferably less than 1.5 bar and could even be below atmospheric pressure.
[0028] FIGS. 4 and 5 are illustrative embodiments of two possible ways in which VC containing stream 113 may be introduced into convective section 109 of heat recovery section 107 . FIG. 4 illustrates a vertical injection manifold, and FIG. 5 illustrates a horizontal injection manifold. Additional embodiments are envisioned, and are within the ability of one of ordinary skill in the art to develop and implement without undue experimentation.
[0029] As indicated in FIG. 4 , VC containing stream 113 is introduced into convective section 109 in a vertical injection manifold. This vertical manifold may have forward facing injection ports (A) or rearward facing injection ports (B). These ports may inject VC containing stream 113 at a positive or negative angle to the horizontal, as required for optimum distribution and mixing in SMR flue gas stream 106 .
[0030] VC containing stream 113 may be injected on one or several sides of convective section 109 , at one or several locations. Special care should be taken to protect heat exchangers close to the injection ports to avoid spraying the vent directly on the exchanger tubes and therefore cooling down the tubes, reducing the efficiency and leading to potential tube damage due to the water.
[0031] As indicated in FIG. 5 , VC containing stream 113 is introduced into convective section 109 in a horizontal injection manifold. This horizontal manifold may have forward facing injection ports (A) or rearward facing injection ports (B). These ports may inject VC containing stream 113 at a positive or negative angle to the vertical as required for optimum distribution and mixing in SMR flue gas stream 106 . Special care should be taken to protect heat exchangers close to the injection ports to avoid spraying the vent directly on the exchanger tubes and therefore cooling down the tubes, reducing the efficiency and leading to potential tube damage due to the water.
[0032] VC containing stream 113 may be injected from near the top of convective section 109 , or at any point above the horizontal midpoint of convective section 109 .
[0033] Turning now to FIG. 6 , hydrocarbon reforming syngas production plant 600 is presented. Reformer feed stream 601 and steam stream (steam inlet stream) 603 are introduced into the catalyst tubes of reformer unit 604 . Reformer unit 604 may be a Steam Methane Reformer (SMR) or an Autothermal Reformer (ATR). Hydrocarbon (primary fuel) fuel and oxidant stream 602 is introduced into the primary combustion system 614 in the shell side of reformer 604 , where they are combusted thereby providing the temperature and heat required for the reforming process. The products of this combustion exit the shell side of reformer 604 as SMR flue gas stream 606 .
[0034] Reformer feed stream 601 and steam stream (steam inlet stream) 603 are converted into syngas stream 605 , which exits reformer 604 and proceeds to downstream cleanup, cooling and utilization. The SMR flue gas stream 606 then enters heat recovery device 607 , where it indirectly exchanges heat with boiler feed water stream 612 , thereby producing steam stream 603 , and with the SMR flue gas stream exiting as cool flue gas stream 610 . The two major sections of system 600 comprise a radiant section 608 , and a convection section 609 , with the convection section primarily comprised of heat exchange tubes.
[0035] Most of the dissolved oxygen, as well as other non-condensable gases, in boiler feed water stream 612 are removed in deaerator 611 . The dissolved oxygen stream also contains volatile compounds (VC) which exit deaerator 611 in VC containing stream 613 . In one embodiment, the blow down stream 614 from heat recovery device 607 is introduced into a phase separation device 615 , where it is separated into a high solids content waste stream 616 and a vapor stream 617 which may contain VCs. Vapor stream 617 may then be introduced into deaerator 611 , after which VC containing stream 613 is introduced into either the radiant section 608 or the convective section 609 of reformer unit 604 . In one embodiment, VC containing stream 613 is introduced into both the radiant section 608 and the convective section 609 of reformer unit 604 . Vapor stream 617 may then be introduced directly into either the radiant section 608 or the convective section 609 of reformer unit 604 . In one embodiment, vapor stream 617 is introduced into both the radiant section 608 and the convective section 609 of reformer unit 604 . | A method for volatile compound (VC) mitigation in a syngas production process is provided. This method includes providing a hydrocarbon reforming syngas production plant, this plant includes a reformer system comprising a primary fuel and oxidant stream, where part of this system is at low pressure, a steam inlet stream, and a primary combustion system for providing heat to the reformer system and producing a reformer flue gas stream, and a gaseous vent stream mainly composed of water and containing VC. This method also includes introducing at least a portion of the vent stream into one or more of the following: the primary fuel and oxidant stream; the steam inlet stream; the reformer flue gas stream. | 2 |
FIELD OF THE INVENTION
The present invention relates to devices for providing medical gas and electrical services to hospitals and other medical care facilities.
BACKGROUND OF THE INVENTION
Construction costs for hospitals and other medical care facilities depend in part on the cost of required medical equipment as well as the efficiency of installation of such equipment during the construction phase. One major item installed in most patient care areas is a wall panel for providing medical gases and electrical services at the bedside. Modular assemblies for such panels have simplified installation of these services. Nevertheless, there remains a need to simplify the production and assembly of these units, and to provide greater efficiency in the installation of the units at the construction site. Further, there is a need for modular in-wall type units that provide a more compact, vertically oriented interface for users. Still further, there is a need for a vertically oriented in-wall unit with convenient equipment management capabilities.
SUMMARY OF THE INVENTION
The present invention comprises a modular in-wall medical services unit for installation in the wall of a structure. The structure has at least a first room with a floor and a ceiling level and a wall at least partially defining the first room. The wall comprises a wall space defined at least in part by wallboard. The unit comprises a frame having a first side. The frame is sized to extend from the floor to above the ceiling level of the structure and adapted to be installed in the wall space of the structure.
A first medical service outlet is supported on the frame to be between the floor and the ceiling level of the structure. The first service outlet is positioned to be accessible from the first side of the frame. A first service conduit is supported on the frame to extend from the first service outlet to above the ceiling level of the structure. A first service connection is included. The service connection is operatively connected to the first service conduit and supported on the frame to be above the ceiling level of the structure and to extend from the first side of the frame forward of the wall space into the first room so as to be accessible after installation of the wallboard.
Further, the present invention comprises modular in-wall medical services unit for installation in the wall of any one of a plurality of structures, wherein each of the structures has a first room, a floor and a wall space, and wherein each of the structures has a different ceiling level. The unit comprises a frame having a length adjustable to extend from the floor to above the ceiling level of any of the plurality of structures. The frame is adapted to be installed in the wall space of the structure. A first medical service outlet is supported on the frame to be between the floor and the ceiling level of all of the plurality of structures. The first service outlet is positioned to be accessible from the first side of the frame in the first room.
Still further, the present invention includes a modular in-wall medical services unit for installation in the wall of a structure having a first room defined in part by a wall having a wall space covered by wallboard. The unit comprises a frame adapted to be installed in the wall space of the structure. The frame has a first side for the first room. A first mounting flange is provided on the frame and is adapted to be connected to the edge of wallboard in the first room. A first cover panel is supported on the first side of the frame. A first trim flange on the cover panel, generally parallel to the first mounting flange on the frame, is positioned forwardly of the first mounting flange a distance sufficient to receive wallboard therebetween during installation of the unit.
A first medical service outlet is supported on the first side of the frame to be accessible in the first room through the first cover panel. The first trim flange is movable horizontally relative to the first mounting flange during installation of the wallboard between a first position and a second position. In the first position, the first trim flange is spaced a distance forward of the wallboard between the first mounting flange and the first trim flange. In the second position, the first trim flange engages the wallboard.
Further still, the present invention is directed to modular in-wall medical services unit for installation in the wall of a structure having a first room with a floor and a ceiling level and a wall at least partially defining the first room, wherein the wall comprises a wall space and wallboard forming the wall's exterior surface. This unit comprises a frame having a first side. The frame is adapted to be installed in the wall space of the structure. Also included is a vertically oriented cover panel supported by the frame, the cover panel having a height and a width, the height being greater than the width. The cover panel comprises a pair of vertically-oriented side edges.
A first medical service outlet is supported on the frame and accessible through the cover panel on the first side of the frame from within the first room. A trim flange is provided along at least a portion of at least one of the vertically-oriented side edges of the cover panel. The trim flange is adapted to join the side edge of the cover panel to the wallboard. The trim flange defines a vertically oriented equipment-mounting track therein. The cover panel is positioned on the frame so that when the frame is installed in the wall space, the first service outlet and the equipment-mounting track are positioned to be used conveniently by a human operator standing in the first room.
Finally, the present invention comprises a modular in-wall medical services unit for installation in the wall of a structure having a first room with a floor and a ceiling level and a wall at least partially defining the first room, the wall comprising a wall space. The unit comprises a frame having a first side. The frame is adapted to be installed in the wall space of the structure. The frame supports a vertically oriented cover panel. The cover panel has a height and a width, the height being greater than the width. The height of the cover panel is less than the distance between the floor and the ceiling level of the first room.
A first medical service outlet is supported on the frame and accessible through the cover panel on the first side of the frame from within the first room. The cover panel is positioned on the frame so that when the frame is installed in the wall space, the first medical service outlet is positioned to be conveniently used by a human operator standing in the first room.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an elevational, fragmented view of hospital room showing the modular medical services unit of the present invention installed in the wall near a bed.
FIG. 2 is an elevational, fragmented view of the hospital room shown in FIG. 1 with the wallboard cut away to reveal the installation of the unit between the wall studs of the wall space.
FIGS. 3A and 3B are a longitudinal sectional view taken along line 3 - 3 of FIG. 2 .
FIG. 4 is a fragmented, cross sectional view taken along line 4 - 4 of FIG. 2 . The service outlets have been omitted for clarity of illustration.
FIG. 5 is a fragmented, exploded cross sectional view of a portion of the cross section of the unit shown in FIG. 4 .
FIGS. 6 and 7 are fragmented longitudinal sectional views taken through a portion of the unit through the cabinet illustrating how the cabinet is slidably mounted to move forward and rearward in the main frame of the unit.
FIGS. 8-10 illustrate the steps employed to install the wallboard around the unit and attach the trim flange along the exposed edges of the unit.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Turning now to the drawings in general and to FIG. 1 in particular, there is shown therein a modular medical services unit constructed in accordance with the present invention and designated generally by the reference numeral 10 . As used herein, “medical service” or “service” refers to any one of a variety of gas, electrical or communication services, including but not limited to oxygen, compressed air, vacuum (suction), electricity, telephone and video cable. The unit 10 is illustrated installed in the wall 12 of at least a first room 14 in a structure 16 . Usually, the unit 10 will be installed at the side of a patient bed 18 . While a conventional hospital room is depicted, the unit 10 may be installed in a variety of structures such as clinics, emergency rooms, nursing home rooms, and virtually any sort of treatment facility.
As shown in FIGS. 2 and 3 A- 3 B, the unit 10 is adapted for installation in the wall space 20 defining the first room 14 . Preferably, the unit comprises a frame 22 sized to be installed between wall studs 24 in the wall space 20 defined by wallboard 28 . More preferably, the frame 22 is sized to extend from the floor 30 to a distance above the ceiling level 32 of the room 14 .
In the preferred embodiment, the frame 22 comprises a main frame assembly 34 and a top frame assembly 36 . The main frame assembly 34 preferably comprises a pair of C-shaped vertical rails 38 stabilized by one or more cross rails 40 ( FIGS. 2 , 3 B). Similarly, the top frame assembly 36 is shorter in length but formed of a pair of opposing C-shaped vertical rails 44 and at least one stabilizing cross rail 46 ( FIGS. 2 , 3 A).
The vertical rails 38 and 44 may be formed from sheet metal having a thickness sufficient to provide the necessary rigidity to the unit 10 . For example, in a preferred construction, the metal of which the rails are made may be only about 1/16 inch. Conventional wallboard typically ha a thickness of about ⅝ inch. However, for clarity of illustration, the thickness of the metal in the vertical rails 38 and 44 , as shown in FIGS. 3A and 3B is exaggerated relative to the thickness of the wallboard.
As best seen in FIGS. 3A-3B , the corresponding C-shaped vertical rails 38 and 44 of the main frame assembly 34 and the top frame assembly 36 may be telescopically engaged so that the overall height or length of the frame 22 can be adjusted. To that end, a plurality of vertically arranged holes 50 and 52 are provided in the vertical rails 38 and 44 , respectively. A bolt 54 or fastener of some sort may be used to secure the vertical rails 38 and 44 at the desired length.
At least a first cabinet 56 is supported in the frame 22 , preferably in the main frame assembly 34 between the vertical rails 38 . When the unit 10 is to be used in a wall space shared by a second room 58 , the unit may be functional on both first and second sides 60 and 62 , as seen in FIGS. 3A and 3B . Thus, a second cabinet 64 may be supported in the frame 22 back-to-back with the first cabinet 56 .
The first cabinet 56 preferably provides a divided enclosure to house the medical service outlets. The service outlets preferably include a first plurality of electrical outlets designated generally at 70 , including at least first electrical outlet 72 , and a first plurality of gas outlets designated generally at 74 , including at least a first gas outlet 76 on the first side 60 of the frame 22 . Similarly, the second cabinet 64 preferably provides a divided enclosure to house medical service outlets. More preferably, the service outlets in the second cabinet 64 comprise a second plurality of electrical outlets designated generally at 80 , including at least a second electrical outlet 82 , and a second plurality of gas outlets designated generally at 84 , including at least a second gas outlet 86 on the second side 62 of the frame 22 . Thus, the gas and electrical outlets and other service outlets are supported on the frame to be positioned between the floor 30 and the ceiling level 32 of the structure 16 and accessible from the first and second sides 60 and 62 of the frame 22 when the unit 20 is installed.
Referring still to FIGS. 2 and 3 A- 3 B, the unit 10 also preferably includes medical service conduits, such as a first plurality of electrical conduits designated generally at 88 including at least a first electrical conduit 90 supported on the frame 22 . The conduits 88 extend from the first electrical outlet 72 up through the main frame assembly 34 to a point in the top frame assembly 36 above the designated ceiling level 32 . As used herein, “electrical conduit” denotes generally the tubular conduit and the wires contained in it.
Also included in the unit is at least one medical service connection for each medical service conduit. For example, in the preferred unit 10 , the service connections include at least a first electrical junction box 92 preferably supported in the top frame assembly 36 and positioned to be above the ceiling level 32 and to extend from the first side 60 of the frame 22 forward of the wall space 20 into the first room 14 (not shown in FIG. 2 ). In this way, the electrical service connection will be accessible before and after the wallboard 28 is installed. The junction box 92 is operatively connected to at least the first electrical conduit 90 .
The service conduits may include gas conduits in addition to electrical conduits. To that end, the unit 10 preferably also comprises at least a first plurality of gas conduits 94 including a first gas conduit 96 supported on the frame 22 to extend from the first gas outlet 76 to a point above the ceiling level 32 of the top frame assembly 36 . The upper end of the gas conduit 96 preferably is bent outwardly or provided with an elbow fitting to provide a gas service connection forward a distance of the wall space 20 once the unit 10 is installed. In this way, the gas connection will also be accessible before and after the wallboard 28 is installed.
As seen in FIGS. 3A and 3B , the unit 10 may also include a second plurality of electrical conduits designated generally at 98 including at least a second electrical conduit 100 extending from the second electrical outlet 82 on the second side 62 of the frame 22 up through the main frame assembly 34 to a point in the top frame assembly 36 above the designated ceiling level 32 . At least a second junction box 102 may be supported in the top frame assembly 36 back-to-back with the first junction box 92 , also positioned to be above the ceiling level 32 and to extend from the second side 62 of the frame 22 forward of the wall space 20 into the second room 58 . Alternately, a single junction box may be utilized, in which case all the electrical conduits will be connected to the single junction box.
As shown in FIG. 1 , a part of the unit 10 remains exposed when fully installed in the first room 14 . This part preferably comprises a cover panel that supports the faces of the various electrical and gas service outlets. More preferably, the cover panel is vertically oriented, that is, it is taller than it is wide, or has a height greater than its width. Most preferably, the cover panel is positioned on the frame 22 so that when the frame is installed in the wall space 20 , the medical service outlets are located for convenient use by a human operator standing in the first room 14 .
A first cover panel 110 covers the first cabinet 56 on the first side 60 of the frame 22 . Likewise, as seen in FIG. 3B , a second cover panel 112 covers the second cabinet 64 on the second side 62 of the frame 22 .
The dual-sided unit 10 further preferably includes a second plurality of gas conduits 106 including a second gas conduit 108 . The second plurality of gas conduits 106 and the second gas conduit 108 , as on the first side 60 , are supported on the second side 62 of the frame 22 to extend from the second plurality of gas outlets 84 and the second gas outlet 86 , respectively, to above the ceiling level 32 of the structure 16 .
The preferred installation of the unit 10 provides for the wallboard 28 to be cut to fit closely around and behind the vertically oriented side edges 114 and 116 ( FIG. 2 ) of the cover panels 110 and 112 . For that purpose, a trim and flange combination is provided to provide a secure installation and an attractive facade for the unit 10 . A detailed description of this trim and flange assembly will be made with reference to FIGS. 4 and 5 , to which attention now is directed.
FIG. 4 is a fragmented cross-sectional view taken through one end (the left end as viewed in FIG. 2 ) of the main frame assembly 34 of the unit 10 . FIG. 5 is an exploded view of one corner of the end shown in FIG. 4 . The outlet assemblies have been omitted to clarify the illustrations.
The left vertical rail 38 comprises a planar central portion 120 arranged to be positioned generally transverse to the wall space 20 . Extending laterally from the central portion 120 are first and second opposing mounting flanges 122 and 124 positioned to be generally co-planar with the wallboard 28 to be applied.
The depth of the frame 22 , that is, the width of the central portion 120 is selected to conform to the depth of the wall space 20 . In this way, when fixed in position between the wall studs 24 (see FIG. 2 ), the central portions 120 of the rails 38 (and the corresponding central portions of the rails 44 in the top frame assembly 36 ) can be used conveniently to attach the frame 22 to adjacent studs 24 . The flanges 122 and 124 provide elongated vertical mounting flanges positioned to abut and support the interior side of the wallboard 28 around the cover panels 110 and 112 ( FIG. 3B ).
The first and second cabinets 56 and are slidably attached to the central portion 120 and the vertical rail 38 by the bolts 126 and 128 in a manner to be described hereafter. Trim flanges 130 and 132 are extruded edge members attached to the vertical sides of the cabinets 56 and 64 . While this attachment can be accomplished in various ways, in the present embodiment, the trim flanges 130 and 132 include inward extensions 134 and 136 that extend inwardly to overlap the sidewalls 138 and 140 of the cabinets 56 and 64 and attached thereto by bolts 142 and 144 .
The trim flanges 130 and 132 further preferably comprise extensions 146 and 148 to underlay the edges of the cover panels 110 and 112 . Bolts 150 and 152 attach the extensions 146 and 148 to the cover panels 110 and 112 . The trim flanges 130 and 132 include legs 154 and 156 . The legs 154 and 156 are configured to be generally parallel to but spaced a distance forward of the mounting flanges 122 and 124 . Bolts 158 and 160 are included to extend through the legs 154 and 156 and mounting flanges 122 and 124 and the wallboard 28 sandwiched therebetween.
With continuing reference to FIGS. 4 and 5 , vertical cover strips 166 and 168 preferably are provided to cover the trim flanges 130 and 132 and the bolts 158 and 160 . Like the trim flanges 130 and 132 , the cover strips 166 and 168 preferably are extrusions. More preferably, the cover strips 166 and 168 comprise angled strips having side portions 172 and 174 and front portions 176 and 178 . The side portions 172 and 174 provide sections to receive small screws 180 and 182 to attach the cover strips 166 and 168 to the trim flange legs 154 and 156 .
Equipment mounting tracks 184 and 186 conveniently be provided in the front portions 176 and 178 of the cover strips 166 and 168 . More preferably, the racks 184 and 186 are integrally formed in the extruded strips 166 and 168 . Thus, in addition to the other advantages of the unit of the present invention, the trim flanges 130 and 132 of the cover panels 110 and 112 include the convenience of built-in equipment management. Moreover, like the medical service outlets also contained in the cover panels 110 and 112 , these mounting tracks 184 and 186 , will be conveniently accessible by a human operator standing in the first room 14 .
The sliding or moving connection between the cabinet/cover panel/trim flange assembly relative to the frame 22 is shown in more detail in FIGS. 6 and 7 . While other types of connections are suitable, in the present embodiment the movable connection comprises an elongated horizontal slot 190 formed in the sidewall 138 of the cabinet 56 to receive the bolt 126 . (See also FIG. 5 .) The allows the cabinet 56 to be moved forwardly and rearwardly, or horizontally relative to the frame 22 , between a first and second position.
The advantage of the movable connection shown in FIGS. 6 and 7 is illustrated in FIGS. 8-10 . In FIG. 8 , the cabinet 56 and attached cover panel 110 are pulled forward to the first position to provide a space 196 between the leg 154 of the trim flange 130 and the surface of the wallboard 28 . In this position, it is easy to run a bead of sealant 198 in the space 196 . Next, as seen in FIG. 9 , the cabinet 56 and attached cover panel 110 are pushed back to the second position forcing the trim flange 130 against the face of the wallboard 28 to engage the wallboard 28 . The bolt 158 then is installed. FIG. 10 illustrates the attachment of the cover strip 166 with the attachment screw 180 .
Having described the construction of the unit, the use will be summarized. The unit, as delivered to the construction site, preferably has the cabinets mounted inside the frame. The cabinets, conduits and junction boxes are secured to the frame. The height of the frame will have been adjusted at the factory to accommodate the specified ceiling level of the room into which the unit is to be installed. The cover panels are secured over the front of the cabinets with the trim flanges on the long vertical edges between the cover panels and the cabinets. The cabinet and attached cover panels will be slightly movable or “floating” on the frame, and the cover strips will be separate or separable from the trim flanges.
After unpacking the unit, the unit will be placed in the wall space between two studs, and the vertical rails of the frame are secured to the partition system. Next, the cabinet/cover panel assembly is pulled to its outward most position and the wallboard is installed. The wallboard may be installed around the cover panel and all the way up to deck above the ceiling level. That is, the wallboard may be installed over the top frame assembly of the unit, leaving the service connections, such as the junction boxes and the ends of the gas conduits accessible.
Once the wallboard is installed, there is still a space between the face of the wallboard and the trim flange around the cover panel. If desired, a bead of caulk or sealant is applied. Next, the cover panel is pushed back against the wallboard, forming a seal between the edge of the wallboard, the trim flange and the sealant therebetween. Now it will be seen that the floating connection allows the cabinet assembly to be self-aligning; it will meet the wall surface closely from top to bottom regardless of irregularities in the wallboard surface of lack of plumb in the wall studs.
Next, screws are inserted through the trim flange, through the wallboard and into the mounting flange of the frame behind it, to hold the wallboard securely between the cover panel in front and the mounting flange of the frame behind it. Finally, the cover strips may be attached over the trim flanges and end caps may be attached at the bottom and top edges of the cover panel for a finished appearance.
Now it will be appreciated that the modular medical services unit of the present invention provides several advantages at both the manufacturing level as well as at the point of installation. The frame is constructed of two rail assemblies joined by an easily adjustable telescoping arrangement. These main structural components can be manufactured and kept in inventory. Upon receipt of an order specifying a specific ceiling level, the unit can be assembled quickly and adjusted to the appropriate length. The length is selected so that the attached gas conduits and junction boxes will be above the ceiling level. The elbow connections on the gas conduits extend the connections out into the space forward of the wallboard. Likewise the junction boxes are positioned forward on the frame so that the front closure on the boxes can be accessed even after the wallboard is installed. Thus, there is no need for the installation of the wallboard to be delayed until the electrical work or piping can be completed.
A further advantage of the unit of this invention is found in the manner in the way the cover panel is attached to the unit. When delivered to the construction site, the trim flange on the cover panel, and typically the entire cover panel, is movably attached to the frame or cabinet providing a self-aligning feature during installation. This floating connection allows the cover panel to be pulled out slightly to apply a bead of caulk or sealant around the opening in the wallboard before the cover panel is fully secured to the wallboard and frame. A further advantage is found in the vertical equipment mounting tracks provided in the vertical cover strips.
Changes can be made in the combination and arrangement of the various parts and steps described herein without departing from the spirit and scope of the invention. | A modular in-wall medical services unit for medical care facilities. A frame supports a cabinet with a cover panel providing electrical and/or gas outlets. Built-in electrical and gas conduits are included. A junction box and ends of the gas conduits near the top of the frame are accessible after wallboard is applied. Thus, wallboard can be installed before or after wiring is completed and gas connections are made. The self-aligning cover panel is “floatingly” supported on the frame so that a bead of sealant can be applied around the edge before the cover panel is “snugged up” to the wall and secured. The trim flanges on the cover panel include vertical equipment mounting tracks. Manufacturing is simplified by making the height of the frame adjustable; the same frame elements can be used to assemble units for different ceiling heights, decreasing the number of required parts in inventory and expediting assembly. | 4 |
CROSS REFERENCES TO RELATED APPLICATIONS
The following applications are related and were filed contemporaneously: “MAGNETIC HELICAL PHYSICAL UNCLONABLE FUNCTION MEASURED ABOVE FLIGHT”, “MAGNETIC HELICAL PHYSICAL UNCLONABLE FUNCTION MEASURED ADJACENT TO FLIGHT”, “MANUFACTURING A HELICAL PHYSICAL UNCLONABLE FUNCTION”.
BACKGROUND
1. Field of the Disclosure
The present disclosure relates generally to anti-counterfeit systems and more particularly to physical unclonable functions.
2. Description of the Related Art
Counterfeit printer supplies, such as toner bottles, are a problem for consumers. Counterfeit supplies may perform poorly and may damage printers. Printer manufacturers use authentication systems to deter counterfeiters. Physical unclonable functions (PUF) are a type of authentication system that implements a physical one-way function. Ideally, a PUF cannot be identically replicated and thus is difficult to counterfeit. Thus, it is advantageous to maximize the difficulty of replicating a PUF to deter counterfeiters. It is also advantageous for the PUF and PUF reader to be low cost.
SUMMARY
The invention, in one form thereof, is directed to a supply item for an image forming device having a body; a physical unclonable function located on the body configured to rotate about an axis of rotation having a shaft centered on the axis of rotation and a helical flight having a length wrapped around the shaft, the helical flight has a top surface furthest away from the axis of rotation, the helical flight contains magnetized particles that generate a magnetic field above the top surface having a varying intensity along the length of the helical flight, the helical flight has a side surface between the shaft and the top surface; and a non-volatile memory located on the body containing a first array of numbers corresponding to the intensity of the magnetic field radial to the axis of rotation above the top surface along a section of the length of the helical flight at a first plurality of locations each at a first fixed distance from the side surface and also containing a digital signature generated from the first array of numbers.
The invention, in another form thereof, is directed to a supply item for an image forming device having a body; a physical unclonable function located on the body configured to rotate about an axis of rotation having a shaft centered on the axis of rotation, the shaft has a helical channel having a length wrapped around the shaft, the shaft contains magnetized particles that generate a magnetic field above the shaft having a varying intensity, the helical channel has a side surface; and a non-volatile memory located on the body containing a first array of numbers corresponding to the intensity of the magnetic field radial to the axis of rotation above the shaft along a section of the length of the helical channel at a first plurality of locations each at a first fixed distance from the side surface and also containing a digital signature generated from the first array of numbers.
The invention, in yet another form thereof, is directed to a supply item for an image forming device having a body; an auger having a spiral flight having magnetized particles that generate a magnetic field above the spiral flight having a varying intensity, the auger is rotatably mounted to the body; and a non-volatile memory located on the body containing an array of numbers corresponding to the intensity of the magnetic field above a section of the spiral flight and also containing a digital signature generated from the array of numbers.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings incorporated in and forming a part of the specification, illustrate several aspects of the present disclosure, and together with the description serve to explain the principles of the present disclosure.
FIG. 1 is a block diagram of an imaging system including an image forming device according to one example embodiment.
FIG. 2 is a top view of a helical PUF.
FIG. 3 is a side view of a PUF reader.
FIG. 4 is a top view of a supply item for an imaging device having a helical PUF.
FIG. 5 is a graph of magnetic field intensity above a helical flight.
FIG. 6 is example values for generating a digital signature.
FIG. 7 is a top view of a helical PUF.
FIG. 8 is a section view of a helical PUF.
FIG. 9 is a section view of a helical PUF.
FIG. 10 , FIG. 11 , and FIG. 12 are top views of a helical PUF.
FIG. 13 is a top view of a helical PUF.
FIG. 14 is a top view of a helical PUF.
FIG. 15 is a top view of a supply item for an imaging device having a helical PUF.
FIG. 16 is a flowchart of a method of manufacturing a supply item for an imaging device.
DETAILED DESCRIPTION
In the following description, reference is made to the accompanying drawings where like numerals represent like elements. The embodiments are described in sufficient detail to enable those skilled in the art to practice the present disclosure. It is to be understood that other embodiments may be utilized and that process, electrical, and mechanical changes, etc., may be made without departing from the scope of the present disclosure. Examples merely typify possible variations. Portions and features of some embodiments may be included in or substituted for those of others. The following description, therefore, is not to be taken in a limiting sense and the scope of the present disclosure is defined only by the appended claims and their equivalents.
Referring to the drawings and particularly to FIG. 1 , there is shown a block diagram depiction of an imaging system 50 according to one example embodiment. Imaging system 50 includes an image forming device 100 and a computer 60 . Image forming device 100 communicates with computer 60 via a communications link 70 . As used herein, the term “communications link” generally refers to any structure that facilitates electronic communication between multiple components and may operate using wired or wireless technology and may include communications over the Internet.
In the example embodiment shown in FIG. 1 , image forming device 100 is a multifunction device (sometimes referred to as an all-in-one (AIO) device) that includes a controller 102 , a user interface 104 , a print engine 110 , a laser scan unit (LSU) 112 , one or more toner bottles or cartridges 200 , one or more imaging units 300 , a fuser 120 , a media feed system 130 and media input tray 140 , and a scanner system 150 . Image forming device 100 may communicate with computer 60 via a standard communication protocol, such as, for example, universal serial bus (USB), Ethernet or IEEE 802.xx. Image forming device 100 may be, for example, an electrophotographic printer/copier including an integrated scanner system 150 or a standalone electrophotographic printer.
Controller 102 includes a processor unit and associated memory 103 and may be formed as one or more Application Specific Integrated Circuits (ASICs). Memory 103 may be any volatile or non-volatile memory or combination thereof such as, for example, random access memory (RAM), read only memory (ROM), flash memory and/or non-volatile RAM (NVRAM). Alternatively, memory 103 may be in the form of a separate electronic memory (e.g., RAM. ROM, and/or NVRAM), a hard drive, a CD or DVD drive, or any memory device convenient for use with controller 102 . Controller 102 may be, for example, a combined printer and scanner controller.
In the example embodiment illustrated, controller 102 communicates with print engine 110 via a communications link 160 . Controller 102 communicates with imaging unit(s) 300 and processing circuitry 301 on each imaging unit 300 via communications link(s) 161 . Controller 102 communicates with toner cartridge(s) 200 and non-volatile memory 201 on each toner cartridge 200 via communications link(s) 162 . Controller 102 communicates with fuser 120 and processing circuitry 121 thereon via a communications link 163 . Controller 102 communicates with media feed system 130 via a communications link 164 . Controller 102 communicates with scanner system 150 via a communications link 165 . User interface 104 is communicatively coupled to controller 102 via a communications link 166 . Processing circuitry 121 and 301 may include a processor and associated memory such as RAM, ROM, and/or non-volatile memory and may provide authentication functions, safety and operational interlocks, operating parameters and usage information related to fuser 120 , toner cartridge(s) 200 and imaging unit(s) 300 , respectively. Controller 102 processes print and scan data and operates print engine 110 during printing and scanner system 150 during scanning.
Computer 60 , which is optional, may be, for example, a personal computer, including memory 62 , such as RAM, ROM, and/or NVRAM, an input device 64 , such as a keyboard and/or a mouse, and a display monitor 66 . Computer 60 also includes a processor, input/output (I/O) interfaces, and may include at least one mass data storage device, such as a hard drive, a CD-ROM and/or a DVD unit (not shown). Computer 60 may also be a device capable of communicating with image forming device 100 other than a personal computer such as, for example, a tablet computer, a smartphone, or other electronic device.
In the example embodiment illustrated, computer 60 includes in its memory a software program including program instructions that function as an imaging driver 68 , e.g., printer/scanner driver software, for image forming device 100 . Imaging driver 68 is in communication with controller 102 of image forming device 100 via communications link 70 . Imaging driver 68 facilitates communication between image forming device 100 and computer 60 . One aspect of imaging driver 68 may be, for example, to provide formatted print data to image forming device 100 , and more particularly to print engine 110 , to print an image. Another aspect of imaging driver 68 may be, for example, to facilitate the collection of scanned data from scanner system 150 .
In some circumstances, it may be desirable to operate image forming device 100 in a standalone mode. In the standalone mode, image forming device 100 is capable of functioning without computer 60 . Accordingly, all or a portion of imaging driver 68 , or a similar driver, may be located in controller 102 of image forming device 100 so as to accommodate printing and/or scanning functionality when operating in the standalone mode.
Several components of the image forming device 100 are user replaceable e.g. toner cartridge 200 , fuser 120 , and imaging unit 300 . It is advantageous to prevent counterfeiting these user replaceable components. A PUF 202 may be attached to the toner cartridge 200 to prevent counterfeiting as described below. A PUF reader 203 may be integrated into the image forming device 100 to verify the authenticity of the PUF 202 . Data related to the PUF 202 may reside in non-volatile memory 201 .
FIG. 2 shows PUF 202 with a helical flight 210 wrapped around a shaft 212 . The helical flight 210 and the shaft 212 may be one integrated part. Alternatively, they may be two separate parts attached together. The PUF 202 has a pair of cylindrical supports 214 , 216 that extend laterally from each end of the PUF 202 . In operation, the PUF 202 rotates about an axis of rotation 218 . The cylindrical supports 214 , 216 , the shaft 212 , and the helical flight 210 are centered on the axis of rotation. The helical flight 210 may be referred to as an auger, and the helical flight 210 may be referred to as a spiral flight.
The helical flight 210 contains magnetized particles that generate a magnetic field above the top surface 220 of the helical flight 210 . The magnetized particles are, for example, flakes of an alloy of neodymium, iron and boron (NdFeB). The shaft 212 may contain magnetized particles to add complexity to the magnetic field. The PUF 202 may be located on a body of a supply item for an image forming device such as, for example, toner cartridge 200 . When the toner cartridge 200 is located in the image forming device 100 , the PUF 202 interfaces with the PUF reader 203 , which contains a magnetic field sensor 222 mounted to a printed circuit board (PCB) 224 . The PCB 224 also has a locating pin 226 .
FIG. 3 shows a side view of the PUF reader 203 , including the magnetic field sensor 222 , the PCB 224 , and the locating pin 226 . The locating pin 226 is taller than the magnetic field sensor 222 . When the PUF reader 203 is engaged with the PUF 202 , preferably the locating pin 226 rides on the shaft 212 and the magnetic field sensor 222 is located above the helical flight 210 without contacting the helical flight 210 . The locating pin material and shape may be selected to minimize the drag against the PUF 202 . Alternatively, the magnetic field sensor 222 may ride on the helical flight 210 . The PUF reader 203 is mounted such that it is free to move in a compliance direction 310 that is preferably radial to the axis of rotation 218 . Preferably, the PUF reader 203 is biased by a spring against the shaft 212 . This mounting compliance helps accommodate mechanical and positional tolerances between the PUF 202 and the PUF reader 203 , which improves reliability and reduces manufacturing costs. The magnetic field sensor 222 may make measurements radial to the axis of rotation 218 i.e. parallel to the compliance direction 310 . The magnetic field sensor 222 may make measurements parallel to the axis of rotation 218 i.e. perpendicular to the compliance direction 310 . The magnetic field sensor 222 may make measurements in three orthogonal directions.
The locating pin 226 is biased against a side surface 230 of the helical flight 210 . The magnetic field sensor 222 follows a measurement path 228 along a section of the helical flight 210 . The measurement path 228 is at a fixed distance from the side surface 230 . The distance between the magnetic field sensor 222 and the locating pin 226 as well as the angle between the PUF reader 203 and the helical flight 210 determines the fixed distance.
In operating, the PUF reader 203 is moved parallel to the axis of rotation 218 . The locating pin 226 pushes against the side surface 230 , causing the PUF 202 to rotate about the axis of rotation 218 . Sine the locating pin 226 remains in contact with the side surface 230 , the positional accuracy of the measurement path 228 will be excellent. This is important, since shifting the measurement path 228 laterally by a small amount may radically change the magnetic field seen by the magnetic field sensor 222 . The helical PUF 202 is superior to a linear PUF since translation of the PUF reader to read the PUF also maintains the position of the PUF reader relative to the PUF. Preferably, the magnetic field sensor 222 and locating pin 226 are aligned parallel to the axis of rotation 218 to prevent a counterfeiter from replacing the helical PUF 202 with a linear PUF since the locating pin 226 would raise the magnetic field sensor 222 too far above the linear PUF.
The helical flight 210 has a helix angle 232 . Preferably, the helix angle 232 is between thirty degrees and sixty degrees inclusive. If the helix angle 232 is less than thirty degrees the PUF 202 may bind and fail to rotate. If the helix angle 232 is more than sixty degrees the PUF 202 may fail to maintain contact between the locating pin 226 and the side surface 230 . Preferably, the helix angle 232 is less than sixty degrees so the maximum helical flight length may be provided for a given PUF length, since a longer PUF is harder to duplicate than is a shorter PUF.
FIG. 4 shows the helical PUF 202 located on a supply item for an imaging device e.g. toner cartridge 200 . The toner cartridge 200 has a body 410 for holding toner. The helical PUF 202 is rotatably mounted to the body by bearings 412 , 414 that encircle the cylindrical supports 214 , 216 . Non-volatile memory 201 is also located on the body 410 and is mounted to a PCB 416 having a column of electrical contact pads 418 . The non-volatile memory 201 may contain an array of numbers corresponding to the intensity of the magnetic field along a section of the measurement path 228 . The non-volatile memory 201 may also contain a digital signature generated from the array of numbers. To clone the toner cartridge, a counterfeiter must either duplicate a genuine helical PUF and also duplicate the accompanying non-volatile memory, which is difficult, or the counterfeiter must create a counterfeit helical PUF and also create a properly signed array of measurements corresponding to the counterfeit PUF, which is also difficult. Thus, the toner cartridge 200 is protected from counterfeiting.
FIG. 5 shows a graph 500 of the intensity 510 of an example magnetic field along a section of the measurement path 228 . An array of numbers 512 corresponds to the magnetic field intensity measured at regular intervals along the path, as shown by dotted lines 514 on the graph. Preferably, the array of numbers 512 are integers to simplify processing. Alternatively, the array of numbers may be, for example, floating point. The numbers in FIG. 5 and FIG. 6 are in hexadecimal format.
FIG. 6 shows an example of generating a digital signature from the array of numbers 512 . Other algorithms for generating a digital signature are known in the art. The digital signature is used by the controller 102 to verify that the PUF data in the non-volatile memory is authentic. The toner cartridge's serial number 610 and the array of numbers 512 are combined to form a message 612 . Preferably, the message is encrypted. Alternatively, the message may be unencrypted. For this example, AES-CBC is used (see, for example, RFC3602 “The AES-CBC Cipher Algorithm and Its Use with IPsec” published by The Internet Society (2003), and NIST (National Institute of Standards) documents FIPS-197 (for AES) and to SP800-38A (for CBC)). The AES key 614 and CBC Initialization Vector (IV) 616 are used as is known in the an to generate the encrypted message 618 . In this example, to sign the encrypted message 618 first the message is hashed then the hash is encrypted with the private key 620 of an asymmetric key pair that includes a public key 622 . This example uses the SHA-512 hashing algorithm and Elliptic Curve Digital Signature Algorithm (ECDSA) utilizing a P-512 curve key, as is known in the art. Other algorithms are known in the art. The SHA-512 hash 624 of the encrypted message 618 is used to generate an ECDSA P-512 digital signature 626 . The signature 626 and encrypted message 618 are stored in the non-volatile memory 201 . The image forming device 100 may use the array of numbers 512 in the encrypted message 618 to verify the authenticity of the helical PUF 202 , and the image forming device 100 may use the digital signature 626 to verify the authenticity of the array of numbers 512 . In this way, the image forming device 100 may verify the authenticity of the toner cartridge 200 .
FIG. 7 shows the helical PUF 202 . FIG. 8 shows a section view of the helical PUF 202 cut along cross-section line 710 . In this example, the shaft 212 and the helical flight 210 are two separate parts attached together. The helical flight 210 contains magnetized particles 810 , 812 that generate a magnetic field above the top surface 220 and adjacent to the side surface 230 . The helical flight 210 has a rectangular cross section. The side surface 230 is planar which improves the locating tolerance of the locating pin 226 . FIG. 9 shows an alternate embodiment with the helical flight 210 having a semi-circular cross section. The side surface 230 is curved which reduces the friction between the locating pin 226 and the helical flight 210 . Other helical flight cross sections may be used e.g. triangular, etc.
FIG. 10 shows an alternate embodiment of a helical PUF 1002 . The helical flight is a shaft 1010 that has a helical channel 1050 wrapped around the shaft 1010 . The shaft 1010 contains magnetized particles that generate a magnetic field above the shaft 1010 having varying intensity. The helical channel 1050 has a first side surface 1030 . The helical PUF 1002 is configured to rotate about an axis of rotation 1018 . A pair of cylindrical supports 1014 , 1016 , the shaft 1010 , and the helical channel 1015 are centered on the axis of rotation.
In operation, the locating pin 226 of the PUF reader 203 pushes against the first side surface 1030 , causing the magnetic field sensor 222 to follow a first measurement path 1028 along a section of the length of the helical channel 1050 . The first measurement path 1028 is at a first fixed distance 1052 from the side surface 1030 . In this example, the PUF reader 203 is moving from right to left. FIG. 11 shows the helical PUF 1002 while the PUF reader 203 is moving from left to right. The locating pin 226 pushes against a second side surface 1054 of the helical channel 1050 , causing the magnetic field sensor 222 to follow a second measurement path 1129 located a second fixed distance 1156 from the first side surface 1030 . The second fixed distance 1156 is shorter than the first fixed distance 1052 . Thus, a single helical PUF 1002 with a single PUF reader 203 may measure two different measurement paths by alternating the direction of travel of the PUF reader 203 . This makes it more difficult to counterfeit the helical PUF 1002 , since two measurement paths must be duplicated. In operation, preferably the PUF reader 203 initially moves by at least the helical channel pitch 1157 to be sure the locating pin 226 falls into the helical channel. Then, the PUF reader 203 moves in the opposite direction at least a distance equal to the helical channel pitch since the actuator moving the PUF reader 203 will be designed to travel at least that distance.
FIG. 12 shows an alternate PUF reader 1203 that may measure along two measurement paths 1028 , 1228 simultaneously. The PUF reader 1203 has two magnetic field sensors 1222 , 1223 located on opposite sides of a locating pin 1226 .
FIG. 13 shows an alternate embodiment of a helical PUF 1302 . A helical channel 1350 wraps around a shaft having magnetized particles. The helical channel 1350 terminates in a stop 1366 at the left end and a second stop 1368 at the right end 1368 . In operation, the PUF reader 203 may be moved laterally along the helical PUF 1302 from left to right until the locating pin 226 hits stop 1368 . The controller 102 may detect this event by monitoring drive current to a motor that moves the PUF reader 203 . When this event is detected, the controller 102 knows the PUF reader 203 is at a home position relative to the PUF 1302 . Knowing this helps the controller 102 to align data measured along a measurement path with data stored in the toner cartridge non-volatile memory. A second home position may be at stop 1366 .
FIG. 14 shows an alternate PUF reader 1472 that measures a magnetic field adjacent to the side surface 1030 . The PUF reader 1472 has a magnetic field sensor 1470 that measures the intensity of the magnetic field normal to the side surface 1030 and parallel to the side surface. The PUF reader 1472 touches the side surface 1030 with a pair of spacers 1474 , 1476 . In operation, the PUF reader 1472 is moved parallel to the axis of rotation to measure a section of the length of the helical channel 1050 .
FIG. 15 shows an alternate embodiment of a supply item for an imaging device e.g. toner cartridge 1500 . The toner cartridge 1500 has a body 1505 for holding toner. A helical PUF 1502 is configured to slide laterally along a drive shaft 1580 located on an axis of rotation 1518 of the helical PUF 1502 . The drive shaft 1580 may be turned by a drive gear 1584 that is coupled to a motor located in the imaging device 100 . The helical PUF 1502 is rotatably mounted to the body 1505 by bearings 1512 , 1515 . The drive shaft 1580 has a flat area 1582 which gives the drive shaft 1580 a “D” shaped cross section i.e. the drive shaft 1580 is a D-shaft. The helical PUF 1502 has a “D” shaped hole around the axis of rotation 1518 that is larger than the cross section of the drive shaft 1580 . Thus, the helical PUF 1502 will rotate when the drive shaft 1580 is rotated and the helical PUF 1502 is free to slide laterally along the drive shaft 1580 parallel to the axis of rotation.
The helical PUF 1502 has a helical flight 1510 and a helical channel 1550 . The helical flight 1510 contains magnetized particles that generate a magnetic field adjacent to the helical flight 1510 . A PUF reader 1503 , located in the imaging device 100 , has a locating pin 1526 and a magnetic field sensor 1522 . The PUF reader 1503 is fixedly mounted to the imaging device 100 . In operation, rotation of the drive shaft 1580 causes a side surface of the helical flight 1510 to contact the locating pin 1526 , which causes the helical PUF 1502 to slide laterally along the drive shaft 1580 . The magnetic field sensor 1522 reads the intensity of the magnetic field along a section of the length of the helical flight, and the controller 102 compares the measured field to an array of numbers stored in a non-volatile memory 1501 mounted to the body 1505 . Alternatively, the magnetic field sensor may be located in the helical channel 1550 and measure along a side surface. This embodiment simplifies mounting the PUF reader 1503 since the PUF reader 1503 does not require a mechanism to translate laterally along the helical PUF 1502 .
Preferably, the locating pin 1526 is positioned offset from the axis of rotation 1518 to provide a torque on the helical PUF 1502 relative to the drive shaft 1580 . This torque increases the friction between the helical PUF 1502 and the drive shaft 1580 to insure continuous contact between the locating pin 1526 and the helical flight 1510 .
FIG. 16 shows an example embodiment of a method of manufacturing a supply item for an imaging device according to one embodiment. Method 1600 creates a supply item that is difficult to counterfeit.
At block 1610 , a body is obtained. The body may be, for example, suitable to hold toner for an imaging device. At block 1612 , a helical auger is obtained. The helical auger has a spiral flight having magnetized particles generating a magnetic field above the flight having a varying intensity. At block 1614 , a non-volatile memory device is obtained. At block 1616 , the non-volatile memory device is attached to the body. At block 1618 , the helical auger is rotatably attached to the body.
At block 1620 , an array of measurements are created by measuring the intensity of the magnetic field along a section of the spiral flight. At block 1622 , a digital signature is generated from the array of measurements. At block 1624 , the array of measurements is stored in the non-volatile memory device, and the digital signature is stored in the non-volatile memory device. These blocks may be performed in alternate orders.
The foregoing description illustrates various aspects and examples of the present disclosure. It is not intended to be exhaustive. Rather, it is chosen to illustrate the principles of the present disclosure and its practical application to enable one of ordinary skill in the art to utilize the present disclosure, including its various modifications that naturally follow. All modifications and variations are contemplated within the scope of the present disclosure as determined by the appended claims. Relatively apparent modifications include combining one or more features of various embodiments with features of other embodiments. | A helical physical unclonable function is disclosed. The helical physical unclonable function may be used to authenticate a supply item for an imaging device. Measurements of the magnetic field above a helical flight are stored in a non-volatile memory to be used by an imaging device to authenticate the supply item. Other systems and methods are disclosed. | 7 |
FIELD OF THE INVENTION
The present invention relates to a roll of the kind that comprises a drivable roll shaft and two axially spaced-apart stop rings, one of which is fixed, and the other one is a lock nut, a plurality of other rings, of which one or more are roll rings, being mounted between the stop rings.
BACKGROUND
Rolls of the type generally mentioned above, are referred to as combi rolls by those skilled in the art. In practice, such rolls are used for hot or cold rolling of long narrow products of metal, such as wires, bars, pipes, etc. For such purposes, the roll ring or rings, i.e., the very rings which, in contrast to spacer rings and the like, carry out the forming of the metals are formed with a number of circumferential grooves, usually having a semi-circular cross section shape.
An important factor for a prolonged proper function of such rolls is that the different roll and spacer rings are rotationally secured in relation to each other and in relation to the roll shaft in a reliable way, since extremely large torques are to be transferred from the shaft to the rings without the same slipping in relation to each other. To overcome this problem, tightening devices are used, which may be divided into two main categories, viz. on one hand devices, which utilize the spring force of mechanical springs, and on the other hand, hydraulically acting devices. Of these devices, the last-mentioned ones are less suitable for many reasons, e.g., the necessity to providing expensive hydraulic oil conduits to the rotating roll, the risk of oil leakage, etc. Therefore, mechanical springs are preferable, in so far that they are technically less complicated, as well as easier and more inexpensive to manufacture, install and use.
In the technique in question, many proposals of mechanical springs for combi rolls have come up. One of these proposals is disclosed in U.S. Pat. No. 5,735,788, and is based on the use of a Belleville spring in the set of dismountable rings of the roll shaft. However, this solution has not been successful, among other things dependent on the placing of the spring inside the set of roll rings and spacer rings, and because of fatigue problems. It is true that the tension or the spring force of the Belleville spring in question should be possible to readjust, viz. by way of a set screw, but as a consequence of the placing thereof inside the set of dismountable rings, the spring is continuously exposed to forces, which deform, more precisely flatten the spring, something which fairly fast results in a slackening or fatigue to such an extent that the spring looses the ability to instantaneously, during operation, keep the rings pressed against each other with such a force in the friction joints there between, that the same do not slip. Furthermore, the inclined spring wears against adjacent rings in such a way that these become worn in a fairly short time due to the fact that the spring has a (circular) line contact and not a surface contact, with the rings.
SUMMARY
The present invention aims at obviating the above-mentioned disadvantages of not only the roll presented in U.S. Pat. No. 5,735,788, but also other rolls, which make use of mechanical springs, and at providing an improved roll. Therefore, in a first aspect, a primary object of the invention is to provide a roll having a mechanically acting spring device, which can apply to the dismountable rings of the roll a high spring pressure or a high degree of prestress, with the purpose of avoiding slipping between the rings during operation, and which furthermore in a simple way can compensate the inevitable deformation, which constantly arise in the rings during operation (because of wear and deformation of the material in the same), so that the high degree of prestress is guaranteed for the instantaneous transfer of torque between the rings. An additional object is to provide a roll, the roll width (the axially available space between the fixed stop ring and the lock nut) of which is utilized in an optimal way by not being occupied by any space-demanding spring devices. Yet an object of the invention is to provide a roll in which service in respect of the spring prestress of the rings may be made in a simple and fast way.
According to a first aspect, a roll comprises a drivable roll shaft and two axially spaced-apart stop rings. One of the stop rings is fixed and the other of the stop rings is a lock nut. A plurality of other rings are included. One or more of the other rings is mounted between the stop rings, wherein at least one of the stop rings comprises a spring device. The spring device is housed in a through hole extending axially and opening in opposite end surfaces of the ring. A mechanical compression spring acting between a front press body that is movable through an opening of the hole in order to constantly pass on a spring force generated by the compression spring to a ring and a support body. The support body during operation of the roll assumes a fixed position in relation to the ring. The support body being adjustable when not in operation by way of an adjusting member to alter the tension of the compression spring.
In a second aspect, the invention relates to a ring as such made with built-in spring functions, and intended for the roll according to the invention. An important object of the invention in this aspect is to provide a ring, in particular in the form of a lock nut, in which one or more spring devices are included, which, on one hand, has such a great working range that considerable deformation in the different rings of the roll can be compensated for, and, on the other hand, instantaneously, during operation, provide the rings with a high, dynamic degree of prestress in order to avoid the risk of slipping. An additional object is to provide a ring made with spring functions, which ring can be mounted on and dismounted from a roll shaft in a simple way, and which furthermore is made in such a way that the active spring force of the spring devices can be adjusted in a simple and ergonomically expedient way.
In a third aspect, a ring for a roll comprises a spring device housed in a through hole extending axially and opening into opposite end surfaces of the ring. A mechanical compression spring acts between a front press body that is movable through an opening of the hole in order to constantly pass on a spring force generated by the compression spring and a support body which may assume a fixed position in relation to the ring, but which is adjustably movable by way of an adjusting member in order to alter the tension of the compression spring.
The invention is based on the idea of building in into a ring mountable on a roll shaft, in particular a stop ring in the form of a lock nut, a spring device in which a mechanical compression spring is included, which acts between, on one hand, a front press body, which is movable to and fro, in order to constantly pass on a spring force generated by the compression spring towards the other rings and, on the other hand, a support body which during the operation of the roll assumes a fixed position in relation to the ring, but which out of operation is adjustably movable by way of an adjusting member in order to alter the tension in the compression spring. Advantageously, a plurality of peripherically spaced-apart spring devices of this type is arranged in a circular rim formation along the ring.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings:
FIG. 1 is a partial longitudinal section through a roll according to the invention.
FIG. 2 is an enlarged cross-section through a ring in the form of a lock nut included in the roll, in which a spring device according to the invention is built-in.
FIG. 3 is a cross section showing only a hollow space in which the spring device is mounted,
FIG. 4 is an exploded view showing the different components included in the spring device.
FIG. 5 is an enlarged section of a compression spring included in the spring device.
DETAILED DESCRIPTION
In FIG. 1 , a combi roll is shown, which in a conventional way includes a drivable shaft or roll shaft 1 having two axially spaced-apart stop rings 2 , 3 , one of which, viz. the stop ring 2 , is fixed, while the other one is a lock nut 3 , which is dismountable from the shaft. In the example, the fixed stop ring 2 is in the form of a ring-shaped shoulder integrated with the rest of the shaft. However, it is also feasible to make the fixed stop ring 2 in the form of a separate, dismountable ring, which in a suitable way is axially locked in relation to the shaft.
Between the fixed stop ring 2 and the detachable lock nut 3 , a number of dismountable rings is arranged, of which certain are roll rings 4 , and certain are spacer rings 5 . Between the lock nut 3 and the roll ring 4 positioned closest to the same, there is an additional ring 6 , the design of which may deviate from the design of the spacer rings 5 , and which below is referred to as tightening ring. Generally, the roll shaft 1 as well as the different rings have a rotationally symmetrical, more precisely cylindrical, basic shape, the rings being delimited by planar end contact surfaces. Of the end surfaces, only the opposite end surfaces of the lock nut 3 are provided with reference designations 7 , 8 , as is seen in FIGS. 2 and 3 . On the cylinder-shaped inside thereof, the lock nut (see FIG. 1 ) is formed with a female thread 9 that is in engagement with a male thread 10 of the roll shaft. The roll rings 4 , which have the purpose of providing the direct roll forming work, and which for this purpose have circumferential, peripheral grooves 11 , may advantageously be manufactured from cemented carbide or other wear-resistant materials, while the intermediate rings 5 , 6 may be composed of a softer metal, e.g., steel or cast iron. However, the material in the different rings is incidental for the realization of the invention. The essential thing is that the friction joints in the interfaces between the end surfaces of the rings efficiently prevent slipping between the rings. For this purpose, the rings have to be held sustainedly compressed by a great spring force or prestress.
FIGS. 2-5 illustrate in detail the nature of a spring device 12 which is built-in into the lock nut 3 . In FIG. 2 , the spring device is shown mounted in the lock nut, while FIG. 3 shows only a through hole in which the spring device is accommodated, and FIG. 4 is an exploded view showing the individual components of the spring device spaced-apart from each other.
The above-mentioned hole, which extends axially through the lock nut 3 , and which generally is designated 13 , includes, on one hand, a front or inner section 14 that opens in the end surface 7 turned inward of the lock nut and, on the other hand, a rear section 15 , which via a widened countersink 16 opens in the rear or outward end surface 8 of the lock nut. In the example, the front hole section 14 has a diameter that is greater than the diameter of the hole section 15 , the countersink 16 in turn having a greater diameter than the section 15 . The inner surface of the front hole section 14 is smooth and cylindrical, while the rear hole section 15 along the entire length thereof is formed with a female thread 17 .
The active component of the spring device 12 (see FIG. 4 ) is a compression spring 18 that acts between a front press body 19 and a rear stop or support body 20 . In the exemplified embodiment, the press body 19 is composed of a suitably cylindrical pin having a flange 21 , against which the front end of the compression spring 18 may be urged. The support body 20 is in the form of a piston which, in addition to a cylindrical envelope surface 22 , has a suitably planar back side 23 , as well as a front side 24 , in which a central seat 25 opens, a rear end of the press body 19 engaging the seat. A screw 26 may be tightened in the hole section 15 with the male thread 27 thereof in engagement with the female thread 17 . A head 28 of the screw is housed in the countersink 16 . A Seeger ring 29 has the purpose of holding the different spring components in place in the hole 13 .
In the shown, preferred embodiment of the invention, the compression spring 18 is a cup spring that includes a plurality of cups 30 , 31 , arranged in a united set. A number of first cups 30 in the set are turned with their small ends pointing in an opposite direction to the small ends of the other cups 31 . More precisely, the cups 30 are placed in such a way that the small ends point to the left in FIG. 5 , while the small ends of the cups 31 point to the right. In such a way, the two intermediate cups will have contact with each other along the outer, peripherical edges thereof, while the two outermost cups are pressed with the internal edges thereof against, on one hand, the flange 21 of the press body 19 and, on the other hand, the front surface 24 of the piston 20 .
The support body 20 , the spring 18 , the press body 19 , and the Seeger ring 29 are, upon mounting, inserted in proper order in the hole section 14 , while the screw 26 is inserted from behind in the threaded hole section 15 . The Seeger ring 19 has only the purpose of holding the spring components 20 , 18 , 19 in place in the hole section 14 .
In the drawings, only one individual spring device 12 is shown. However, in practice, the lock nut 3 is made with a plurality of peripherical spring devices which are spaced-apart and arranged in a circular rim formation. For instance, the lock nut may include eight equidistantly spaced-apart spring devices along the circumference thereof.
When the roll rings 4 and other rings 5 , 6 have been applied to the roll shaft 1 , as is shown in FIG. 1 , the lock nut 3 is tightened on the male thread 10 . More precisely, the lock nut is tightened by a considerable pressure against the tightening ring 6 . When the lock nut has reached a maximally tightened end position, the spring devices 12 are activated, more precisely by the fact that the individual screw 26 is screwed-in a distance in the hole. As a consequence of the free front end of the press body 19 being urged against the tightening ring 6 , the compression spring 18 will then be compressed, more precisely by the fact that the piston moves in the forward direction in the hole section. When the piston by way of the screw reaches a position in which the desired spring prestress has been achieved, the tightening of the screw is terminated. Thereafter, the roll is ready to be taken into operation.
During operation, the different rings of the roll shaft are exposed to dynamic stresses that in an effective way are carried by the compression springs in the different spring devices. More precisely, the individual spring forces are transferred to the common tightening ring 6 in which they are distributed so that the same will act with an even, high pressure against the adjacent roll ring 4 . Because the compression springs in the described way are made in the form of powerful cup springs, a dynamic spring action is attained and maintained during long working operations. However, if the spring force eventually is reduced, readjustment may be effected, viz. by additional tightening of the screws 26 so as to press in the pistons additionally into the holes. In such a way, the springs are compressed afresh to the desired degree of prestress.
An important advantage of the roll according to the invention, and the spring arrangement included therein, is that the spring prestress between the rings in a simple way may be held reliably high. This in turn guarantees that the rings do not slip in relation to each other.
Another significant advantage is that the means being necessary for the spring prestress, do not occupy any part of the roll width, i.e., the available space between the stop rings 2 , 3 . The invention is not limited only to the embodiment described above and shown in the drawings. Thus, it is feasible to arrange the described spring devices in the fixed stop ring 2 instead of in the lock nut 3 . It is even possible to arrange spring devices in the fixed stop ring as well as the movable lock nut.
The presently disclosed embodiments are considered in all respects to be illustrative and not restrictive. The scope is indicated by the appended claims, rather than the foregoing description, and all changes that come within the meaning and range of equivalents thereof are intended to be embraced. | A ring, preferably in the form of a lock nut, made for combi rolls, which ring includes at least one spring device in which a mechanical compression spring is included that acts between, on one hand, a front press body that is movable to and fro in order to constantly forward a spring force generated by the compression spring and, on the other hand, a support body, which may assume a fixed position, but which is adjustably movable by way of a screw in order to alter the tension in the compression spring. | 1 |
FIELD OF THE INVENTION
The invention relates to an improved fireplace grate and heat transfer unit of the type which uses natural gas as a fuel.
BACKGROUND OF THE INVENTION
U.S. Pat. No. 4,078,542 discloses a fireplace grate and forced air heat exchanger useful in a wood burning fireplace. The device is useful for circulating air from a room through a manifold and tube which support burning logs for discharge into the room. The air passing through the manifold and tubes is heated thereby enhancing the utility of the fireplace by improving the efficiency of heat transfer from the fireplace to the room.
There are numerous other issued patents disclosed in U.S. Pat. No. 4,078,542 which relate to various heat exchangers incorporated with a fireplace grate for the purpose of improving efficiency of heat transfer from the fireplace to a room. The prior art devices are designed for use with combustible materials, principally wood in the form of logs.
In the modern home, however, many fireplaces have been converted so that natural gas is burned in the fireplace. The natural gas is combusted to provide flames that pass through synthetic logs or coals. Heretofore a fireplace grate has been designed for use with gas and also utilizing a manifold and blower construction to enhance the efficiency of heat transfer from the fireplace into a room. Such a product is manufactured by Heat-N-Glo Fireplace Products, Inc. of Burnsville, Minn.
While such a gas combusting fireplace heat transfer unit appears to be desirable, such prior units are believed to be lacking in one or more important characteristics; for example, simplicity and therefore economy of construction, efficiency of heat transfer, attractiveness of design, suitable alignment and maintenance of alignment of the non-combustible, synthetic logs or coals.
SUMMARY OF THE INVENTION
Accordingly, an object of the present invention is to overcome the deficiencies of the prior art indicated above.
Yet a further object of the invention is to provide an improved heat transfer device for fireplaces particularly fireplaces utilizing natural gas as a fuel.
Another object of the invention is to provide an improved and inexpensive fireplace grate for improved heat transfer.
Another object of the invention is to provide a fireplace heat transfer unit utilizing natural gas as a fuel which can be easily incorporated within an existing fireplace opening and which does not interfere with the operation of a fireplace screen or door.
Yet a further object of the present invention is to provide a fireplace heat transfer unit which yields measurable improvement in heat output into a room wherein the fuel used in the fireplace is natural gas.
Yet another object of the invention is to provide a fireplace heat transfer unit which includes means for properly supporting and spacing synthetic, non-combustible logs and/or coals with respect to one another as well as with respect to a burner construction associated with the natural gas fireplace unit.
Briefly, therefore, the present invention is an improved fireplace heat transfer unit for placement in a fireplace of the type having a floor, a back wall and a front wall. The unit includes a forced air fed distribution manifold adapted to extend across the back wall of the fireplace opening, a series of heat transfer conduits extending transversely from the manifold toward the front of the fireplace opening, each conduit including an emission orifice for jetting air direction into a room, a frame for support of these components, an air supply tube connected to the manifold, a blower for forcing air through the air supply tube, manifold and conduits, a plurality of synthetic combustibles such as logs, and a gas supply tube supported below the frame at an appropriate distance for emission of ignitable gas as it flows over the logs. In a preferred embodiment, the gas supply tube extends transversely with respect to the conduits and is also positioned within a trough or pan below the conduits. The supply tube is covered by sand in order to more effectively disperse the gas. The construction is especially useful for effective combustion of natural gas in a fireplace and simultaneous heat transfer of air circulated through the fireplace.
BRIEF DESCRIPTION OF THE DRAWING
The objects, advantages and other features of the invention will be set forth in greater detail in the description which follows. In the detailed description which follows, reference will be made to the drawing comprised of the following figures:
FIG. 1 is an exploded perspective view of the component parts of the improved fireplace grate;
FIG. 2 is an assembled perspective view of the device depicted in FIG. 1 as positioned in a typical fireplace;
FIG. 3 is a top plan view of the frame for the fireplace grate;
FIG. 4 is a side view of the pan associated with the fireplace grate;
FIG. 5 is an end view of the pan associated with the fireplace grate; and
FIG. 6 is a detailed view of the positioner plate associated with the air flow conduits for positioning the synthetic logs associated with the device.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the figures, the improved fireplace grate of the invention is a rugged yet simple construction which includes a manifold 10 positioned within the fireplace along the rear wall generally parallel to the rear wall. The manifold 10 is comprised of a hollow rectangular parallelepiped or plenum chamber having a series of equally spaced apertures 12 along the inside wall of the manifold directed toward the front of the fireplace. An air supply inlet tube 14 connects at one end of manifold 10 to the interior a blower which directs air through a connecting tube 18 to the inlet tube 14, thence through the manifold 10 and the apertures 12.
The manifold 10 forms the rear member of a generally rectangular frame comprised additionally of connected side members 20 and 22 and a front cross member 24. The frame is supported above the hearth of the fireplace by legs 42 positioned at the four corners of the rectangular frame. The front cross member 24 includes a series of keyed apertures 26 which are aligned with respective apertures 12 of manifold 10. Air flow conduits 28 connect between respective manifold apertures 12 and keyed apertures 26. Conduits 28 are hollow tubes having a restricted outlet orifice 30 as defined by a reduced forward cross section of the conduit 28. The reduced forward cross section of the conduit 28 also includes upwardly and downwardly extending key members 32 and 34 which cooperate respectively with the keyed aperture 26 to maintain alignment or conduits 28.
A retaining bar 36 attached by fasteners 38 to the front frame member 24 cooperates with slots 40 in the key member 32 of each conduit 28 to retain the conduits 28 aligned and generally immovable within the frame. Andirons 44 are also retained on the frame by means of the fasteners 38 which retain the retaining bar 36. The andirons 44 prevent material such as the synthetic logs from accidentally falling from the frame and out of the front of the fireplace. Andirons 44 are also a decorative feature.
Attached to the bottom of the frame by means of appropriate fastening means is a pan 46. The pan 46 is suspended below the conduits 28 and defines a longitudinal trough 48 which is generally transverse to the direction of the conduits 28. The trough 48 is thus formed by first and second inclined panels 50 and 52 which join together to define the pan 46 having the trough 48 with a generally V-shaped cross section. Positioned within the trough 48 toward the bottom thereof is a gas burner tube 54 having gas discharge openings or orifices 56 which depend downwardly with respect to the frame, conduits and the like. The tube 54 has a generally constant diameter though it is flared at its closed end 55. The tube 54 includes the openings or orifices 56 generally uniformly distributed along the bottom surface thereof.
In operation, the tube 54 is covered with a layer of sand 55 in FIG. 5 which is retained by the pan 46. Natural gas is discharged through the orifices 56 into the sand 55. Since the gas is generally lighter than air, it migrates upwardly through the sand in a diffuse pattern where it ignites as it passes between the conduits 28 and over a set of synthetic logs 58. The logs or combustibles 58 may constitute lava or other rock material which simulates logs or coals that are retained on top of the conduits 28.
Referring again to the burner tube 54, the tube 54 projects through a side wall 60 of the pan 46. The tube 54 thus connects with a gas supply valve 62 on the outside of the pan 46. The gas supply valve 62 connects with a gas supply line 61 in FIG. 3 and is controlled by a manual valve lever 64. In this manner the supply of gas to the unit is controlled. The gas may be ignited by an automatic ignition system such as known to those skilled in the art of gas log construction. Alternatively, the gas may be ignited, for example by a match.
Referring now to the conduits 28, each conduit is, as previously explained, connected to the manifold 10 and defines an air flow path through the region of gas combustion. Additionally, the conduits 28 serve the function of retaining the synthetic combustibles 58 in a properly spaced and oriented relationship with respect to the gas burner tube 54 so that the most efficient combustion can be effected in order to maximize heat transfer through the conduits 28. Consequently, one or more conduits 28 include a vertical positioner plate 66 projecting from the top of the conduit. The plate 66 provides a mechanism for spacing the synthetic logs, for example, and also for supporting the logs relative to one another. The size and position of the plate 66 is devised to enhance the combustion of the natural gas within the unit and thereby enhance the efficiency of heat transfer from the combustible gas to the conduit 28.
It is noted that the construction of the present invention is not useful with respect to actual combustible materials. Rather, it is designed for use in association with synthetic combustibles such as molded, non-flammable logs. Nonetheless, the construction or unit provides for the maximum efficiency of heat transfer between the combusted fuel in the unit and air passing through the conduits. This is accomplished by the appropriate spacing of the tubes 54 beneath the conduits 28, the appropriate maintenance of the shape and size of the trough or pan 46; the appropriate compactness or density as well as level of sand within the pan 46; the spacing and number of conduits 28; the diameter or size of the conduits 28 relative to the capacity of the blower 16; and the utilization of the positioner plates 66.
Thus, while there has been set forth a preferred embodiment of the invention, it is to be understood that the invention is limited only by the following claims and their equivalents. | An improved fireplace heat transfer unit includes a gas burner tube in a layer of sand retained in a trough beneath air conduction tubes arranged transversely to the burner tube. The air transfer tubes are all connected to a manifold at the rear of the fireplace grate unit which receives air for transport through the conduits and ejection into a room. | 5 |
FIELD OF THE INVENTION
This invention generally relates to image sensor devices and more particularly to charge coupled devices.
BACKGROUND OF THE INVENTION
Without limiting the scope of the invention, its background is described in connection with virtual phase charge coupled device (CCD) image sensors and bulk charge modulated device (BCMD) image sensors, as an example.
Heretofore, in this field, the virtual phase CCD was developed to provide a single phase CCD comparable in performance to multiphase CCD's while retaining all the advantages of single level structure. See Hynecek, J., "Virtual Phase Charge Transfer Device", U.S. Pat. No. 4,229,752, issued Oct. 21, 1980; and Hynecek, J., "Virtual Phase Technology: A new Approach to Fabrication of Large-Area CCD's", IEEE Transactions on Electron Devices, Vol. ED-28, No. 5, May 1981, which are incorporated herein by reference. The bulk charge modulated device (BCMD) device was developed to achieve optimal imaging performance in all aspects of image sensing. See Hynecek, J., "Bulk Charge Modulated Transistor Threshold Image Sensor Elements and Method of Making", U.S. Pat. No. 4,901,129, issued Feb. 13, 1990; and Hynecek, J., "BCMD-An Improved Structure for High-density Image Sensors", IEEE Transactions on Electron Devices, Vol. 38, No. 5, May 1991, which are incorporated herein by reference.
Charge coupled devices (CCDs) are well known monolithic semiconductor devices and are used in various applications such as shift registers, imagers, infrared detectors, and memories. A virtual phase CCD device contains a single set of gates and a single clocking bias. The virtual phase CCD device operates on the principle of selectively doping different regions of each cell so that clocking the gate affects only the energy bands in a portion of each cell and drives them from below to above the fixed energy bands in the remainder of each cell. The doped region that shields this remainder of a cell from the effect of the clock bias of the gate voltage is normally called the "virtual gate". The virtual gate is a doped region that is built directly into the silicon surface and is biased at the substrate potential. The virtual phase CCD minimizes the possibility for gate-to-gate shorts encountered in previous CCD technologies, and provides high quantum efficiency, excellent uniformity, low dark current, and blemish free imagery.
The BCMD sensor consists of a buried-channel MOS transistor with a specially designed storage well located under the transistor channel in the silicon bulk. When the device is illuminated, charge accumulates in the well and changes the potential profile of the entire structure. This in turn affects the potential of the MOS transistor channel that carries the current. The resulting new level of the channel potential is then simply sensed as a voltage of the source junction of the transistor when the device is connected as a source follower. The well is then easily emptied by applying a large negative pulse to the gate of the transistor. The BCMD well is emptied in the vertical direction to the substrate, whereas charge is emptied from CCD wells in a lateral direction. The resulting BCMD is an X-Y addressable MOS image sensor that has a high-sensitivity low-noise high-blooming overload capability, no detectable smear, and no image lag.
It is well known that image sensors based on the CCD concept provide high performance imaging with minimum fixed pattern noise. On the other hand X-Y addressed sensors such as charge injection devices (CID) and BCMD devices which sense charge in each photosite without any charge transfer have an advantage that they can be read out nondestructively. The nondestructive readout is necessary in devices which are used in still photography or in auto focussing elements or in exposure control elements where the correct integration time is not known before hand. The nondestructive readout can be used to interrogate the sensing element several times to determine in "real time" if enough charge has accumulated for a "good signal" before the element is read out and reset.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-section of a virtual phase CCD element with an active transistor pixel;
FIG. 2 is a diagram of the potential wells created by the device of FIG. 1;
FIG. 3 is a perspective view of the device of FIG. 1;
FIG. 4 is a side view cross-section of the device of FIG. 1;
FIG. 5 is a side view cross-section of the device of FIG. 1 showing an antiblooming, drain;
FIGS. 6-8 show the device of FIG. 1 at three stages of fabrication;
FIG. 9 is a diagram of a CCD array with a CCD sensor array having vertical and horizontal registers and a CCD memory array;
FIG. 10 is a timing diagram showing the various inputs to the device of FIG. 9;
FIG. 11 is a circuit diagram of an array using the CCD element of FIG. 1;
FIG. 12 is a diagram of a CCD array with a CCD sensor array having vertical and horizontal decoders and a CCD memory array having vertical and horizontal decoders.
Corresponding numerals and symbols in the different figures refer to corresponding parts unless otherwise indicated.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
FIG. 1 is a cross-section of a preferred embodiment of a virtual phase CCD element with an active transistor pixel. The structure of FIG. 1 includes a P type silicon substrate 20, an N type layer 22 in the substrate 20, P+ virtual phase regions 24, 26, 28, and 30 formed in the upper portion of N type layer 22, P+ source 32 formed in the upper portion of N type layer 22, gate insulator layer 34, transfer gates and 38, transistor gate 40, donor implants 42 in the N type layer 22, transfer gate input (φ TG ), transistor gate input (φ PG ), and source voltage (V PD ).
The operation of the device of FIG. 1 will be described below and is illustrated by the potential profile shown in FIG. 2, directly below the corresponding regions of the device of FIG. 1. These regions are given the following names: P+ regions 24, 26, 28, and 30 are called virtual gates (or virtual electrodes) and also serve as a drain for the active transistor, the regions below the virtual gates 26 and 30 are called virtual barriers, the regions below virtual gates 24 and 28 are called virtual wells, the regions below the transfer gates 36 and 38 and below donor implants 42 are called the clocked wells, the regions below the transfer gates 36 and 38 and not below the donor implants 42 are called the clocked barriers, the region below the transistor gate 40 is the transistor gate well, and the region below P+ region 32 is the source.
FIG. 3 is a perspective view of the device of FIG. 1. FIG. 3 shows the top of the device which includes the transfer gates 36 and 38, the transistor gate 40, P+virtual phase regions 26 and 28, and P+ trench 44. The donor impurities 43 extend under the entire virtual phase region 28. Since the P+ virtual phase regions 26 and 28 are in contact with the P+ trench 44 and the P+ trench 44 is in contact with the substrate 20, the virtual phase regions 26 and 28 are maintained at the substrate potential. Virtual phase regions 24 and 30 are maintained at the substrate potential in the same way as regions 26 and 28. The P+ trench 44 also provides isolation between the CCD columns.
FIG. 4 is a side view of the device of FIG. 3 crossing through the plane A-A' as shown in FIG. 3. FIG. 4 shows the P+ trenches 44 and 48 which connect the virtual phase regions (P+ regions) 24, 26, 28, and 30 to the substrate 20. The structure of FIG. 4 extends further in the A' direction than does the structure in FIG. 3 in order to show the trench 48.
Also, an antiblooming drain can be formed in the trench area, as shown in FIG. 5. The antiblooming drain is an alternative embodiment formed in place of the trench 48 in FIG. 4. The antiblooming drain consists of a small N+ region 49, shown in FIG. 5, instead of the larger P+ region 48, shown in FIG. 4. The donor impurities in the area 45 are less than in area 43 to form the potential profile which serves as a charge overflow barrier. When the charge level in the virtual well goes above this overflow barrier, the charge flows over this barrier and into the drain. The antiblooming drain allows excess charge to flow out of the virtual well to prevent the excess charge from spreading to other cells. Other types of antiblooming structures can be formed as well. For example, a structure with a gate controlled antiblooming barrier in place of the implant 45 can be formed.
FIGS. 6-8 illustrate successive steps in a process for fabricating an active transistor pixel CCD element, as shown in FIG. 1. Referring first to FIG. 6, an N type layer 22 is implanted in P type semiconductor substrate 20. A dopant such as phosphorus may be used as the implant dopant. Then a gate insulator layer 34 is grown over the surface of the device. The gate insulator layer 34 is preferably formed of oxide and may be grown from the substrate. Next, a photoresist layer is used to pattern an implant into N type layer 22 to form the donor implants 42 shown in FIG. 6. This implant is done with an N type dopant such as phosphorous.
After the photoresist layer is stripped, the transistor gate 40 and the transfer gates 36 and 38 are deposited, doped to be conductive, patterned, and etched as shown in FIG. 7. The transistor gate 40 and the transfer gates 36 and 38 can be polysilicon, in which case they may be doped in place by a dopant such as phosphoric oxytrichloride (POCl 3 ). Next, the transistor gate 40 and the transfer gates 36 and 38 are used for a self-aligned implantation step to form P+ source 32 and P+ drain regions (virtual phase regions) 24, 26, 28, and 30, as shown in FIG. 8. This implant is done with a P type dopant such as boron. Then a photoresist layer is used to pattern an implant to form the donor implants 43 shown in FIG. 1. This implant is done with an N type dopant such as phosphorous.
The operation of the device shown in FIGS. 1, 3, and 4 consists of two steps. In the first step, the device integrates the charge signal generated by incident light into the device while the level of charge is being nondestructively interrogated. After the signal reaches a satisfactory level, charge is transferred out from the device of FIG. 1 into a CCD memory and is read out destructively with a high accuracy and uniformity.
During charge integration the transfer gates 36 and 38 are biased negative which separates individual active transistors. The transistor is a P-channel MOS device with enclosed source 32 and drain common to virtual phase regions 26 and 28. If the source 32 is biased by a constant current source from a power supply, the potential of the source 32 will adjust itself to a level which will be sensitive to charge in the transistor region. This is similar to BCMD operation. The P-channel transistor operates in a source follower mode with the gate-source threshold determined by the doping profiles of the structure and by the amount of electrons under the transfer gates 36 and 38.
During nondestructive readout, the transistor gate 40 and the transfer gates 36 and 38 are biased as follows: the transfer gates 36 and 38 are negative to separate the pixels and the transistor gate 40 is addressed either high or mid level. If the transistor gate 40 is biased mid level, the cell is selected. If the transistor gate 40 is biased high, it is not selected.
During nondestructive readout the fixed pattern noise caused by transistor threshold variations is not important since the array is used only to find a suitable integration time and to make a rough measurement of the charge level. However, various fixed pattern noise subtraction schemes can be used to subtract fixed pattern noise if necessary. After the integration is completed, the charge signal is read out more accurately by the CCD action.
During charge transfer, the transistor gate 40 and the transfer gates 36 and 38 are clocked out of phase to accomplish a CCD charge transfer. During this phase the device functions as a standard CCD device. Several types of CCD architectures can be used such as frame transfer, interline transfer, frame-interline transfer, full frame, charge sweep device, and line addressable device.
The operation of the device of FIG. 1 during charge transfer is explained by referring to the potential profile shown in FIG. 2. The energy levels for an electron in the buried channel (conduction band minimum) are shown for the various regions of the device and for different bias levels of the transfer gates 36 and 38, and different bias levels of the transistor gate 40. Starting with an electron in the clocked barrier 60 at level 61 below transfer gate 36 with the transfer gate bias approximately equal to substrate bias, the operation is as follows. First the electron falls into the clocked well 64 at level 65. The electron will remain in the clocked well 64 as long as the transfer gate bias is approximately equal to substrate bias because the potential wells of both adjacent regions are higher. When the transfer gate 36 is switched to a negative bias with respect to the substrate 20, the potential level of the clocked well 64 moves up to level 67 and the potential level of clocked barrier 60 moves up to level 63. Then the electron passes from the clocked well 64 to the virtual barrier 68. The electron then moves from the virtual barrier 68 into the transistor gate well 70 at level 73.
When the transistor gate bias returns to a more negative voltage, the electron passes from the transistor gate well 70 to the virtual well 74 as the transistor gate well moves from potential level 73 to level 71. The electron remains in the virtual well 74 until the transfer gate bias moves to a more positive value which lowers the potential of clocked barrier 76 from level 77 to level 79 which is below the potential of the virtual well 74, and also lowers the potential of the clocked well 80 from potential level 81 to level 83. When the transfer gate bias is switched to this more positive value, the electron passes through the clocked barrier 76 and into the clocked well 80 at level 83. Movement of the electron to further cells is just a repeat of the same steps and clocking of the transfer gates 36 and 38, and the transistor gate 40 as described above.
A schematic block diagram representation of a first preferred embodiment of a basic sensor system architecture for an active transistor pixel CCD is depicted in FIG. 9 and incorporates the structure of FIGS. 1, 3, and 4. The system includes image sensing area 100, dual field CCD memory area 102, horizontal shift register 104, vertical shift register 106, horizontal switches 108, vertical switches 110, serial CCD register 112, clearing gate 113, charge clearing drain 114, and charge detection amplifiers 116 and 118.
FIG. 11 is a detailed circuit diagram of the image sensing area 100 along with the horizontal shift register 104, horizontal switches 108, vertical shift register 106, and the vertical switches 110, shown in FIG. 9. The circuit includes vertical shift register 106, horizontal shift register 104, photosites 120 (the device of FIG. 1), array columns 122 (X-address), array lines 124 (Y-address), vertical switches 110, horizontal switches 108, transfer gate voltage (φ TG ), charge transfer input (φ PG ) to transistor gates, transistor mode input (V ML ) to transistor gates, and output circuit 132 with output transistor 134.
In the circuit of FIG. 11, the vertical shift register 106 is used to select an array line for nondestructive readout of the active transistor in the photosites. The vertical shift register 106 selects the vertical switches in sequential order. Each vertical switch is connected to all of the transistor gates in the corresponding line of the array. The horizontal shift register 104 selects an array column for nondestructive readout. The horizontal shift register 104 selects the horizontal switches in sequential order. Each horizontal switch is connected to all of the transistor sources in the corresponding column of the array. The nondestructive output is taken from line 136 of the output circuit 132.
One purpose of the nondestructive readout is to determine the optimum charge integration time. As incident light causes charge to build up in the device, the active transistor element can be sensed to measure the level of charge building up in the device. The charge level is sensed from the source of the transistor. The use of the transistor to detect the charge level will have minimal effect on the charge that has already built up. Once the charge has reached the desired level, the charge can then be transferred in CCD mode to the memory array. This process will allow the charge integration time to be optimized before the charge is transferred from the image sensing array to the memory array.
In the CCD array shown in FIG. 9, the dual field CCD memory area 102 is constructed such that it can accept charge from one channel and direct it either to the memory "A" or "B". This dual feature allows for field signal subtraction. If one field is with signal and the other without (just the background), the subtraction is easily accomplished during the readout. Two consecutive charge signals are subtracted. The time domain sequential subtraction reduces problems with amplifier mismatch and balance if two channels and a dual amplifier system is used.
FIG. 10 is a timing diagram showing the various inputs to the device of FIG. 9. φ Vi is the input which starts the vertical shift register. φ Vs is the input to the vertical clock. φ Vr is the input to the vertical reset clock. φ Pg is the photogate pulse to bias the gate for readout. φ Tg is the charge transfer pulse. φ MA/B is the memory A and B pulses. φ Hi is the input for the horizontal scan start. φ Hs is the horizontal scan pulses. φ Hr is the horizontal reset pulses. Horizontal CCD register pulses are not included in this timing diagram.
The timing cycle starts with a charge clearing period from the image sensing area 100 and the memory areas 102. Charge is dumped into the charge clearing drain 114 located below the serial register 112. In this interval clocking pulses are similar to the charge transfer to memory cycle.
After the charge clearing period, the charge integration and nondestructive readout period 150 follows. This interval is as long as necessary to integrate a sufficient amount of charge in the pixels. The sufficient amount is determined in the external circuitry by supplying the nondestructive signal to it. External circuits determine when to stop the integration and proceed with the next cycle.
Next is charge transfer to memory 152. During this interval the device operates in a standard CCD mode. This interval can be followed by another integration period 154 and transfer cycle of identical length but with the light source turned off to load memory "B" with the background information for subtraction.
After both memories "A" and "B" are loaded with the corresponding signals, the data is transferred into the serial register 112 and read out. This is performed in a serial fashion with pixel by pixel analog subtraction. The serial register 112 shifts the charge serially into the charge detection amplifier 116. Serial readout is common to all CCD devices. This is not shown on the timing diagram in FIG. 10.
Vertical as well as horizontal switches and shift registers are typically built using CMOS devices. It is therefore beneficial to integrate CMOS and CCD architectures into a single process.
A schematic block diagram representation of a second preferred embodiment of a basic sensor system architecture for an active transistor pixel CCD is depicted in FIG. 12 and incorporates the structure of FIG. 1. The system includes image sensing area 200, field memory area 202, horizontal decoder 204 to the image sensing area 200, vertical decoder 206 to the image sensing area 200, horizontal switches 208 for the image sensing area 200, vertical switches 210 for the image sensing area 200, horizontal decoder 212 to the memory area 202, vertical decoder 214 to the memory area 202, logic input 205 to horizontal decoder 204, logic input 207 to vertical decoder 206, logic input 213 to horizontal decoder 212, logic input 215 to vertical decoder 214, horizontal switches 216 for the memory area 202, vertical switches 218 for the memory area 202, serial register 220, clearing gate 230, charge clearing drain 222, and charge detection amplifiers 224, 226, and 228.
The difference between the system of FIG. 12 and the system of FIG. 9 is that the shift registers of the system in FIG. 9 have been replaced by decoders in the system of FIG. 12. Also, the active transistor pixel (ATP) CCD is used in the field memory area 202 as well as in the image sensing area 200. The decoders 212 and 214 in the memory area 202 are used for the ATP CCD in the memory area.
The use of decoders in the system of FIG. 12 instead of shift registers, as in the system of FIG. 10, allows the cells in the array to be non-destructively read out in any order. With the decoders each cell can be selected directly without having to scan through the other cells as with the shift registers. This provides more flexibility in the operation of the system. For example, the decoders allow a coarse readout of the array by reading out only selected cells in the array.
For a coarse readout, the array can be divided into several regions with each region consisting of more than one ATP CCD cell. Then each region can be coarsely monitored by reading only one cell in that region. The output from the selected cell will be compared to a threshold level. Then only those regions of the array having a selected cell with an output above the threshold will be read out in CCD mode. The contents of the other regions of the array will be discarded. This process will save time in the readout of the device because only those parts of the memory with significant information will be read out.
This coarse readout process can be used in either the image sensor array area 200 or the memory area 202. If used in the image sensor area 200, only the regions of the image sensor array above the threshold will be transferred to the memory array 202, then only that data will be transferred out of the memory array 202. If this coarse readout process is done only in the memory array 202, then all of the data in the image sensor array cells will be transferred to the memory array 202. Then the memory array 202 will be coarsely scanned to determine which cells to read out in CCD mode.
In another technique for a coarse readout, the array can be divided into regions and the transistors in each region can all be connected together to determine the charge level in each region. For each cell in a region to be weighted evenly with the other cells in that region, all the transistors in a region can be shorted together. In this way, the signals from all the cells in a region will be treated equally. For situations where some cells need to be weighted more heavily than others, the transistors can be connected together through resistive networks that provide the desired weighting between the cells.
The image sensor array 200 of FIG. 10 can also be scanned to determine optimum charge integration time as described above for the device of FIG. 9. With the decoders, there is more flexibility in selecting array cells for determining optimum charge integration time. The cells in the array can be selected in any order and in any area of the array. Also, any number of the cells in the array can be selected for determining charge integration time. For a coarse determination, only a small number of cells can be measured in selected areas of the array. For a fine determination, more cells can be measured.
This invention incorporates both the CCD transfer as well as nondestructive X-Y addressable capability into a single pixel of an imaging device. This provides several advantages. One advantage of the invention is that the nondestructive X-Y addressable capability can be used to interrogate the sensing element several times to determine in real time if enough charge has accumulated for a good signal before the element is read out and reset. Another advantage of the invention is provided by the ability to scan the image sensing array to determine which elements in the array have sufficient charge levels so that only those elements with sufficient charge levels will be read out. This advantage reduces read out time of the device. Another advantage of the invention is the ability to have the nondestructive read out capability in the memory array as well as in the image sensing array. The memory array can be scanned to determine which elements in the memory array have sufficient charge levels so that only those elements with sufficient charge levels will be read out. This advantage also reduces read out time of the device.
The nondestructive X-Y addressable capability also allows the array to be coarsely scanned by measuring only selected elements located at strategic positions in the array. In this manner, the array can be quickly scanned to determine which regions of the array have sufficient charge levels for read out. Then, in order to reduce read out time, only those regions of the array with sufficient charge levels will be read out. This coarse scanning technique can be accomplished in either the image sensing array or the memory array.
A few preferred embodiments have been described in detail hereinabove. It is to be understood that the scope of the invention also comprehends embodiments different from those described, yet within the scope of the claims.
For example, the cells can be connected through logic networks that perform arithmetic operations such as the sum, difference, and division. The signals from the transistors in the array can also be input into a processor for performing arithmetic operations on the signals to determine the status of the signal levels in the array.
While this invention has been described with reference to illustrative embodiments, this description is not intended to be construed in a limiting sense. Various modifications and combinations of the illustrative embodiments, as well as other embodiments of the invention, will be apparent to persons skilled in the art upon reference to the description. It is therefore intended that the appended claims encompass any such modifications or embodiments. | An image sensor element having at least one charge storage well 70 and 80, charge transfer structures for transferring charge from one charge storage well 70 to another charge storage well 80, and a charge sensor for sensing charge levels in a charge storage well 70 without removing the charge from the well.
Other devices, systems and methods are also disclosed. | 6 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a wireless keyboard and computer system, and more particularly, to a wireless keyboard and computer system having the flexibility of keystroke allocation to enhance convenience of usage.
[0003] 2. Description of the Prior Art
[0004] In a computer system, a keyboard is one of the most essential input devices, and is composed of a plurality of keystrokes. Each of the keystrokes generates a key value or a key code when pressed, such that a keyboard controller of the computer system can determine input signals of a user. For example, FIG. 1 is a schematic diagram of a laptop 10 according to the prior art. The laptop 10 includes a keyboard 100 , which has a plurality of keystrokes related to different key codes.
[0005] In the keyboard 100 , relative positions of the keystrokes are fixed, and a key value (or definition) of a keystroke is also fixed; therefore, a user cannot arbitrarily adjust the positions of the keystrokes, add more keystrokes, and needless to say, define the key value of each keystroke. In other words, the conventional keyboard is not allowed for the user to adjust the position or key value of each keystroke, and to add or remove keystrokes.
[0006] Moreover, a conventional wired keyboard requires operating power supplied by a computer system, and if wirelessly transmitting the key values is requested, a wireless transmitting module and a power storage device, such as battery, are required to ensure normal operation. Under such a condition, if the battery runs out of electricity, the wireless keyboard suspends, affecting convenience of usage.
[0007] As can be seen, the prior art keyboard lacks of flexibility of keystroke allocation and cannot meet a user's demand for adjusting the positions or key values of the keystrokes, and adding or removing keystrokes. In addition to the above drawbacks, the prior art wireless keyboard further requires a power storage device, which may be out of use due to battery power insufficiency, affecting convenience of usage.
SUMMARY OF THE INVENTION
[0008] It is therefore a primary objective of the claimed invention to provide a wireless keyboard and a computer system.
[0009] The present invention discloses a wireless keyboard for a computer system, which comprises at least a keystroke and a reader. Each of the at least a keystroke comprises a first resonating circuit for responsing a first wireless signal to generate an induced electromotive force and provide a power source, a chip for storing a key data, and a switch coupled between the first resonating circuit and the chip for conducting a connection between the first resonating circuit and the chip when receiving an external force, to transmit the power source provided by the first resonating circuit to the chip, such that the chip outputs the key data as a second wireless signal via the first resonating circuit. The reader is coupled to the a computer system, and utilized for emitting the first wireless signal to the each keystroke and responsing the second wireless signal outputted by the each keystroke, so as to determine commands inputted to the computer system.
[0010] The present invention further discloses a computer system, comprises a host and a wireless keyboard. The wireless keyboard comprises at least a keystroke and a reader. Each of the at least a keystroke comprises a first resonating circuit for responsing a first wireless signal to generate an induced electromotive force and provide a power source, a chip for storing a key data, and a switch coupled between the first resonating circuit and the chip for conducting a connection between the first resonating circuit and the chip when receiving an external force, to transmit the power source provided by the first resonating circuit to the chip, such that the chip outputs the key data as a second wireless signal via the first resonating circuit. The reader is coupled to the a computer system, and utilized for emitting the first wireless signal to the each keystroke and responsing the second wireless signal outputted by the each keystroke, so as to determine commands inputted to the computer system.
[0011] These and other objectives of the present invention will no doubt become obvious to those of ordinary skill in the art after reading the following detailed description of the preferred embodiment that is illustrated in the various figures and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 is a schematic diagram of a laptop according to the prior art.
[0013] FIG. 2 is a schematic diagram of a wireless keyboard according to an embodiment of the present invention.
[0014] FIG. 3A to FIG. 3C are schematic diagrams of explosion, combination, and cutaway view of the keystroke shown in FIG. 2 .
[0015] FIG. 4 is a schematic diagram of a wireless keyboard according to an embodiment of the present invention.
[0016] FIG. 5 is a schematic diagram of a wireless keyboard according to an embodiment of the present invention.
DETAILED DESCRIPTION
[0017] To improve the drawbacks of the prior art keyboard, the present invention utilizes a radio frequency identification (RFID) technique to realize a wireless keyboard, which is allowed to change positions or key values of keystrokes, or to add or remove keystrokes. Firstly, the RFID technique is a non-contact automatic recognition technique, and mainly composed of an electric tag, a reader and a related application system. The electric tag works as a transponder, and is composed of a chip including analog, digital and memory functionalities, and an antenna designed for various frequencies and application environments. The reader is mainly composed of an analog control unit, a digital control unit, a micro-processing unit and a set of reading antennas. The application system is a middleware, for retrieving or receiving internal digital information of the electric tag through a wired or a wireless method, and utilizing the information coordinated with various application requirements to perform further processes. The RFID system has the advantages of non-contact reading, data renewable, high data storage capacity, reusable, high data security, and small volume of the RFID chip, so that the present invention applies the RFID technique to a wireless keyboard, for improving the drawbacks of the prior art.
[0018] Please refer to FIG. 2 , which is a schematic diagram of a wireless keyboard 20 according to an embodiment of the present invention. The wireless keyboard 20 is used in a computer system 200 , and includes a reader 202 and keystrokes PAD_ 1 -PAD_n. The reader 202 is coupled to the computer system 200 , and composed of a signal transceiving circuit 204 and a resonating circuit 206 . The signal transceiving circuit 204 emits wireless signals through the resonating circuit 206 to the keystrokes PAD_ 1 -PAD_n, or inducts the wireless signals output from the keystrokes PAD_ 1 -PAD_n, to determine the contents of commands inputted to the computer system 200 . The keystrokes PAD_ 1 -PAD_n are composed of the resonating circuits RNC_ 1 -RNC_n, chips CHIP_ 1 -CHIP_n and switches SW_ 1 -SW_n respectively. Operating principles of the keystrokes PAD_ 1 -PAD_n are substantially the same. Therefore, for sake of clarity, the following description takes the keystroke PAD_ 1 as an example. The resonating circuit RNC_ 1 can induct wireless signals output from the resonating circuit 206 , so that the resonating circuit RNC_ 1 and the frequency resonating circuit 206 are coupled to each other via an alternating current (AC) magnetic field, and such coupling triggers the resonating circuit RNC_ 1 to generate an induced electromotive force, providing adequate power source for the chip CHIP_ 1 to work, and making the reader 202 and the keystroke PAD_ 1 capable of performing bi-directional communication. The chip CHIP_ 1 stores a key data or key value, and can read and output the key data when power is supplied for the chip CHIP_ 1 . The switch SW_ 1 is coupled between the resonating circuits RNC_ 1 and the chip CHIP_ 1 , and can conduct an electric connection between the resonating circuit RNC_ 1 and the chip CHIP_ 1 when the switch SW_ 1 is pressed by an external force, so as to conduct power source provided by the resonating circuit RNC_ 1 to the chip CHIP_ 1 , so that the chip CHIP_ 1 can output the stored key data as wireless signals through the resonating circuit RNC_ 1 , and send the wireless signals out to the reader 202 .
[0019] In brief, the keystrokes PAD_ 1 -PAD_n are similar to a variety of electric tags in an RFID system, while the difference is that the keystrokes PAD_ 1 -PAD_n induct the wireless signals from the reader 202 only when the switches SW_ 1 -SW_n are pressed, and reply the stored key data in the chips CHIP_ 1 -CHIP_n accordingly. In other words, when a user presses a keystroke, the reader 202 will receive the key data or key value stored in the keystroke, and will not receive key data or key values stored in other keystrokes.
[0020] In addition, in the keystrokes PAD_ 1 -PAD_n, the key data stored in the chips CHIP_ 1 -CHIP_n can be preset in the system or defined by a user. If “defined by the user” is required, the chips CHIP_ 1 -CHIP_n can respectively include a key data updating unit or a corresponding firmware, for receiving control signals output from the user for updating the stored key data. However, the updating method is not limited to specific processes. For example, in an embodiment, the computer system 200 includes a key value configuration software, which can be executed by the user to send a key value configuration command through the signal transceiving circuit 204 to a specific keystroke, so that the key data updating unit of the specific keystroke can update the stored key value accordingly. Under such a condition, the user can arbitrary set the key value of each keystroke; for example, the user can store his/her name, phone number and address in various chips, and when the user needs to input some of these data, the user can quickly finish the inputting process; thus, efficiency is improved.
[0021] Moreover, since the wireless keyboard 20 adopts the RFID technique, the keystrokes PAD_ 1 -PAD_n are powered by the reader 202 using the method of AC magnetic field coupling. In other words, the keystrokes PAD_ 1 -PAD_n are not required to include physical wires or connect to power supplies. Under such a condition, the keystrokes PAD_ 1 -PAD_n can be designed as independent pieces respectively, namely mechanically independent elements, such that flexibility of keystroke allocation is greatly improved accordingly.
[0022] For example, please refer to FIG. 3A to FIG. 3C , which are schematic diagrams of explosion, combination, and cutaway view of a keystroke PAD_x of the keystrokes PAD_ 1 -PAD_n. As illustrated in FIG. 3A to FIG. 3C , a resonating circuit RNC_x of the keystroke PAD_x and a chip CHIP_x are disposed on a base plate BRD_x; a switch SW_x includes a flexible structure, and is covered by a key cap KH_x with a specific symbol painted to represent key data of the keystroke PAD_x. As a result, when a user presses the key cap KH_x, the switch SW_x is triggered to conduct the resonating circuit RNC_x and the chip CHIP_x.
[0023] As illustrated in FIG. 3A to FIG. 3C , the keystroke PAD_x does not need to connect with the other keystrokes or the reader 202 in view of either the structure or the electric circuitry, and therefore, the keystroke PAD_x can be independently allocated. Certainly, for convenience of usage, fastening structures such as hooks or tenons, or binding structures such as backing adhesive or magnetic materials can be added, in order to fix the keystroke PAD_x to the other keystrokes or an object. For example, the four sides of the base plate BRD_x can include fastening structures that can hook other base plates, such that the base plate BRD_x and the base plates of the other keystrokes can be fixed together. Or, the button of the base plate BRD_x can coated with backing adhesive or magnetic materials, such that the base plate BRD_x can stick on a plane surface or a metal surface. As a result, a user can easily allocate the keystrokes PAD_ 1 -PAD_n.
[0024] On the other hand, the main concept of the present invention is to use the RFID technique, such that the wireless keyboard 20 can meet the user's demand for adjusting positions or key values of the keystrokes, and adding or removing keystrokes; meanwhile, the wireless keyboard 20 does not require power storage devices such as batteries, so as to enhance convenience of usage. Besides, those skilled in the art can make modifications accordingly. For example, because a inductive distance of a passive RFID technique is restricted, if the inductive distance is required to be extended, independent power sources can be further settled for the keystrokes PAD_ 1 -PAD_n, and the passive RFID technique becomes a semi-passive or an active radio RFID technique, in order to extend the distance for use. Shapes of the keystrokes PAD_ 1 -PAD_n are not restricted to squares, and can be long straps, circles, etc. Or, the keystrokes PAD_ 1 -PAD_n can be classified into various blocks according to the functionalities, e.g. number blocks or character blocks.
[0025] Moreover, the computer system 200 represents all types of computer systems that can receive data inputted by a user, such as a laptop, a tablet, a smart phone or a PDA. According to various applications, a designer can properly adjust appearance or manufacturing of the wireless keyboard 20 according to system requirements. For example, FIG. 4 is a schematic diagram of a wireless keyboard 40 according to an embodiment of the present invention. The wireless keyboard 40 is derived from the wireless keyboard 20 , and basic structures of the wireless keyboard 40 and the wireless keyboard 20 are identical. The wireless keyboard 40 is used for a PC system; therefore, a reader 400 thereof connects with the host through physical wires, while keystrokes are allocated in an area 402 according to user's demand.
[0026] Furthermore, FIG. 5 is a schematic diagram of a wireless keyboard 50 according to an embodiment of the present invention. The wireless keyboard 50 is derived from the wireless keyboard 20 , and the basic structures of the wireless keyboard 50 and the wireless keyboard 20 are identical. The wireless keyboard 50 is used for a laptop system; therefore, a reader 500 thereof is disposed in a host (i.e., a chassis of the laptop system), and keystrokes are allocated in an area 502 on the chassis or an area 504 surrounding the area 502 according to user's demand.
[0027] The prior art keyboard lacks of flexibility of keystroke allocation and cannot meet the user's demand for adjusting the positions or key values of the keystrokes, and adding or removing keystrokes. In addition to the above drawbacks, the prior art wireless keyboard requires a power storage device, which may be out of use due to battery power insufficiency, affecting convenience of usage. In comparison, the wireless keyboard of the present invention can meet the user's demand for adjusting keystroke allocation or key values, and adding or removing keystrokes; and meanwhile, the wireless keyboard of the present invention does not require a power storage device such as battery, which further enhance convenience of usage.
[0028] In conclusion, the wireless keyboard of the present invention has the flexibility of keystroke allocation, to enhance convenience of usage.
[0029] Those skilled in the art will readily observe that numerous modifications and alterations of the device and method may be made while retaining the teachings of the invention. Accordingly, the above disclosure should be construed as limited only by the metes and bounds of the appended claims. | A wireless keyboard comprises at least a keystroke each comprising a first resonating circuit for responsing a first wireless signal to provide a power source, a chip storing a key data, and a switch coupled between the first resonating circuit and the chip for conducting a connection between the first resonating circuit and the chip when receiving an external force, to transmit the power source provided by the first resonating circuit to the chip, such that the chip outputs the key data as a second wireless signal via the first resonating circuit, and a reader coupled to a computer system for emitting the first wireless signal to the each keystroke and responsing the second wireless signal outputted by the each keystroke, so as to determine commands inputted to the computer system. | 6 |
BACKGROUND
1. Field of the Invention
The present invention relates to the design of programming languages for computer systems and associated development tools. More specifically, the present invention relates to a method and an apparatus for associating metadata attributes that do not affect program execution with program elements.
2. Related Art
It is often desirable for programmers to annotate program elements, such as fields, methods, and classes, as having particular attributes that indicate that they should be processed in special ways by development tools, deployment tools, or run-time libraries. We call such annotations “metadata.” Ideally, this metadata should be easily accessible at development time, deployment time, and run time.
Metadata has many uses. Custom tools may use metadata to generate auxiliary source files to be used in conjunction with the source file containing the annotation. For example, a stub generator can generate remote procedure call stubs based on annotations indicating that certain methods are designed for remote use.
A number of existing mechanisms presently allow programmers to associate metadata with programs. For example, the C++ programming language has a preprocessor directive called “#pragma” that affects the actions of the compiler as it compiles the program. Some uses of this directive associate metadata with the program. For example, this directive's COPYRIGHT function associates a copyright string with a program. The copyright string is then embedded in the object code where it can be read with the Unix strings utility. However, the C++ #pragma directive does not allow the programmer to associate arbitrary metadata, does not allow metadata to be associated with particular program elements, and does not allow metadata to be read at run time.
JAVA's doclet API has been used to associate metadata with program elements by various tools such as ejbdoclet, webdoclet, ejbgen, and icontract. Although this usage does allow the programmer to associate arbitrary metadata with particular program elements, it does not allow metadata to be read at run time, nor does it provide a mechanism to manage the namespace of metadata attributes.
Hence, what is needed is a facility that allows programmers to associate arbitrary metadata with arbitrary program elements in a manner that allows the metadata to be accessed by development tools, deployment tools, and programmatically at runtime without the limitations of the mechanisms described above.
SUMMARY
One embodiment of the present invention provides a system for associating metadata attributes with program elements. During operation, the system receives source code containing syntactic elements that specify metadata attributes for program elements, wherein the metadata attributes do not affect program execution. The system then parses the source code to obtain the metadata attributes. Next, the system associates the metadata attributes with corresponding program elements and determines values associated with the metadata attributes. Finally, the system incorporates the metadata attributes, including identifiers for the associated values and the associated program elements, into object code for the program, thereby allowing the metadata attributes to be accessed from the object code.
In a variation on this embodiment, a metadata attribute for a program element is expressed in the source code as a modifier for a declaration for the program element.
In a variation on this embodiment, a given metadata attribute can contain nested metadata attributes.
In a variation on this embodiment, a given metadata attribute is defined by a corresponding class for the given metadata attribute.
In a variation on this embodiment, the corresponding class for the given metadata attribute is located in a package named according to a unique package naming convention. This allows parties to define their own metadata attributes that are guaranteed not to interfere with attributes defined by other parties.
In a variation on this embodiment, the system additionally validates a given metadata attribute using validation criteria from an object file for a class associated with the given metadata attribute.
In a variation on this embodiment, determining values associated with the metadata attributes involves evaluating constant expressions.
In a variation on this embodiment, the object code for the program includes one or more class files for the program.
In a variation on this embodiment, a program element can include, a method, a class, and or a field.
One embodiment of the present invention provides a system for accessing metadata attributes associated with program elements. During operation, the system receives object code for a program, wherein the object code contains metadata attributes for program elements; these the metadata attributes do not affect program execution. Next, the system stores the object code in a memory buffer without loading the object code for program execution. The system then accesses the metadata attributes for the program elements from the object code through an application programming interface (API).
In a variation on this embodiment, the API includes: a method that returns a specified attribute of a specified element; a method that returns all attributes of a specified element; a method that returns all elements having a specified attribute; and a method that returns all elements having a specified attribute-value pair.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 illustrates a computer system in accordance with an embodiment of the present invention.
FIG. 2 illustrates the structure of a compiler in accordance with an embodiment of the present invention.
FIG. 3 is a flow chart illustrating the process of incorporating metadata attributes for program elements into object code in accordance with an embodiment of the present invention.
FIG. 4 is a flow chart of the process of accessing metadata attributes associated with program elements in accordance with an embodiment of the present invention.
DETAILED DESCRIPTION
The following description is presented to enable any person skilled in the art to make and use the invention, and is provided in the context of a particular application and its requirements. Various modifications to the disclosed embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be applied to other embodiments and applications without departing from the spirit and scope of the present invention. Thus, the present invention is not limited to the embodiments shown, but is to be accorded the widest scope consistent with the principles and features disclosed herein.
The data structures and code described in this detailed description are typically stored on a computer-readable storage medium, which may be any device or medium that can store code and/or data for use by a computer system. This includes, but is not limited to, magnetic and optical storage devices such as disk drives, magnetic tape, CDs (compact discs) and DVDs (digital versatile discs or digital video discs), and computer instruction signals embodied in a transmission medium (with or without a carrier wave upon which the signals are modulated). For example, the transmission medium may include a communications network, such as the Internet.
Computer System
FIG. 1 illustrates a computer system 100 in accordance with an embodiment of the present invention. As illustrated in FIG. 1 , computer system 100 includes processor 102 , which is coupled to a memory 112 and to peripheral bus 110 through bridge 106 . Bridge 106 can generally include any type of circuitry for coupling components of computer system 100 together.
Processor 102 can include any type of processor, including, but not limited to, a microprocessor, a mainframe computer, a digital signal processor, a personal organizer, a device controller and a computational engine within an appliance. Processor 102 includes a cache 104 that stores code and data for execution by processor 102 .
Processor 102 communicates with storage device 108 through bridge 106 and peripheral bus 110 . Storage device 108 can include any type of non-volatile storage device that can be coupled to a computer system. This includes, but is not limited to, magnetic, optical, and magneto-optical storage devices, as well as storage devices based on flash memory and/or battery-backed up memory.
Processor 102 communicates with memory 112 through bridge 106 . Memory 112 can include any type of memory that can store code and data for execution by processor 102 .
As illustrated in FIG. 1 , memory 112 contains compiler 116 . Compiler 116 converts source code 114 into object code 118 . In doing so, compiler 116 incorporates metadata attributes that are specified by syntactic elements within source code 114 into object code 118 . This process is described in more detail below with reference to FIG. 3 .
Incorporating metadata into object code enables development tool 120 to access the metadata attributes from object code 118 through an API. This process is described in more detail below with reference to FIG. 4 .
Note that although the present invention is described in the context of computer system 100 illustrated in FIG. 1 , the present invention can generally operate on any type of computing device. Hence, the present invention is not limited to the specific implementation of computer system 100 illustrated in FIG. 1 .
Compiler
FIG. 2 illustrates the structure of compiler 116 in accordance with an embodiment of the present invention. Compiler 116 takes as input source code 114 and outputs object code 118 . Note that source code 114 may include any computer program written in a high-level programming language, such as the JAVA programming language. Object code 118 includes executable instructions for a specific virtual machine or a specific processor architecture.
Compiler 116 includes a number of components, including front end 202 and back end 206 . Front end 202 takes in source code 114 and parses source code 114 to produce intermediate representation 204 .
Intermediate representation 204 feeds into back end 206 , which produces object code 118 . Within backend 206 , intermediate representation 204 feeds through optimizer 208 , and the resulting optimized intermediate representation 209 feeds though code generator 210 which produces object code 118 .
During this process, compiler 116 incorporates metadata attributes into object code 118 as is described below with reference to FIG. 3 .
Process of Incorporating Metadata into Object Code
FIG. 3 is a flow chart illustrating the process of incorporating metadata attributes for program elements in object code in accordance with an embodiment of the present invention. The system starts by receiving source code for a program, wherein the source code contains syntactic elements that specify metadata attributes for program elements (step 302 ). Note that the metadata attributes do not effect program execution.
The program elements can include methods, classes or fields that can be associated with attributes. For example, a method can be associated with attributes, such as: (1) a remote attribute that specifies whether the method is a remote method or a local method; (2) a precondition attribute and a postcondition attribute that collectively facilitate “design by contract;” (3) a deprecated attribute which indicates that a given method is supported, but should no longer be used; or (4) a query attribute that facilitates forming a database query for an accessor method.
A class can be associated with attributes, such as: (1) an author attribute that identifies the author of the class; (2) a deprecated attribute, which indicates that the class is supported, but should no longer be used; and (3) a framework membership attribute that signifies that the class participates in a framework.
A field can have attributes, such as a persistence attribute, which indicates whether or not the field is persistent. Note that this persistence attribute can be a boolean attribute, or alternatively a multi-valued attribute that specifies a type of persistence.
Next, the system parses the source code to obtain metadata attributes (step 304 ). In one embodiment of the present invention, a metadata attribute is expressed in the source code as a modifier associated with a declaration for a program element. In this embodiment, each attribute is declared as a class. For example, an interface for a class associated with “deprecated” attribute can have the form,
interface @deprecated extends Java.lang.BooleanAttribute{ }.
The deprecated attribute is associated with a program element as a modifier for a declaration for the program element. For example, a class can be associated with both the deprecated attribute and the author “Mickey Mouse” in the following way,
@deprecated @author(“Mickey Mouse”) public static final class Foo extends Bar { public static final void main { } }.
Note that in the above example, a modifier associated with an attribute can be easily identified by “@” symbol. Also note that multiple attribute modifiers can be associated with a given declaration.
Attributes can also be nested. For example, a “remote” attribute for a class can the specified as follows,
@remote( @comstyle(“Corba”), @timeout(10), ) <<method declaration>>.
This nested remote attribute specifies that the communication style for the remote method is “Corba” and that the timeout period for the remote method is 10 seconds. Note that this information can be used by a programming tool to build a stub for the remote method.
An interface for a class that defines the nested “remote” attribute can have the form,
public interface @remote extends CompoundAttribute {
public interface @comstyle
extends java.lang.StringAttribute{ }
public interface @timeout
extends java.lang.IntAttribute{ }
. . .
}
Note that by placing the classes that define the attributes in packages named according to a unique package naming convention like the one described in Section 7.7 of the Java(tm) Language specification, Second Edition (Gosling, Joy, Steele, Bracha; Addison-Wesley 2000), the present invention can leverage off the existing namespace management features enabled by the convention. Hence, unrelated parties can define their own classes for their own attributes, and these classes can be located within their own portions of the package namespace. This allows unrelated parties to define different attributes using the same name without interfering with each other.
Next, the system determines values associated with the metadata attributes, which may involve evaluating constant expressions (step 306 ). After or during the parsing process, the system can validate the metadata attributes (step 308 ). In one embodiment of the present invention, this involves using validation criteria retrieved from an object file for a class that defines a given metadata attribute to validate the given metadata attribute.
The system then associates metadata attributes with corresponding program elements (step 310 ). The system then incorporates the metadata attributes, including identifiers for associated values and associated program elements, into object code (class files) for the program (step 312 ). In one embodiment of the present invention, the metadata attributes are stored as “class file attributes” in a JAVA class.
Process of Accessing Metadata Attributes from Object Code
FIG. 4 is a flow chart of the process of accessing metadata attributes associated with program elements in accordance with an embodiment of the present invention. This process can take place either at run time (while the class is loaded), or at design time (while the class is not loaded).
If the process takes place during run time, one embodiment of the present invention adds an accessor method to class for each primitive type attribute. For example, we can add the following accessor methods to class,
String getStringAttribute(name of attribute), and int getlntAttribute(name of attribute).
These accessor methods can be used to retrieve a string and an integer, respectively. For example, “Foo.class.getStringAttribute@author.class)” returns a string for the attribute “author” during run time. However, note that in order to do this the class literal “Foo.class” must be evaluated, which requires loading the class.
If the process takes place during design time, one embodiment of the present invention provides an application programming interface (API) to obtain metadata associated without program elements without having the load the class.
The process operates as follows. Upon receiving object code for a program (step 402 ), the process loads the object code into a memory buffer—without performing the time-consuming verification operations involved in loading the class into a virtual machine (step 404 ). Next, the process accesses metadata attributes for program elements through an API (step 406 ).
Note that API can be defined as a class. For example, the class can include methods to: (1) return a specified attribute of a specified element; (2) return all attributes of a specified element; (3) return all elements having a specified attribute; (4) return all elements having a specified attribute-value pair; (5) return a specified sub-attribute of a complex attribute; and (6) to return all sub-attributes of a complex attribute.
The foregoing descriptions of embodiments of the present invention have been presented only for purposes of illustration and description. They are not intended to be exhaustive or to limit the present invention to the forms disclosed. Accordingly, many modifications and variations will be apparent to practitioners skilled in the art. Additionally, the above disclosure is not intended to limit the present invention. The scope of the present invention is defined by the appended | One embodiment of the present invention provides a system for associating metadata attributes with program elements. During operation, the system receives source code containing syntactic elements that specify metadata attributes for program elements, wherein the metadata attributes do not affect program execution. The system then parses the source code to obtain the metadata attributes. Next, the system associates the metadata attributes with corresponding program elements and determines values associated with the metadata attributes. Finally, the system incorporates the metadata attributes, including identifiers for the associated values and the associated program elements, into object code for the program, thereby allowing the metadata attributes to be accessed from the object code. Another embodiment of the present invention provides a system for accessing metadata attributes for program elements from object code through an application programming interface (API). | 6 |
TECHNICAL FIELD
The present disclosure relates generally to devices and methods of fabrication of semiconductor devices, and more particularly to the fabrication of field-effect transistors (FETs) with reduced gate contact resistance.
BACKGROUND
Continuous scaling of the gate dielectric in metal-oxide semiconductor (MOS) devices, along with its undesired increase in leakage current, has resulted in the evolution of high-K/metal gate stacks. These stacks are constructed either by forming the gate first or forming the gate last. In the gate first approach, the gate stack typically includes an amorphous silicon (a-Si) electrode on the metal gate with high dielectric (high-K) material, and the a-Si is formed after the high-K/metal gate is formed.
Referring to FIGS. 1A and 1B , there are illustrated prior art high-K/metal gate stacks 100 a , 100 b formed using a gate first approach. The gate stack 100 a illustrated in FIG. 1A is an ideal high-K/metal gate stack, while the gate stack 100 b illustrated in FIG. 1B shows the actual structure of such a gate stack. During a-Si deposition, a thin layer of native oxide 102 forms at the a-Si/metal interface as shown in FIG. 1B . This oxide layer 102 increases the gate contact resistance and in particular, increases the AC Reff. AC Reff is a measure of resistance to alternating current.
In these prior art high-K/metal gate stacks 100 a , 100 b, the gate stack is disposed on a substrate 110 , and the stacks typically include the following layers: silicon oxynitride (SiON) 120 , hafnium silicon oxynitride (HfSiON) 130 , lanthanum oxide (La 2 O 3 ) 140 , titanium nitride (TiN) 150 and amorphous silicon (A-Si) 160 . The FET gate stack shown in FIGS. 1A , 1 B is a typical gate stack for an nFET. For pFET, the lanthanum oxide could be replaced with a combination, such as TiN/Al/TiN. As will be appreciated, different manufacturers may utilize different gate stack structures with different high-K materials.
One method of reduce the oxide layer 102 is to control the oxygen flow during the a-Si deposition process. However, the AC Reff is still high. One method may be to utilize pre-doping in the a-Si gate. This may result in a reduction of AC Reff of about 150 ohms (at a fixed DC Reff when pre-doping is introduced in the a-Si region of a pFET). Another method is to increase the source/drain (S/D) doping, which effectuates an increase in doping within the a-Si region. This may result in a reduction of AC Reff of about 200 ohms (with increased doping of S/D regions in nFET).
The main reason to utilize pre-doping or an increase in S/D doping is to increase the doping at the a-Si/metal interface to reduce the gate contact resistance, Rco. The issue of gate contact resistance is analogous to the issue of diffusion contact resistance (diffusion Rco). Similarly, scaling is limited by diffusion Rco which is dependent on the schottky barrier height (SBH). Since diffusion Rco depends on SBH, reducing SBH will reduce diffusion Rco and improve device performance.
Current techniques developed by one or more of the inventors for reducing SBH at the S/D contacts employ impurity segregation at the silicide/semiconductor (e.g., NiSi/Si) interface. The segregated layer, which could use for example impurities like As, B, In, Sb, N, Cl, S, Se, Al, Dy, Yb, Yt, etc., either passivates the surface or creates interface dipoles to reduce the SBH.
Accordingly, there is a need for an improved fabrication process (and resulting devices) that lowers contact Rco (and decreases AC Reff) and improves device performance. Also needed is a high-K/metal/a-Si gate stack with a segregated layer structure (metal/a-Si) to reduce contact Rco.
SUMMARY
In accordance with one embodiment, there is provided a method of forming a semiconductor device. The method includes providing a semiconductor substrate with dopants of a first conductivity type and forming first and second source/drain (S/D) regions with dopants of a second conductivity type. A high-K/metal gate stack is formed by forming a gate dielectric having a high dielectric constant (K), depositing metal to form a metal gate electrode, and forming a gate contact layer. An impurity layer is formed between the metal gate electrode and the gate contact layer and an anneal process is performed to convert the impurity layer into a segregation layer.
In accordance with another embodiment, there is provided a semiconductor device having a semiconductor substrate of a first conductivity type and a field-effect transistor (FET) structure formed on the substrate. The FET structure includes a first source/drain (S/D) region and a second S/D region each of a second conductivity type, and a gate stack structure including a gate dielectric, a gate electrode, and a gate contact layer. A segregation layer comprises an impurity, and the segregation layer is disposed between the gate electrode and the gate contact layer.
In yet another embodiment, there is provided a method of forming a field-effect transistor (FET) structure having reduced gate contact resistance. The method includes forming a gate stack structure on a semiconductor substrate having dopants of a first conductivity type, the gate structure including a gate dielectric and a metal gate electrode; forming a first source/drain (S/D) region having dopants of a second conductivity type and positioned proximate the gate structure; forming a second S/D region having dopants of the second conductivity type and positioned proximate the gate structure; forming a gate contact layer above the metal gate electrode; forming an impurity region between the metal gate electrode and the gate contact layer; and after forming the impurity region, performing an anneal process to form impurity region into a segregation layer that segregates the metal gate electrode from the gate contact layer.
Other technical features may be readily apparent to one skilled in the art from the following figures, descriptions, and claims.
BRIEF DESCRIPTION OF THE DRAWINGS
For a more complete understanding of the present disclosure, and the advantages thereof, reference is now made to the following descriptions taken in conjunction with the accompanying drawings, wherein like numbers designate like objects, and in which:
FIG. 1A illustrates an ideal prior art high-K/metal gate stack formed using a gate first approach;
FIG. 1B illustrates an actual prior art high-K/metal gate stack formed using the gate first approach;
FIG. 2 is a cross-sectional view depicting a FET structure in accordance with the present disclosure;
FIGS. 3A-3D illustrate a method or process for forming a high-K/metal/a-Si gate stack in accordance with the present disclosure;
FIGS. 4A-4E illustrate another method or process for forming a high-K/metal/a-Si gate stack in accordance with the present disclosure; and
FIGS. 5A-5D illustrate another embodiment of a method or process for forming a high-K/metal/a-Si gate stack in accordance with the present disclosure.
DETAILED DESCRIPTION
Referring to FIG. 2 , there is depicted a cross-sectional view of a FET semiconductor device 200 formed on a substrate 202 in accordance with the present disclosure. The FET device 200 can be structured as either an n-type or p-type FET. As will be appreciated, the structures and regions shown in the FIGURES are not drawn to scale or actual form, and are for illustrative purposes.
Substrate 202 may include, for example, silicon, silicon-on-insulator (SOI), epitaxial silicon-germanium channel on Si substrate, or other suitable semiconductor substrate materials, now known or later developed. The substrate 202 may include silicon (e.g., n-type, p-type, or no type) provided in a single well or twin-well process, and may further include an epitaxial layer.
The FET 200 includes a gate stack 210 having various regions or layers. Two n-type (or p-type) regions form the source/drain (S/D) regions 210 , which include either n-type (or p-type) dopants (while the substrate 202 includes dopants of an opposite conductivity type). The gate stack 210 is considered a high-K/metal/a-Si gate stack, and includes a gate dielectric layer 220 , a metal gate electrode 230 and a gate contact region/layer 240 . Though not shown, the S/D regions 210 may include a S/D extension region and a deep S/D region. In addition, and again not shown, the gate stack may include sidewall spacers, as known to those skilled in the art.
The gate dielectric 220 layer may be a single layer of high-K (high dielectric constant) dielectric material or multiple layers of dielectric materials (which overall form a high-K dielectric gate). In one embodiment, the gate dielectric 220 includes a first layer of silicon oxynitride (SiON) 222 , a second layer of hafnium silicon oxynitride (HfSiON) 224 , and a third layer of lanthanum oxide (La 2 O 3 ) 226 . Other layers and materials may be utilized (shown is a typical dielectric stack for an nFET, and a pFET may be different such as substituting TiN/AL/TiN for the lanthanum oxide layer). In different and varying embodiments, the thickness of the layers may be in the ranges of: SiON—about 5 to about 15 angstroms; HfSiON—about 15 to about 25 angstroms; La 2 O 3 —about 3 to 5 angstroms; and TiN—about 30 to about 60 angstroms.
Disposed above and in contact with the gate dielectric 220 is the metal gate electrode 230 formed to include metal. In one embodiment, the gate electrode 230 includes metal silicide, and in one particular embodiment is titanium nitride. As will be appreciated, the metal silicide may include any suitable metal. In the embodiment shown, the gate electrode 230 contacts the La 2 O 3 layer 226 of the gate dielectric 220 .
Disposed above the gate electrode 230 is a segregation region or layer 240 formed to include one or more impurities. Examples of such impurities may include As, B, In, Sb, N, Cl, S, Se, Al, Dy, Yb, Yt, and the like. In two specific embodiments, the impurity is nitrogen (N) or aluminum (Al). Disposed above the segregation layer 240 is the gate contact layer 250 which, in one embodiment, is amorphous silicon which will eventually become polysilicon. The segregation layer 240 functions as (or provides) an interface or buffer layer between the gate electrode layer 230 and the gate contact layer 250 and is intended to reduce gate contact resistance in the device 200 . In different and varying embodiments, the thickness of the metal gate electrode 230 (e.g., TiN) may be in the range of about 30 to about 60 angstroms, while the thickness of the gate contact layer 250 (e.g. a-Si) may be in the range of about 300 to about 700 angstroms.
As will be understood, most of the semiconductor device 200 may be formed using conventional processes, and a method or process will be described below by which the device 200 may be fabricated to achieve reduced gate contact resistance and improve device performance.
Now referring to FIGS. 3A-3D , there is illustrated one method or process 300 of fabricating the FET device 200 in accordance with the present disclosure. In general terms, this new process provides more effective SBH engineering of the device by minimizing impurity diffusion, achieving peak or high impurity concentration and/or high impurity activation at the interface (segregation region 240 ) between the gate electrode 230 and the gate contact layer 250 within the gate stack 210 .
The process 300 includes conventional processing steps up to the formation of the high-K/metal gate stack 210 . The gate dielectric layer 220 , including the SiON ( 222 ), HfSiON ( 224 ) and La 2 O 3 ( 226 ) layers, are formed by a suitable process. Metal (including metal alloy(s) or compounds) is deposited on at least a portion of the gate dielectric 220 (more particularly, the La 2 O 3 layer 226 ). The metal may be any suitable metal, including a metal to form a metal silicide (by an annealing process) in the gate stack 210 , and in specific embodiments, may be titanium or titanium nitride, or any combination of these, or other metals and metal silicides, such as tantalum or tantalum nitride. The structure resulting from the above process is illustrated in FIG. 3A . It will also be understood that other embodiments, the metal gate electrode 230 may be metal, without any silicide formed contemporaneously therewith (and a post metal anneal may be performed).
After formation of the high-K/metal gate, amorphous silicon (a-Si) is deposited by any suitable process on the gate electrode 230 and forms the gate contact layer 250 . The a-Si may be undoped, pre-doped or later doped, and may be pre-doped with other dopants by insitu doping or implantation. Alternatively, doping may be accomplished by using S/D implants later in the process. In such embodiments, the goal of this doping step is to achieve uniform dopant concentration throughout the a-Si. As will be appreciated, doping to produce the segregated layer 240 is described below. The resulting structure (high-K/metal/a-Si) is shown in FIG. 3B .
Impurities, which may include dopant and/or metal, are implanted near or at the interface between the gate electrode 230 and the gate contact layer 250 . The implanted impurities form a thin implanted impurity layer 240 a . The resulting structure (high-K/metal/impurities/a-Si) is shown in FIG. 3C . It is desirable to implant the impurities in a thin region substantially at the interface. In certain embodiments, the thickness of the segregation layer 240 may be in the range of about 10 to about 50 angstroms.
The implantation of these impurities, as described above, may also be referred to as schottky barrier height (SBH) engineering implantation (for decreasing the barrier height). This implantation increases peak concentration around the metal/metal-silicide-silicon (amorphous) interface (in the segregation region 240 ). Examples of suitable impurities may include As, B, In, Sb, N, Cl, S, Se, Al, Dy, Yb, Yt, and the like. In one embodiment, the impurity is aluminum (Al) and in another specific embodiment, the impurity is nitrogen (N). During the implantation process, the implanted impurities are imparted with an energy level in an effort to generate peak impurity levels at or near the interface between the TiN ( 230 ) and the a-Si ( 250 ). The implant energy will depend on the thickness of the a-Si ( 250 ). The goal is to produce a specific distribution (depth) into the a-Si layer 250 at about the interface with the TiN ( 230 ). Implant energy levels may range from a few eV to a few hundred keV, depending on the targeted a-Si thickness to be formed and the implant species. Implant dosage may range from about 1×10 13 cm 2 to 1×10 16 cm 2 , depending on the implant species, as well.
In the previous embodiment, the SBH engineering implant is implanted after high-K/metal gate/a-Si stack formation (e.g., deposition) but before gate etch. In another embodiment, impurity implant may occur after gate etch and S/D formation. In another embodiment, the SBH engineering implant may be performed just before or after S/D silicidation. In yet another embodiment, the implantation may be performed during intermediate steps of the S/D silicidation process (e.g., deposition of metal for silicidation, rapid thermal anneal process, removal of unreacted metal, SBH impurity implant, second rapid thermal anneal, and laser/dynamic spike annealing.
One or more anneal process steps convert or form the implanted layer 240 a into the segregation layer 240 . FIG. 3D illustrates the gate stack 210 with the segregation layer or region 240 after an anneal process. As will be appreciated, the anneal process may be performed immediately after the impurities are implanted, or the anneal process may be accomplished by one or more standard annealing steps performed during later processing, e.g., S/D activation anneal, or the immediate anneal process may be assisted by the one or more later standard annealing steps.
If the anneal step is performed immediately after implantation, a furnace anneal, rapid thermal process (RTA), spike anneal (e.g., laser spike anneal (LSA) or dynamic spike anneal (DSA)) may be performed to convert or form the segregation layer 240 . The spike anneal process may be a laser spike annealing (LSA) process or a dynamic spike annealing (DSA) process, or other known spike anneal process, and may be a flash anneal. LSA and DSA work in such a way that it ramps up the temperature of the applied region from a floor (e.g., ambient) temperature to the intended temperature in a short period of time. The main difference between LSA and DSA is that DSA has a shorter dwell time, i.e., this process is able to achieve the intended temperature in a shorter time period than LSA. Thus, a “spike anneal” process is described as an anneal process in which the temperature is raised to the intended temperature in a short period of time, such as less than about 5 seconds, and in some embodiments less than about 1 second. Due to the short duration and meta-stable state induced by LSA/DSA, diffusion is minimized and the impurity is highly activated—aiding in the surface passivation of dangling bonds and/or impurity segregation at the interface (between the gate electrode region 230 and the gate contact layer 250 ) which lowers SBH.
As will be appreciated, any suitable implantation process may be used, and cluster, molecular or plasma implants may be employed to form sharper and/or shallower impurity profiles.
The above described method 300 aids in the fabrication of the FET structure 200 through reductions in gate contact resistance (by decreasing SBH). In sum, this reduces the series contact resistance of the device 200 and improves device performance by lowering AC Reff.
Now referring to FIGS. 4A-4E , there is illustrated another method or process 400 of fabricating the FET device 200 in accordance with the present disclosure. In general terms, this process 400 is similar to the process 300 except the gate contact layer (a-Si) 250 is formed using a two-step process and the implantation layer 240 a is formed between the two steps.
The high-K/metal gate electrode illustrated in FIG. 4A is formed in the same manner at that described above with respect FIG. 3A .
After formation of the high-K/metal gate, a first layer of amorphous silicon (a-Si) is deposited by any suitable process on the gate electrode 230 and forms the gate contact layer 250 a. The resulting structure (high-K/metal/a-Si) is shown in FIG. 4B .
Next, the impurities are implanted near or at the interface between the gate electrode 230 and the gate contact layer 250 a and form the thin implanted impurity layer 240 a . The resulting structure (high-K/metal/impurities/first layer of a-Si) is shown in FIG. 4C .
One or more anneal process steps convert or form the implanted layer 240 a into the segregation layer 240 . FIG. 4D illustrates the gate stack 210 with the segregation layer or region 240 after an anneal process.
As will be appreciated, the anneal process may be performed immediately after the impurities are implanted, or the anneal process may be accomplished by one or more standard annealing steps performed during later processing, e.g., S/D activation anneal, or the immediate anneal process may be assisted by the one or more later standard annealing steps.
After formation of the segregation layer 240 , a second layer of amorphous silicon (a-Si) is deposited by any suitable process on the gate electrode 230 and forms the gate contact layer 250 b . These two a-Si layers 250 a , 250 b form the gate contact layer 250 . The a-Si layer(s) may be undoped, pre-doped or later doped, and may be pre-doped with other dopants by insitu doping or implantation. Alternatively, doping may be accomplished by using S/D implants later in the process. The resulting structure (high-K/metal/segregation layer/a-Si) is shown in FIG. 4E . The thicknesses of the layers 250 a and 250 b may be any suitable thicknesses, and in one embodiment, the first layer 250 a is thinner than the second layer 250 b.
The anneal step represented by FIG. 4D may be optionally omitted, and annealing may be performed at a later stage (after the gate contact layer 250 is formed). For example it may be accomplished by one or more standard annealing steps performed during later processing, e.g., S/D activation anneal. In yet another embodiment, the immediate anneal process may be performed and assisted by the one or more later standard annealing steps.
Now referring to FIGS. 5A-5D , there is illustrated another method or process 500 of fabricating the FET device 200 in accordance with the present disclosure. In general terms, this process 500 is similar to the process 300 except the segregation layer is deposited, instead of implanted.
The high-K/metal gate electrode illustrated in FIG. 5A is formed in the same manner at that described above with respect FIG. 3A .
After formation of the high-K/metal gate, impurities deposited by any suitable process on the gate electrode 230 and form an impurity (or solid source) layer 550 . The resulting structure (high-K/metal/impurity layer) is shown in FIG. 5B . Example solid sources that may be suitable include Sb, Al and other metals.
Next, a layer of a-Si is formed and disposed above the impurity layer 550 to form the gate contact layer 250 . The a-Si layer may be undoped, pre-doped or later doped, and may be pre-doped with other dopants by insitu doping or implantation. Alternatively, doping may be accomplished by using S/D implants later in the process. The resulting structure (high-K/metal/impurity layer/a-Si) is shown in FIG. 5C .
One or more anneal process steps convert or form the impurity layer 550 into the segregation layer 240 . FIG. 5D illustrates the gate stack 210 with the segregation layer or region 240 after an anneal process.
The anneal step represented by FIG. 5D may be optionally omitted, and annealing may be performed at a later stage. For example it may be accomplished by one or more standard annealing steps performed during later processing, e.g., S/D activation anneal. In yet another embodiment, the immediate anneal process may be performed and assisted by the one or more later standard annealing steps.
It will be understood that some of processes/steps described above to form the segregation layer 240 , e.g., the anneal process, may be performed either prior to or after S/D contact silicidation.
The order of steps or processing can be changed or varied form that described above, unless otherwise described above (or in the claims below). It will be understood that well known process have not been described in detail and have been omitted for brevity. Although specific steps, insulating materials, conductive materials and apparatuses for depositing and etching these materials may have been described, the present disclosure may not limited to these specifics, and others may substituted as is well understood by those skilled in the art.
It may be advantageous to set forth definitions of certain words and phrases used throughout this patent document. The terms “include” and “comprise,” as well as derivatives thereof, mean inclusion without limitation. The term “or” is inclusive, meaning and/or. The phrases “associated with” and “associated therewith,” as well as derivatives thereof, mean to include, be included within, interconnect with, contain, be contained within, connect to or with, couple to or with, be communicable with, cooperate with, interleave, juxtapose, be proximate to, be bound to or with, have, have a property of, or the like.
While this disclosure has described certain embodiments and generally associated methods, alterations and permutations of these embodiments and methods will be apparent to those skilled in the art. Accordingly, the above description of example embodiments does not define or constrain this disclosure. Other changes, substitutions, and alterations are also possible without departing from the spirit and scope of this disclosure, as defined by the following claims. | A method (and semiconductor device) of fabricating a semiconductor device provides a field effect transistor (FET) with reduced gate contact resistance (and series resistance) for improved device performance. An impurity is implanted or deposited in the gate stack in an impurity region between the metal gate electrode and the gate contact layer. An anneal process is performed that converts the impurity region into a segregation layer which lowers the schottky barrier height (SBH) of the interface between the metal gate electrode (e.g., silicide) and gate contact layer (e.g., amorphous silicon). This results in lower gate contact resistance and effectively lowers the device's AC Reff. | 7 |
CROSS REFERENCE TO RELATED APPLICATION APPLICATIONS
This application is a continuation of U.S. application Ser. No. 13/328,779, filed Dec. 16, 2011 (now U.S. Pat. No. 8,523,623), which is a continuation of U.S. application Ser. No. 12/890,240, filed Sep. 24, 2010 (now U.S. Pat. No. 8,079,888), which is a continuation of U.S. application Ser. No. 12/400,214, filed Mar. 9, 2009 (now U.S. Pat. No. 7,811,145), which is a continuation of U.S. application Ser. No. 12/028,227, filed Feb. 8, 2008 (now U.S. Pat. No. 7,500,893), which is a continuation of U.S. application Ser. No. 11/554,197, filed Oct. 30, 2006 (now U.S. Pat. No. 7,335,080), which is a continuation of Ser. No. 11/143,703, filed Jun. 3, 2005 (now U.S. Pat. No. 7,134,930), which is a continuation of U.S. application Ser. No. 10/847,339, filed May 18, 2004 (now U.S. Pat. No. 7,147,528), which is a continuation of U.S. application Ser. No. 10/295,906, filed Nov. 18, 2002, (now U.S. Pat. No. 7,097,524), which is also a continuation of U.S. application Ser. No. 09/772,739, filed Jan. 30, 2001, (now U.S. Pat. No. 6,485,344), which claims priority from U.S. Provisional Application Ser. No. 60/238,988, filed Oct. 10, 2000; the entire disclosures of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to inflatable flotation devices. In particular, the present invention relates to inflatable flotation devices which are collapsible through use of a spring mechanism.
2. Description of the Related Art
Inflatable flotation devices are well known in the form of floats, rafts, lifeboats, life preservers and other like devices. Previously known devices generally maintain their shape through air pressure alone and generally collapse when deflated.
In one of many examples, U.S. Pat. No. 3,775,782 issued to Rice et al. describes an inflatable rescue raft. When deflated, the raft can be rolled into a compact size.
Also well known in the art are collapsible items which are collapsible through the use of a collapsible metal or plastic spring. U.S. Pat. No. 4,815,784 shows an automobile sun shade which uses these collapsible springs. The springs are also used in children's play structures (U.S. Pat. Nos. 5,618,246 and 5,560,385) and tent-like shade structures (U.S. Pat. Nos. 5,579,799 and 5,467,794).
The collapsible springs are typically retained or held within fabric sleeves provided along the edges of a piece of fabric or other panel. The collapsible springs may be provided as one continuous loop, or may be a strip or strips of material connected at the ends to form a continuous loop. These collapsible springs are usually formed of flexible coilable steel, although other materials such as plastics are also used. The collapsible springs are usually made of a material which is relatively strong and yet is flexible to a sufficient degree to allow it to be coiled. Thus, each collapsible spring is capable of assuming two configurations, a normal uncoiled or expanded configuration, and a coiled or collapsed configuration in which the spring is collapsed into a size which is much smaller than its open configuration. The springs may be retained within the respective fabric sleeves without being connected thereto. Alternatively, the sleeves may be mechanically fastened, stitched, fused, or glued to the springs to retain them in position.
SUMMARY OF THE DISCLOSURE
A device comprises a spring and a sleeve. The spring is configured to form a closed loop. The spring is moveable between a coiled configuration when the spring is collapsed and an uncoiled configuration when the spring is expanded. The spring defines a circumference while in the uncoiled configuration. The spring is disposed within the sleeve. The sleeve includes an inflatable portion disposed about at least a portion of the circumference.
It is therefore an object of the present invention to provide a collapsible flotation device.
It is another object of the present invention to provide a collapsible flotation device which is easily collapsed and extended to full size through a mechanical means.
It is yet another object of the present invention to provide a collapsible flotation device which is easily collapsed and extended to full size through the use of a spring.
It is yet a further object of the present invention to provide a collapsible flotation device which requires minimal force to twist and fold into the collapsed configuration.
Finally, it is an object of the present invention to accomplish the foregoing objectives in a simple and cost effective manner.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a top view of the preferred embodiment of the present invention;
FIG. 2 is a cross sectional view of the preferred embodiment of the present invention taken along line II-II of FIG. 1 ;
FIG. 3 is a view of a joining method as used in one embodiment of the present invention;
FIG. 4 is a top view of an alternate embodiment of the present invention;
FIG. 5 is a top view of another alternate embodiment of the present invention;
FIG. 6 is a cross section view of the alternate embodiment of the present invention across line VI-VI of FIG. 5 ;
FIG. 7 is a top view of an alternative embodiment of the present invention;
FIG. 8 is a cross sectional view of the embodiment of the present invention, taken along line VIII-VIII of FIG. 7 ; and
FIG. 9 is a plan view of another embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The following detailed description is of the best presently contemplated modes of carrying out the invention. This description is not to be taken in a limiting sense, but is made merely for the purpose of illustrating general principles of embodiments of the invention.
The present invention provides a collapsible flotation device. The device includes a coilable metal or plastic spring. The coilable spring can be made from other materials, however, it is important that the coilable spring be made from a material that is strong and flexible. The spring must be coilable such that it folds on top of itself to become more compact. In its uncoiled state, the coilable spring can be round or oval or any shape satisfactory for use as a flotation device. Because it is to be used in water, the coilable spring is preferably either manufactured from a waterproof material or coated to protect any material which is not waterproof. The coilable spring can be a single continuous element or can include a joining means, such as a sleeve, for joining the ends of one or more spring elements together. The coilable spring can be of any appropriate shape and dimension. The coilable spring also has memory such that is biased to return to its uncoiled configuration when not held in the coiled configuration.
Stretched across the coilable spring is a flexible panel of material. The flexible panel can be one continuous piece or can be made up of several different types of material. In a preferred embodiment, the center portion of the flexible panel is mesh to allow water to flow through while the perimeter edges are nylon or polyester. At the edges of the flotation device, the material is a double thickness, forming a pocket around the perimeter of the flotation device. In this pocket are one or more inflatable chambers. One inflatable chamber may surround the entire perimeter of the flotation device or it may be divided into two or more inflatable chambers with each inflatable chamber having a means for inflating and deflating the inflatable chamber. In a preferred embodiment, one inflatable chamber is specifically designed to accommodate the user's head. In this embodiment, the pocket formed by the material is wider along a small portion of the perimeter of the flotation device to allow for a wider inflatable chamber. This will prevent the user's head from sinking below the rest of the user's body. The size of the inflatable chamber can vary significantly and need only be as wide as necessary to support the user's body weight. A preferred embodiment includes an inflatable chamber which is 3 inches in diameter when inflated. The inflatable chamber can be made from any appropriate float material but is preferably resistant to punctures. The coilable spring may also be located within the perimeter pocket. If one inflatable chamber is selected, the coilable spring can be placed inside or outside the inflatable chamber. If multiple inflatable chambers are used, the coilable spring will be outside the inflatable chambers. Alternatively, the coilable spring may be located outside the perimeter pocket along the outer edge of the flotation device. The coilable spring may be attached to the flexible panel through mechanical means such as fastening, stitching, fusing, or gluing.
A preferred embodiment of the flotation device is shown in FIGS. 1 and 2 in its expanded configuration. The perimeter pocket 12 portion of the flexible panel is nylon while the central portion 14 of the flexible panel is made from a mesh material. The pillow 16 is part of the perimeter pocket 12 as it includes a double layer of fabric to accept an inflatable chamber 20 between the layers of fabric. In this particular embodiment, there are two inflatable chambers 20 in the perimeter pocket of the flotation device and one in the pillow 16 , each of which includes a means for inflating the inflatable chamber 20 . The inflation means is a valve on the underside of the flotation device. The inflatable chambers 20 in the perimeter pocket of the flotation device expand to approximately a 3-inch diameter when inflated. The coilable spring 18 is made from flexible, collapsible steel and is coated with a layer of PVC 22 to protect the coilable spring 18 from corroding and rusting due to contact with water during normal use of the flotation device. The coilable spring 18 also has memory such that will open to its uncoiled configuration when not held in the coiled configuration. The coilable spring 18 can be a single unitary element or can include sleeves 24 for joining the ends of one or more strips as shown in FIG. 3 in which the ends of the coilable spring 18 within the sleeve 24 are shown in dashed lines for clarification.
Alternatively or in addition to the perimeter inflatable chambers, the device can include inflatable chambers 26 which cross the panel as shown in FIG. 4 . FIGS. 5 and 6 show a further alternate embodiment of the present invention in which the coilable spring 18 is attached to the external perimeter of the pocket portion 12 of the flexible panel through the use of a mechanical means. In this particular embodiment, several loops 28 are used to attach the coilable spring 18 to the pocket portion 12 of the flexible panel.
While the description above refers to particular embodiments of the present invention, it will be understood that many modifications may be made without departing from the spirit thereof. The accompanying claims are intended to cover such modifications as would fall within the true scope and spirit of the present invention. | A device comprises a spring and a sleeve. The spring is configured to form a closed loop. The spring is moveable between a coiled configuration when the spring is collapsed and an uncoiled configuration when the spring is expanded. The spring defines a circumference while in the uncoiled configuration. The spring is disposed within the sleeve. | 1 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The present application is a continuation of U.S. Non-Provisional application Ser. No. 12/274,124 filed Nov. 19, 2008, still pending, which claims the benefit of prior U.S. Provisional Application No. 61/003,647, filed Nov. 19, 2007.
FIELD OF THE INVENTION
[0002] The present invention relates generally to self-standing riser assemblies utilized during oil and gas exploration and production operations, and in a particular though non-limiting embodiment, to a self-standing riser system equipped with multiple buoyancy chambers suitable for deployment in a variety of water depths and sea conditions.
BACKGROUND OF THE INVENTION
[0003] Self-standing risers (hereinafter “SSR”) are employed in the oil and gas industry to suspend production and injection lines from subsea production units, and to support holding tendons associated with floating offshore structures. Known SSR can be used to facilitate standard “shallow-water” (e.g., between 0 feet and around 600 feet of water) drilling units and cost effective production facilities by placing blow-out preventers and production trees on top of a buoyancy chamber.
[0004] The conventional approach to the SSR design has been to employ one large buoyancy chamber that supports the riser or tendon loads. However, this approach has led to increased costs associated with the construction and installation of the buoyancy chambers. Such factors have resulted in a lack of significant SSR system development by operators who could realize a broad spectrum of associated benefits. Nonetheless, the industry as a whole desires a reduction in oil and gas production costs, a decrease in time delays for drilling exploration wells, and increased development of previously discovered fields. There is, therefore, a long-felt but unmet need for smaller, more flexible riser systems capable of more rapid manufacture and deployment that assist in the profitable development of previously under produced oil and gas fields.
SUMMARY OF THE INVENTION
[0005] A self-standing riser system suitable for deepwater oil and gas exploration and production is provided, the system including a lower riser assembly disposed in communication with a primary well-drilling fixture; one or more intermediate buoyancy chambers disposed in communication with the lower riser assembly and one or more portions of intermediate riser assembly, wherein one or more of the buoyancy chambers further includes an open-bottomed lower surface portion; and an upper riser assembly disposed in communication with one or more upper buoyancy chambers, wherein one or more of the upper buoyancy chambers further includes a fully enclosed portion.
[0006] Ballast loads for the chambers; stress joints for the riser assemblies; methods and means of system deployment and maintenance; access to blow-out preventers, wellheads and production trees; and various system interconnections are also provided.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] The embodiments disclosed herein will be better understood, and numerous objects, features, and advantages made apparent to those skilled in the art by referencing the accompanying drawings.
[0008] FIG. 1A is a schematic diagram of a self-standing riser system equipped with an open-bottom buoyancy chamber in calm waters, according to an example embodiment known in the prior art.
[0009] FIG. 1B is a schematic diagram of a self-standing riser system equipped with an open-bottomed buoyancy chamber that is nearing its spill point.
[0010] FIG. 1C is a schematic diagram of a self-standing riser equipped with an open-bottomed buoyancy chamber that has tilted beyond its spill point.
[0011] FIG. 2 is a schematic diagram depicting the effects of pressure, temperature and depth on a closed-bottom buoyancy chamber.
[0012] FIG. 3 is a schematic diagram of a self-standing riser system comprising multiple buoyancy chambers, according to example embodiments of the present invention.
[0013] FIG. 4 is a schematic diagram depicting the installation of a self-standing riser system comprising multiple buoyancy chambers, according to example embodiments of the invention.
DETAILED DESCRIPTION
[0014] There are presently two known types of submersible buoyancy chambers suitable for oil and gas exploration and production: a closed container design, and an open-bottomed design. Both types of chambers, if pressurized and secured by a riser, will exert an upward lifting force on the riser. Certain embodiments also comprise features lending adjustability to the system, as may be known to those of skill in the art.
[0015] The closed container design is similar in some respects to a submarine, in that there are typically one or more ballast chambers used to house a fluid, such as a light gas, seawater, etc. Once a desired ratio of fluids is achieved, the chamber is closed off by valves or other means known in the art.
[0016] An open-bottomed buoyancy chamber includes many design functions similar to those of the closed container design. However, once desired buoyancy characteristics are achieved, fluid disposed within the chamber is simply trapped by the sides and top thereof.
[0017] FIG. 1A illustrates a known, open-bottomed, buoyancy chamber disposed in communication with an SSR and filled with a fluid, for example, a pressurized gas. As seen, a combination of calm water currents, minimal external forces, and a sufficient amount of buoyancy applied to the SSR results in minimal lateral displacement force. Accordingly, the buoyancy chamber illustrated in FIG. 1A experiences little or no tilt relative to its vertical axis, and fluid contained within the chamber remains enclosed.
[0018] If, however, a sufficiently large enough force is applied to the chamber, such as a strong current as depicted in FIG. 1B , the SSR will begin to tilt away from its vertical axis. FIG. 1B also illustrates how the fluid contained within the chamber has shifted relative to the system's tilt away from its vertical axis. However, the chamber can accommodate a tilt of up to a certain critical angle (which depends largely on its design dimensions) before the critical spill point angle is reached, and fluid begins to escape from the chamber.
[0019] FIG. 1C further illustrates how the spill rate of the gas contained within an open-bottomed buoyancy chamber will increase as the critical tilt angle is reached and exceeded. In particular, spillage will result in even greater loss of buoyancy, and therefore a proportionately increasing tilt angle, which will cause more and more gas to escape from the chamber. Eventually, enough gas escapes that the buoyant force is reduced to the point where the chamber can no longer support the riser, thereby causing the system to fail.
[0020] Despite such drawbacks, open-bottomed chambers can operate at extreme water depths with a reduced concern of structural collapse than a closed system, since the open design allows fluid pressures within the chamber to equalize with surrounding pressures at even great depths. Furthermore, the open-bottomed design has less overall system weight due to a reduction in required construction materials, since there is no bottom, and the remainder of the shell will require less thickness and reinforcement in order to withstand deepwater fluid pressures.
[0021] In contrast, closed container buoyancy chambers do not suffer as greatly from the problem of tilting caused by currents and surface effects, and are typically the appropriate design choice in areas where currents and surface effects are significant enough to cause major lateral displacement from the vertical axis. However, if either of the described buoyancy chambers sustain a leak (for example, a leak caused by container breach, valve malfunction, etc.), the gas or other fluid will escape and the SSR can fail, as illustrated in FIG. 1C .
[0022] Closed container buoyancy chambers must also be robust enough to offset external forces such as deepwater fluid pressure. As illustrated in FIG. 2 , such chambers must, as a threshold matter, have sufficient structural integrity and wall thickness to resist expected pressures that might cause a collapse of the chamber's outer shell. Moreover, when deploying a closed buoyancy chamber filled with a gas, the internal gas pressures and temperatures should be sufficiently proportional to the external water pressures and temperatures that an associated pressure or temperature gradient will not induce an effective change in gas volume within the chamber which could cause the chamber's outer shell to crack or collapse.
[0023] Typically, SSR systems are constrained to include the use of only a single buoyancy chamber due to the chamber's large size. However, the larger buoyancy chamber designs increase the time and cost associated with building and deploying the operating system. Moreover, deployment of large, pressurized chamber at great depths (e.g., >500 ft. or so) can prove to be an exceedingly difficult task. Furthermore, as the diameter of the buoyancy chamber is increased, the probability of structural failure and warping caused by handling during construction and deployment is also increased.
[0024] The detailed description that follows includes exemplary systems, methods, and techniques that embody techniques of the presently inventive subject matter. However, it will be understood by those of skill in the art that the described embodiments may be practiced without one or more of the specific details disclosed herein. In other instances, well-known manufacturing equipment, protocols, structures and techniques have not been shown in detail in order to avoid obfuscation in the description.
[0025] Referring now to the example embodiment depicted in FIG. 3 , an SSR system 14 is depicted comprising a plurality of subordinate buoyancy chambers configured to admit to installation in deeper water depths than any previously known SSR systems. According to an alternative embodiment, SSR 14 can be stacked with multiple buoyancy chambers as illustrated in FIGS. 4A , 4 B, 4 C and 4 D. Although illustrated in FIG. 3 as a combination of lower SSR assembly 10 and upper SSR assembly 12 , embodiments of the overall SSR system 14 can comprise any number of individual SSR assemblies.
[0026] In the embodiment depicted in FIG. 3 , lower SSR assembly 10 is first deployed. In one example, a specially designed vessel equipped specifically to deploy buoyancy chambers and SSR assemblies is used. Following deployment, lower SSR assembly 10 is joined in mechanical communication with a casing wellhead established near the mud-line. In a typical embodiment, the casing wellhead has been preset into a well hole bored into an associated seafloor surface.
[0027] In further embodiments, one or more intermediate buoyancy chambers 16 is attached to lower SSR assembly 10 , thereby providing increased stability in deep or turbulent waters. Depending on operating conditions, intermediate buoyancy chamber 16 can comprise a closed-container design, but in most instances will comprise the open-bottomed design for the reasons described above, with the only firm requirement being that intermediate chamber 16 must in any event be capable of providing the support required to control lower SSR assembly 10 and upper SSR assembly 14 .
[0028] In further example embodiments, intermediate buoyancy chamber 16 is disposed in mechanical communication with either previously known or custom-designed drilling, production and exploration equipment. Thus, for example, the top and bottom portions of an intermediate buoyancy chamber may comprise one or more of a blowout preventer, a production tree, or a wellhead that functions in a manner similar to the casing wellhead placed near mud-line of the ocean floor. Attachment of the drilling, production and exploration equipment can be achieved using either known or custom connection and fastening members, e.g., hydraulic couplers, various nut and bolt assemblies, welded joints, pressure fittings (either with or without gaskets), swaging, etc., without departing from the scope of the invention.
[0029] In further embodiments, an upper SSR assembly 12 is deployed and disposed in mechanical communication with a wellhead, blowout preventer, or production tree (or another, custom-designed device combining elements of one or more of such devices) installed atop an upper surface of the intermediate chamber 16 or a connecting member associated therewith. According to other example embodiments, the installation process continues until the desired number of such assemblies are installed in serial communication with one another in order to achieve a stable and efficient SSR system 14 , as depicted in FIGS. 4A-4D .
[0030] In order to further stabilize the SSR system 14 , example embodiments can utilize stress joints 22 , as depicted in FIG. 3 . Stress joints 22 can comprise any known material, for example, a plastic, rubber, or metal material, but should in any event be capable of maintaining the SSR 14 system's structural integrity and overall stability.
[0031] Consistent with the example SSR system 14 illustrated in FIG. 3 , a plurality of upper buoyancy chambers 18 , 20 includes an open-bottomed chamber 18 and a closed-container type chamber 20 . In a one example embodiment, at least one of said upper chambers—generally the topmost—will comprise a closed design, while others in the system, including intermediate chamber 16 , will comprise an open-bottomed design. In another example embodiment, all of the chambers in the system are either open or closed, and in still further embodiments, combinations of open and closed chambers are employed across the system.
[0032] In some embodiments, the multiple open-bottomed design buoyancy chambers are utilized to facilitate deployment in deeper waters in which surrounding fluid pressures are greatest. Other embodiments utilize a plurality of closed-container type chambers disposed near the top of the SSR system 14 , thereby improving the system's overall stability and balance. Such configurations can also help avoid the system's tendency to tilt away from its vertical axis as a result of external lateral forces, such as a forceful cross-current.
[0033] In still further embodiments, a plurality of buoyancy chambers disposed in mechanical communication with upper SSR assembly 12 allows for the overall SSR system 14 to maintain required functionality and stability in varying water depths and conditions, thereby improving its efficiency and operability.
[0034] Further example embodiments comprise a plurality of upper buoyancy chambers disposed in mechanical communication with commonly known drilling, production and exploration equipment. Thus, for example, the top and bottom portions of an upper buoyancy chamber may comprise one or more of a blowout preventer, a production tree, or a wellhead designed to function in a manner similar to the casing wellhead placed near mud-line of the ocean floor.
[0035] In further embodiments, the buoyancy chambers utilized throughout the system further comprise auxiliary buoyancy materials, such as syntactic foam or air filled glass micro-spheres that lend buoyancy to the system. Injecting one or more of these materials within an open-bottomed chamber will assist in prevention of buoyancy fluid (e.g., gas, liquid, etc.) loss should tilting occur, or if there is a breach or failure of tubing, valves, or other equipment utilized in connection with the buoyancy chamber.
[0036] In the example embodiment illustrated in FIG. 4A , a deployment vessel deploys a lower SSR assembly 40 to the ocean floor where it is mechanically disposed in communication with a casing wellhead near the mud-line. FIG. 4A further depicts an intermediate buoyancy chamber 41 installed atop the SSR assembly 40 . Various embodiments of the intermediate buoyancy chamber 41 further comprise one or more previously known or custom-fit attachment mechanisms, such as a combined blowout preventer and production tree, so that the intermediate chamber 41 is useful during operations for purposes other than mere connection with an upper SSR assembly 42 . In various other embodiments, a plurality of intermediate buoyancy chambers 41 are deployed and mechanically disposed in communication with a previously installed SSR assembly or another intermediate buoyancy chamber (see, for example, FIGS. 4B-4D ).
[0037] In FIG. 4C , intermediate SSR assemblies 42 and 44 are deployed and disposed in mechanical communication with a well-head affixed atop intermediate buoyancy chamber 41 . In some example embodiments, additional intermediate buoyancy chambers 41 , 43 , 45 serve as additional support and connection components for the intermediate SSR assemblies. Such redundant embodiments can achieve heretofore unknown SSR system depths of more than 15,000 ft. with the addition of multiple intermediate SSR assemblies.
[0038] In the example embodiment depicted in FIG. 4D , a final SSR assembly 46 is deployed to complete the SSR system 50 . FIG. 4D further depicts an embodiment employing a plurality of buoyancy chambers 47 atop SSR assembly 46 in order to complete the overall SSR system 50 . As previously discussed, embodiments of the plurality of buoyancy chambers 47 can comprise a mixture of open-bottomed and closed-container designs, or any other configuration made desirable by operating conditions, including of course the installation of only a single such chamber.
[0039] The foregoing specification is provided for illustrative purposes only, and is not intended to describe all possible aspects of the present invention. Moreover, while the invention has been shown and described in detail with respect to several exemplary embodiments, those of ordinary skill in the art will appreciate that minor changes to the description, and various other modifications, omissions and additions may also be made without departing from the spirit or scope thereof. | A multi-tiered self-standing riser system includes one or more intermediate buoyancy chambers configured to provide an upward lifting force on strings of associated riser assemblies. The intermediate chambers have either an open-bottomed or closed container design. The chambers can further include an auxiliary buoyant material designed to either mix with or contain pressurized fluids injected into the chambers. The self-standing riser system further includes a lower riser assembly affixed to a primary well-drilling fixture. The system also includes an upper riser assembly and one or more additional buoyancy chambers disposed in either direct or indirect communication with one another, as well as with drilling, production and exploration equipment as required by associated operations. | 4 |
This application claims the priority of Provisional Application No. 60/070,887 filed Jan. 9, 1998.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to the field of separation of molecules using selective adsorbents.
2. DESCRIPTION OF THE ART
Since its discovery by Tswett nearly a century ago, the technique of adsorption chromatography has evolved into a tool of fundamental importance to the biological and chemical sciences. Early chromatographers employed readily available adsorbents such as calcium carbonate, sugar, starch, paper, wool, silk, alumina and silica to perform an impressive variety of separations. Today, researchers with a problem separation are faced with a variety of adsorbents from which to choose. Furthermore, additional adsorbents can readily be prepared using combinatorial chemistry approaches. As a general rule, the more selective adsorbents allow for more economical chromatographic separations, with simple and inexpensive batch adsorption separations becoming possible with extremely selective adsorbents. A means of rapidly finding the most selective adsorbent for a given separation task is needed.
One area where the development of highly selective adsorbents is of great importance is the large scale separation of enantiomers using chiral stationary phases (CSPs). The current selection of commercial chiral stationary phases (CSPs) for large scale chromatographic separations is rather limited, and most have been developed as general purpose CSPs rather than the best CSP for a particular separation. While new CSPs can be designed, the development time is often too long to merit serious consideration by process engineers.
Within the past decade the technique of chromatographic enantioseparation has become the method of choice for analytical determinations of enantiopurity. Allenmark, Chromatographic Enantioseparation: Methods and Applications, Ellis Horwood, N.Y., 1991. The method is widely used, particularly in the pharmaceutical industry where most new chiral drugs are manufactured in enantiomerically pure form. In recent years the use of preparative chromatographic enantioseparation has become increasingly popular. While generally more expensive than manufacturing routes employing enantioselective synthesis or classical resolution, chiral HPLC offers a considerable advantage of speed. Consequently, many pharmaceutical companies use preparative chiral HPLC in the early stages of drug discovery to rapidly produce enantiomerically pure drug candidates for animal testing, metabolism and toxicology studies, etc. Once a drug candidate has been selected for larger scale development, alternative manufacturing methods are often used, although in a few cases chiral HPLC is used to produce enantiopure drugs on large scale.
Most commercial CSPs have been developed using trial and error methodology, and have been commercialized because they demonstrate some general ability to separate enantiomers. Of these many commercial CSPs, only a small fraction are available in bulk or can be produced in an economical fashion for large scale preparative chromatography. Francotte, E., J. Chromatogr ., 666, 565-601, 1994. Furthermore, rather than a CSP which has a general ability to separate the enantiomers of a large number of racemates, the process engineer considering a potential manufacturing route for an enantiopure drug is interested in a CSP which can separate the enantiomers of one particular compound.
Practical large scale chromatographic enantioseparation requires highly enantioselective CSPs. For example, chromatographic resolution of the enantiomers of a racemate using a CSP with an enantioselectivity of 1.3 can be rather tedious. A comparable CSP having an enantioselectivity of 2 can sometimes afford 5-10 fold greater productivity.
SUMMARY OF THE INVENTION
The present invention relates to a process for screening candidate selective adsorbents for differential adsorption of two or more chemical components. In this process a solid phase consisting of the candidate adsorbent is allowed to contact a solution phase containing the component or components of interest. Interaction or equilibration of material in the solution phase with the stationary phase of the selective adsorbent results in a change of concentration of the analyte or analytes in both the stationary phase and solution phase. This change in concentration can be measured by a variety of techniques and gives an indication of the degree of adsorption of the analyte by the stationary phase. Thus, small amounts of candidate selective adsorbents are placed in an array of containers and a solution of the chemical compounds to be separated is added to each container. The components are allowed to interact or equilibrate with the selective adsorbent and the amount of each component in the solution phase or in the solid phase of the array of containers is measured. The adsorbent showing the greatest differential adsorption for the chemical components is identified as being potentially useful for large scale separations. The invention is particularly useful in identifying selective adsorbents for enantiomer separations.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 is an expanded view of the solid phase prior to equilibration.
FIG. 2 is an expanded view of the liquid phase prior to equilibration.
FIG. 3 is a view of the liquid and solid phase after equilibration.
FIG. 4 shows that the performance of the DNB Leu CSP prepared by solid phase synthesis is comparable with the performance of the commercial version of this CSP.
FIG. 5 shows a variety of DNB-peptido CSPs prepared by solid phase synthesis.
FIG. 6 illustrates substantial differences in the performance of structurally similar dipeptide and tripeptide CSPs.
FIG. 7 illustrates five amino acids used to prepare a library of 50 dipeptide DNB CSPs and the test racemate, 1 , used for evaluation.
FIG. 8 shows three representative screening chromatograms including the blank (no CSP), a CSP which strongly adsorbs the (R) enantiomer of the test racemate, 1 , and a CSP which strongly adsorbs the (S) enantiomer of the test racemate, 1 .
FIG. 9 shows the results of a screening of a library of 50 dipeptide DNB CSPs for the separation of the enantiomers of test racemate, 1 .
FIG. 10 shows results of a screening of a focused library of dipeptide DNB CSPs containing hydrogen-bonding sidechains in the aa 1 position and sterically bulky sidechains in the aa 2 position. Many of these second generation CSPs are superior to the best CSPs in the library shown in FIG. 9 .
FIG. 11 shows a separation of the enantiomers of test racemate, 1 , using a conventional 4.6×250 mm analytical HPLC column containing one of the best dipeptide DNB CSPs from FIG. 10 .
FIG. 12 shows preparative HPLC separation of the enantiomers of the test racemate, 1 , using the column from FIG. 11 .
FIG. 13 illustrates four libraries of DNB tripeptide CSPs.
FIG. 14 illustrates the results of the screening of leucine library from FIG. 13 for enantioselective naproxen recognition.
FIG. 15 illustrates chromatographic separation of the enantiomers of the drug, naproxen, using the best CSP indicated by the CSP library screening shown in FIG. 14 .
FIG. 16 illustrates libraries of acyl amino acid CSPs comprised of four different amino acids each acylated with 40 different carboxylic acids.
FIG. 17 illustrates the results of the screening of two of the acyl amino acid libraries from FIG. 16 for enantioselective recognition of test racemate, 1 . In both instances, 3,5-dinitrobenzamide and 4-methyl, 3,5-dinitrobenzamide are shown to be superior to other acyl groups.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The invention encompasses a method whereby candidate selective adsorbents can be rapidly evaluated for their potential for carrying out the separation of a mixture of two or more chemical components. Using this method, libraries containing small amounts of about 1 mg to 100 mg of many different candidate adsorbents can be rapidly evaluated using automated equipment. This approach dramatically decreases the time required to find a suitable selective adsorbent for a given separation. The method is useful for finding adsorbents which can be used for the analytical or preparative chromatographic separation of enantiomers, the separation of impurities from pharmaceuticals or other products, the separation of fermentation products from their associated impurities or any process in which two or more compounds are separated by a chromatography or any process which relies upon differential adsorption of two or more chemical species. The method has the added advantage that the compound mixture for which a separation is desired can be used directly without the need for separations, purifications, radiolabeling or other chemical derivatization.
The screening process is depicted schematically in the figures which follow. A small amount of a candidate absorbent is placed in a vial or similar receptacle (FIG. 1 ). The expanded view of the candidate absorbent shows two particles containing four pendant selectors each. Any number of particles can be used, and in contrast to chromatography, the performance of the assay does not require the use of very small and regular particles. Indeed, there are some advantages to be found in the use of large particles or even a single bead. For example, since larger particles tend to settle more rapidly and completely, the use of large particles allows the supernatant solution to be sampled without risk of particles clogging the syringe.
In the case where a solid phase material which preferentially binds one enantiomer is desired (e.g. a chromatographic chiral stationary phase) the preferred method involves adding a solution of the racemic mixture to the candidate chromatographic adsorbents and measuring the enantioenrichment of either the solution phase or the stationary phase using chromatographic techniques such as chiral HPLC, HPLC/MS, GC, CE or spectroscopic techniques such as NMR with chiral solvating agents or NMR analysis of diastereomeric derivatives or chiroptical spectroscopic techniques such as CD or polarimetry. An alternative method of performing the assay could involve analysis of a nonracemic solution of the target analyte or could involve independently measuring the degree of complexation of each enantiomer.
A dilute solution containing known relative concentrations of the mixture of the analytes of interest is then added (FIG. 2 ). In this example, two analytes are represented as circles and crosses. It is important that the analyte solution be of low enough concentration to prevent saturation of the adsorption sites on the chromatographic adsorbent. In addition, the polarity of the solution phase should be such that the target molecules are neither completely adsorbed nor completely free in solution. Equilibration or interaction of the material in the liquid phase with the chromatographic adsorbent may result in the preferential binding of one of the analytes in the mixture to the chromatographic adsorbent, resulting in a depletion of that analyte in the solution phase.
Analysis of the relative abundance of the analytes in either the solid phase or the solution phase gives some indication of the degree of selectivity of the adsorbent-analyte interaction. In the case illustrated here, a strong preference for adsorption of the circular analyte is depicted. Those adsorbents which show the highest degrees of selectivity are likely candidates for a chromatographic stationary phase which may be capable of separating the mixture of chemical components in question, FIG. 3 .
This technique has several advantages over previous methods of evaluating candidate selective adsorbents. Only a small amount, about 1 mg to 100 mg, of the candidate adsorbent is used in an assay, and this material need not be packed into a column or capillary for evaluation. Furthermore, the candidate adsorbent can be washed free of all chemical components and reused. The target analytes can be used directly without any need for purifications, resolutions, or synthetic operations. A variety of analytical techniques can be used to measure the relative abundance of the analyte molecules in either the solid phase or the solution phase. The process is not limited to mixtures of two analytes, but could conceivably be used to screen for e.g., an adsorbent which would show preferential adsorption of a single desired product from a complex mixture containing a number of different associated impurities. Similarly, the technique could conceivably be used to search for an adsorbent which would preferentially adsorb the various impurities from this same complex mixture while only weakly adsorbing the desired product. The screening process is rapid, and is amenable to automation, which allows for high throughput screening of libraries of new candidate chromatographic adsorbents prepared using solid phase diversity-generating synthetic approaches.
A variety of analytical tools can be used to determine the relative concentrations of the analytes in the solid phase. For example, analysis of the relative concentrations of the analytes in the liquid phase can be performed using chromatographic techniques such as HPLC, HPLC/MS, SFC, CE or GC or spectroscopic techniques such as NMR or chiroptical techniques such as CD or any analytical technique or chemical process capable of showing the absolute or relative concentrations of the analytes in question.
Determination of the relative concentrations of the analytes in the solid phase can be done by a variety of methods. The extent of enrichment in the solid phase is typically greater than that in the supernatant solution. However, these measurements are often more difficult, usually requiring a filtration or other phase separation before the determination of the relative concentration of materials adsorbed onto the solid phase can be determined. A convenient method for determining the relative concentration of the analytes in the solid phase simply involves removal of the supernatant layer by rapid suction filtration, followed by the addition of a solvent which liberates most of the adsorbed material from the solid phase, followed by analysis of the resulting supernatant solution by HPLC or other analytical techniques mentioned above.
Those skilled in this art will recognize that a wide variety of solid polymeric or inorganic particles may be functionalized to form candidate selective adsorbents using techniques and procedures which are known from the fields of solid phase synthesis and combinatorial chemistry. Such particles bearing pendant groups such as amine, carboxylic acid, hydroxyl, halide, aldehyde, or thiol may be used for attachment of one or more molecular fragments to provide a large number of candidate selective adsorbents. Further, by linking enantiopure moieties to functionalized solid particles, a large number of candidate CSPs and CSP libraries can be prepared.
Suitable candidate adsorbents are made by techniques described in the following examples or can be purchased from Regis Technologies, Inc., 8210 Austin Avenue, Morton Grove, Ill. 60053-0519.
EXAMPLE 1
Silica-Based Solid Phase Synthesis.
Modified solid phase peptide synthesis on aminopropyl silica particles was chosen as a preferred method for preparing combinatorial libraries of CSPs.
Silica-Based Solid Phase Synthesis of DNB-Leu CSP
As a model study, the well known 3,5-dinitobenzoyl Leucine (DNB-Leu) CSP was prepared on 5 g scale using the solid phase synthesis protocol outlined in FIG. 4 . The CSP thus obtained was packed in a column which separated a group of test analytes nearly as well as the commercial column.
Silica-Based Solid Phase Synthesis of DNB-Peptido CSPs
Preparing and evaluating a group of peptido CSPs using a split synthesis was conducted in a manner analagous to that shown in FIG. 4. A representative sampling of some of the CSPs which were made and evaluated is shown in FIG. 5 . Each CSPs was prepared on 5 g scale, packed into a column and evaluated chromatographically. Two additional CSPs from this initial group are shown in FIG. 6 . These CSPs are nearly identical, differing only in one leucine residue. Nevertheless, substantial differences in enantioselectivity are noted for the group of test analytes.
Microscale Silica-Based Solid Phase Synthesis of CSPs
The foregoing experiments show the utility of a silica based solid phase synthesis approach to CSP development. While the cost and time required to make each of these materials on 5 g scale is less than that of conventional CSP development, an even more rapid way of sampling the structural diversity of the DNB peptide family was required. Consequently, candidate CSPs on 50 mg scale were prepared and screened ex-column to evaluate the enantioselectivity of each CSP.
A library of 50 dipeptide DNB CSPs were prepared using combinations of the 5 amino acids; valine, glutamine, phenylalanine, phenylglycine and proline (FIG. 7 ). This set includes sterically bulky, strong hydrogen bonding and aromatic amino acids.
The solid phase peptide synthesis which was used in the multigram scale preparation of the CSPs shown in FIGS. 5 and 6 was scaled down to prepare 50 mg of each of 50 dipeptide DNB CSPs resulting from combinations of the 5 amino acids shown in FIG. 7 .
Evaluation of CSP Library
The CSP library was first evaluated using the test racemate, 1 . The evaluation procedure consists of adding 1 ml of a 1×10 −5 M solution of the test racemate in 20% IPA/hexane to each of the 50 CSP-containing vials. The vials were then capped and transferred to an HPLC autosampler, where they were allowed to sit for a period of 30 min. HPLC analysis of 50 μl of the supernatant solution from each vial was performed using a 46×250 mm (S) DNB-Leucine CSP operating at a flow rate of 1 ml/min with a mobile phase of methanol and detection at 254 nm. Three representative chromatograms are shown in FIG. 8, including the blank (no CSP), a CSP which strongly adsorbs the (R) enantiomer of the test racemate, and a CSP which strongly adsorbs the (S) enantiomer of the test racemate. The results of the screen are presented in FIG. 9 . The vertical axis in FIG. 9 represents enantioselectivity, with the tallest bars indicating the most enantioselective CSPs. The overall method provides useful information on the separation capability of each material. Previous experience with this chiral recognition system had led us to believe that an amide hydrogen on the amino acid closest to the DNB group (aa 2) is essential for good separation. Furthermore, it was suspected that amino acids with a large steric group at this position should work best, with aromatic groups at this position generally being poorer than steric groups. It thus comes as no surprise that the proline in position aa 2 works very poorly, while valine and phenylalanine in this position work best. Some unexpected results are obtained, even though this chiral recognition system has been extensively studied for more than a decade by a variety of techniques in addition to chromatography, including X-ray analysis of co-crystals and nOe NMR analyses of 1:1 complexes. One unexpected result of the screen is the finding that glutamine in position aa 1 seems to have a beneficial effect on enantioselectivity.
Preparation and Evaluation of a Focused CSP Library
This initial screen provides a basis for further optimization for this chiral recognition system. The initial screen indicates that DNB dipeptide CSPs having a strong hydrogen bonding sidechain in the aa 1 position and a sterically bulky sidechain in the aa 2 position work best for the test analyte. A focused library based on this motif was prepared and evaluated. As shown in FIG. 10, many of the members of this new library show superior enantioselectivity to the DNB Val-Gln CSP, which was the best CSP in the initial library.
Selection, Scale-Up and Evaluation of an ‘Optimal’ CSP
One of the preferred CSPs shown in FIG. 10 was prepared on 5 g scale and packed into 4.6×250 mm HPLC column for evaluation. As shown in FIG. 11, this HPLC column was shown to separate the enantiomers of the test analyte, 1 , with an enantioselectivity in excess of 20. This HPLC column was shown to be highly effective for the preparative separation of the enantiomers of the test analyte, 1 , as shown in FIG. 12 . In this example, near baseline resolution of enantiomers is observed, even with a single injection of 100 mg of racemate. Analysis of the two fractions from this preparative separation shows that the collected enantiomers are isolated in a highly enantioenriched form. Furthermore, the relatively rapid separation time permits a very high preparative throughput.
This example illustrates the utility of the technology for the discovery of a highly selective adsorbent for a given separation problem.
EXAMPLE 2
Using an approach analogous to that described in Example 1, a series of tripeptide DNB CSPs were prepared and evaluated. Four such libraries of 36 CSPs each were prepared by analogous solid phase synthesis techniques and are shown in FIG. 13 . Evaluation of this CSP library as candidate adsorbents for separation of the enantiomers of the drug, naproxen, revealed several promising library members, as shown in FIG. 14 . FIG. 15 shows the evaluation of the best CSP indicated by the library screening shown in FIG. 14 using a 4.6×250 mm HPLC column.
EXAMPLE 3
Using an approach analogous to that described in Example 1, the series of acyl amino acid CSPs shown in FIG. 16 were prepared. Several different BOC amino acids were coupled with aminopropylsilica, followed by deprotection to afford the corresponding CSPs bearing a free terminal amino group. These CSPs were next transferred to individual vials, where they were coupled with each of a group of 40 different carboxylic acids. The resulting library of acyl amino acid derived CSPs was screened for ability to separate the enantiomers of the test racemate, 1 . The results of the screens for two such sub-libraries are shown in FIG. 17 . These results emphasize the fact that 3,5 dinitrobenzamide groups works well for separation of the enantiomers of test racemate, 1 .
EXAMPLE 4
This example illustrates that the technique is not limited to CSP libraries on a silica surface. We have prepared and evaluated a subset of the library illustrated in FIG. 9 using polystyrene based media. In this example, Chiron SynPhase™ Crowns (PS Crown Type:I series: aminomethylated) were used to prepare several CSPs in the dipeptide DNB series. Evaluation of the resulting Crown CSPs showed results which were similar to those found in Example 1, although some differences were noted. The use of polystyrene as a solid phase may be of some use for the preparation of adsorbent libraries owing to the fact that many types of solid phase synthesis are possible on polystyrene or other media which are not possible with silica. Furthermore, existing solid phase libraries can be accessed and evaluated as candidate adsorbents.
EXAMPLE 5
Several members of the CSP library described in Example 1 were evaluated for their ability to selectively adsorb the enantiomers of the test racemate, 1 , using HPLC with MS detection. The evaluation procedure was the same as that described in Example 1, except that HPLC evaluation was performed using a 46×250 mm (R) DNB-Phenylglycine CSP operating at a flow rate of 1 ml/min with a mobile phase of 1:1:1 methanol/acetonitrile/water with detection by mass spectrometry. This detection method was shown to afford essentially the same information obtained using UV detection, and in other cases where the analyte under investigation has poor UV absorbance, HPLC with MS detection has proven to afford the requisite sensitivity and reliability for direct screening of the CSP libraries.
EXAMPLE 6
An indirect chemical derivatization method was used to evaluate several CSP libraries for their ability to separate the enantiomers of a racemic secondary amine which had poor UV absorbance and was not well separated by chiral HPLC. A 10 −4 M solution of the racemic secondary amine in 5% IPA/hexane was added to a group of vials, each containing about 50 mg of a different candidate CSPs on a porous silica support. After waiting for one hour, 500 μl of supernatant solution was withdrawn from each vial and transferred to a fresh autosampler vial. 3,5-dinitrobenzoyl chloride (5.5×10 −7 moles) and diisopropylethylamine chloride (6×10 −7 moles) were then added to each vial. After two hours of reaction, the contents of each vial was analyzed using an autosampler HPLC system with UV detection.
These examples illustrate the invention and are not intended to limit in spirit or scope. | The invention discloses a method for rapid identification of a candidate selective separation material by placing small samples of the candidate material in an array of vials and adding a solution of the analytes to be separated. The solution is allowed to interact or equilibrate and the distribution of the analytes in the solid or liquid phase is measured usually by gas or liquid chromatography. The identified candidate material with the greatest differential adsorption of the analytes is selected and used as an adsorbent for large scale separation. The rapid screening of chromatographic adsorbents provides an efficient way of finding suitable absorbent materials for large scale separations. | 2 |
FIELD OF THE INVENTION
This invention relates to memory devices and more particularly, to disc type storage drives that incorporate magnetic or optical discs as an information storage medium.
BACKGROUND OF THE INVENTION
Electronic members are used to store large quantities of digital data and other information used in computers and other computerized electronic devices in which large amounts of information need to be recorded and/or retrieved and displayed upon a cathode ray tube or other video display device. In more recent years, forms of digital storage devices have been incorporated within computerized entertainment devices such as those used for presenting video information, pictures as well as digitally stored music. A typical form of storage device employs a rotatable storage medium or "disc", either permanently housed within the device or which is removable and may be removed and replaced by another disc; and a transducer or "head" by means of which the information stored on the disc is interrogated or "read out" and coupled to other devices in the system. Disc drives of this type include magnetic disc drives in which the discs are of magnetic material and in which the information is stored in the form of magnetic flux, whereby the information is read out by magnetic type transducer means, and optical disc drives in which the information is stored in the form of pits or other broader optical discontinuities in the disc material and in which a readout is accomplished by light transducer means, typically a laser diode and photodetector combination. The information is arranged and stored in the "tracks" located on the disc. Those tracks may be in the form of a continuous spiral track or a series of concentric circular tracks.
Information is stored by filling the disc tracks with closely spaced disc continuities; so called "pits" for optical discs, magnetic flux reversals for magnetic discs. In a typical arrangement for an optical disc, there may be approximately 5,000-10,000 of such "pits" in each centimeter of circumferential track length.
The information stored is retrieved by a pick-up transducer, suitably a servo driven head which contains a sensor, either optical or magnetic. The servo positions the head over a selected track and the sensor reads the information previously stored on that track. In additional to reading the information on a particular track, a provision in the system provides rapid switching between one track and another, which may be spaced some distance apart on the disc; an action that is referred to as "seeking" in magnetic disc drives and/or "track jumping" in optical disc parlance. In the operation of a computerized device a "command" is given to procure certain information from within storage. Given the identifying information, the command causes the sensor to seek the track location in which the particular information is stored, following which, the head or sensor retrieves the stored information and returns it to the other electronic circuits within the computer for further processing or for display.
In particular, interactive video used that is often used for games, education, training, and the like, frequently requires a "branching" function; that is, instantaneous switching to a new scenario under user control. The branching is accomplished by interleaving a number of scenarios on the disc track. The user initiates a branch by causing the video disc player to execute "track jumps" in a sequence which selects one of the interleaved scenarios. In order to create a steady video image, the track jumps must be accomplished within the video display's vertical retrace inverval and the number of tracks in each jump must be precisely controlled.
The foregoing retrieval operations require that the head and sensor be moved rapidly in a radial direction with a controlled motion so that the sensor comes to rest over the desired track. Various technologies for accomplished sensor positioning in this arrangement are known and are in wide use. Those existing techniques are, however, either quite elaborate, typically requiring a separate channel for track jumping which is electronically switched in at the beginning of a track jump, followed by a switch out at the conclusion, or is of crude design in that only short track jumps can be executed with acceptable levels of precision. The present invention provides a relatively simple means to permit highly accurate track jumps of any length.
With existing technology, the first approach to head positioning is accomplished in a three-step process. First, the tracking servo loop is opened and an "accelerate signal" is applied to the sensor head. Second, at the mid-point of head travel between the two track positions, the signal applied to the sensor head is changed to a "decelerate" signal. And, at the conclusion of travel, the "decelerate" signal is removed and the tracking servo loop is closed which, ideally, leaves the sensor positioned over the correct disc track. Because there is no closed loop control of the sensor head during a track jump, this approach is believed to be suited only to short jumps.
The existing technology for long "jumps" or "seeks" contains some means for monitoring the movement of the sensor as it travels from its start position to the selected disc track. This uses a closed loop control insuring that the sensor remains on course, so to speak, and arrives at the correct track, even after lengthy travel. Typically, the velocity of the sensor movement is a parameter used for head positioning control. In addition, a technique for sampling position error once for each track crossing is presented in U.S. Pat. No. 4,547,822, granted to Stewart Brown, the present application.
An advantage of the present invention is that it avoids the need for an additional channel and the accompanying electronic hardware as in the case of the prior drives.
A principle object of the invention is to provide an improved control for positioning a moveable disc head transducer. A further object is to provide accurate track jumps under adverse conditions such as video disc with dust, fingerprints, etc., on the optical surface. A further object is to provide a disc head control circuit that accurately positions the head even over long jumps and is less expensive than existing techniques that perform that function. A still additional object is to provide a lowcost disc head position controller capable of accurately positioning the head.
SUMMARY
In accordance with the aforecited objects, the disc drive of the invention includes a reference signal generating means for sythesizing a signal that is a real time analogue representation of a "perfect signal", one that would be outputted from the tracking sensor during a perfect movement of the head to the specified disc track and, in effect, simulates the perfect signal as a reference. This reference signal is combined in a subtractive relationship with the actual signal generated by the sensor during its movement. The resulting difference signal is applied to the input of the tracking servo and functions as an error signal to control the sensor position during the track jump. As is apparent, in this system the existing tracking servo is employed, avoiding the need for an additional channel.
A further important advantage is that this difference signal is a position difference signal, and it is valid for a high percentage of time (as opposed to a signal derived only once per track crossing).
The foregoing advantages and objects of the invention, together with additional advantages, are better understood by giving consideration to the detailed description of the preferred embodiment, which follows in this specification, taken together with the illustrations thereof presented in the figures of the drawings.
DESCRIPTION OF THE DRAWINGS
In the Drawings:
FIG. 1 is a block diagram of the tracking servo control system in accordance with the invention;
FIG. 2 is a diagrammatic depiction of the servo head position relative to time when crossing a plurality of tracks of a disc, or the like;
FIG. 3 is a position versus time waveform showing an idealized or perfect signal from the sensor head of the system of FIG. 1, with portions of the waveforms highlighted in solid and open blocks, the waveform being correlated to the servo head position of FIG. 2 by vertical broken lines;
FIG. 4 is a partial analog waveform showing a reference signal derived from the waveform of FIG. 2, and correlated thereto by vertical broken lines;
FIG. 5a is a partial graphical depiction of a digital control signal for the track and hold circuit of the system of FIG. 1 correlated in time to the waveforms thereabove by vertical broken lines;
FIG. 5b is a partial graphical depiction of a digital control signal for the normal/invert circuit of the system of FIG. 1 correlated in time to the waveforms and control signals thereabove by vertical broken lines;
FIG. 5c is a partial graphical depiction of a digital control signal for the accelerate positive signal generated by the microprocessor circuit of the system of FIG. 1 correlated in time to the waveforms and control signals thereabove by vertical broken lines; and
FIG. 5d is a partial graphical depiction of a digital control signal for the accelerate negative signal generated by the microprocessor circuit of the system of FIG. 1 correlated in time to the waveforms and control signals thereabove by vertical broken lines.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
In a preferred form, the embodiment contains the sensor and head 1; a servo driver 3; and a transfer function generator 5. A positive accelerator signal input 7 and an accelerate negative or a decelerate signal input 9 are included and are coupled to the corresponding inputs of driver 3. The sensor head 1, contains an output 11, the tracking signal output which output 11 is designated "E", and is a serve head tracking signal. The elements described are found in conventional disc drives. As those skilled in the art appreciate, the various mechanical details of the disc or the sensor head positioning means and other aspects of the conventional structure depicted in block diagram form, may be of any conventional type and, hence, are not illustrated in detail in the drawings and are not further described.
A digital-to-analogue converter 13, has an input 15, coupled to associated equipment which equipment may include a microprocessor or other logic circuits for performance of the function to be described, which equipment is represented by dash line 17 and an output with the output 19 being, coupled by resistor 21 to the input 23 of track and hold circuit 25. In the drawings, the output 19 is designated "R", which is a reference signal as will be hereafter described. Output 27 of the track and hold circuit 25 is connected to the input of an invert/normal circuit 29. In turn, the output 31 of invert/normal 29 is coupled to the input of the servo transfer circuit 5. A second input 33 to track and hold circuit 25 is coupled to the associated equipment 17. A second input 35 to invert/normal circuit 29 is coupled to the output of the associated circuit 17. Circuit 17, represented in block form, contains the microprocessor and its associated program. The program contains the information which is processed to provide a reference signal in digital form in a waveform that meets the criteria elsewhere described in this specification. The program also contains the commands for applying, at appropriate intervals, a positive accelerate signal to lead 7, a negative accelerate, or decelerate signal to input 9, an invert/normal signal to input 35 and a track and hold signal to input 33.
The trajectory of the sensor head in a perfect jump over eight tracks of the disc, is illustrated in FIG. 2. There is a constant acceleration from the start, T-0, to the midpoint, T/2, followed by constant deceleration from the mid-point of travel, to the final position on the 8th track, T-End; FIG. 3 illustrates a frequency modulated quasi sinusoidal wave form outputted from the tracking sensor during the hypothetical perfect track jump in the example of FIG. 2.
FIG. 2 depicts a curve of servo head position relative to time as a function of track position, with the track being designated track "0" through track "8", this being used as an example to show an eight track jump of the servo head. This jump takes place between the times designated T-0 and T-END, with the mid-point of the cycle designated T/2.
FIG. 3 depicts an idealized or perfect waveform 50, which would be the output waveform from the servo head sensor 1 under ideal or perfect conditions. The waveform 50 is of a generally quasi-sinusoidal configuration, with this waveform 50 having segments thereof shown in blackened or solid blocks, e.g. 51-59, and other segments of the waveform depicted in open blocks, e.g., 60-67. The significance of this particular marking of the waveform relates to the correlation of the waveform segment to the track position of FIG. 2. For example, all solid or darkened blocks 51-59 depict segments of the waveform 50 relative to an "on-track position", while the open blocks 60-67 depict segments of the waveform 50 which correlate to the "inter-track" positions, that is, the servo head is between tracks of the disc.
With respect to the highlighted segments of waveform 50, the on-track segments 51-59 and the inter-track segments 60-67 are valid analogues of the instantaneous position of the servo head sensor 1. It is to be noted that the segments 51-59 have an ascending or positive slope, while the segments 60-67 have a descending or negative slope. These on-track and inter-track segments are then replicated to synthesize portions of a reference signal, in digital form, which portions are stored in the associated microprocessor circuit 17. The portions of the waveform 50 between these segments, that is, the tops and bottoms of the quasi-sinusoidal waveform 50, do not contain much useful information and, accordingly, those waveform portions are not used in connection with the generation of the reference signal.
Useful information extracted from this waveform 50, is shown by the truncated waveform of FIG. 4, which depicts the reference signal. By correlating, via the vertical broken lines, it can be seen, that solid line segment 51 of FIG. 3 corresponds to the segment 51a of FIG. 4, the open block segment 60 of waveform 50 corresponds to the segment 60a of FIG. 4, segment 52 corresponds to segment 52a, etc., with segments 67 and 59 of waveform 50 corresponding to segments 67a and 59a, respectively, in FIG. 4.
The on-track segments 51-59 and the inter-track segments 60-67 are replicated to synthesize the reference signal of FIG. 4 indicative of the perfect waveform. The inter-track segments 60-67 have a polarity opposite that of track segments 51-59 and, accordingly, for use, provision is made in the circuitry for taking this into consideration, that is, invert/normal circuit 29 is triggered by the associated circuit 17 to effect polarity reversal during the time the inter-track segments 60-67 are being used.
The reference signal R is depicted in FIG. 4. The reference signal is presented, as a digital signal, from control circuit 17, as an input 15 to the digital-to-analogue converter 13 by the microprocessor as shown in FIG. 1. Alternatively, if the disc drive microprocessor is too slow or too busy, the digital-to-analogue converter can be driven by hardware that consists of an electronic counter, a read-only memory and associated logic, the exact details of which, including its assembly, are apparent to those skilled in the art from the foregoing description.
The analogue equivalent, designated as reference signal "R" in FIG. 1, is outputted from the digital to analogue converter 13 at 19, and is then subtracted from the head sensor tracking signal "E" appearing at output 11 of the head sensor 1, and the resulting difference signal is inputted via lead 23 to the input of the track and hold circuit 25, and this difference is presented at output 27 to the input of the inverter 29. The output 31 of inverter 29 is a polarity-correlated error signal "e", which is applied to the input of servo circuit 5.
In operation, at such time as the associated control circuitry 17 determines that a track jump is to occur, the elements of that control circuit contain information as to the present position of the sensor head and the position to which the sensor head is to be moved, such as from track number "0" to track number "8", as shown in FIG. 2, a jump of 8 tracks in the example discussed in the preceding figures. It is to be understood that any number of tracks may be jumped, with corresponding information relating to all permitted track jumps, programmed or stored within the control circuitry 17.
At the time a jump is to be performed, the control circuitry 17 at that time issues an accelerate signal to driver 3 on input 7 in FIG. 1, with the "accelerate signal" represented by waveform 70 in FIG. 5c. As a result, the command causes an open loop acceleration of the servo head. The detailed mechanisms that actually move the head are not illustrated, but are conventional in the disc drive art.
The associated circuitry in control circuit 17 generates digital information that represents, in digital form, the idealized waveform of the type described in connection with FIGS. 3 and 4, which digital information is based on the information as to the present track position and the final track position anticipated after the desired number of tracks to be jumped. In the preferred form, this digital information, on the idealized or perfect jump, is synthesized mathematically and, for example, is of the form R=sin Kt 2 , where t represents time and K represents an empirically determined constant. Thus, the control circuitry 17 supplies digital numbers at input 15 of digital-to-analogue converter 13 that are representative of the instantaneous value of reference signal amplitude as of the given point in time. The digital-to-analogue converter 13 converts that digital information into an analogue signal "R", which signal is represented in FIG. 4, which is the output at lead 19.
By reference to FIGS. 3 through 5d, the waveform of FIG. 3 shows relevant time intervals, such as T 0 , T 1 , T 2 , T 3 , etc., which are designated times at which certain events occur, these events being correlated to the time by the vertical broken lines. The track and hold gating signal 33 (in FIG. 1) is depicted as waveform 72 in FIG. 5a, the normal/invert gating signal 35 (in FIG. 1) is depicted as waveform 74 in FIG. 5b, the accelerate positive signal 7 (in FIG. 1) is depicted as waveform 70 in FIG. 5c, and the accelerate negative (or decelerate) signal 9 (in FIG. 1) is depicted as waveform 75 in FIG. 5d.
During the time interval between the start T 0 and T 1 , the difference between reference signal "R" at 19 and the servo head tracking signal "E" generated by the head sensor 1 appearing at output lead 11, is applied at input 23 of track and hold circuit 25. The track and hold circuit 25, whose input signal is represented by waveform 50, during this same time interval, is in track condition. Similarly, the normal/invert signal 35, represented by waveform 74, is in a normal state, since the segment 51a is of a positive slope. Of course, as previously described, the accelerate positive signal 35, represented by waveform 70 is on, while the accelerate negative signal, represented by waveform 75, is off.
During the next time interval between T 1 and T 2 , by reference to waveform 50 of FIG. 3, the idealized waveform is at the top, which as shown in FIG. 4, is not used as part of the synthesizing of the idealized or perfect signal waveform. During this time, the microprocessor in circuit 17 issues a hold signal, portion 72a of the waveform 72, which signal is applied at input 33 to place the track/hold circuit 25 in the hold condition. A normal signal of waveform 74 is still applied, along with the accelerate positive signal 7 of waveform 74. During this time, the servo head coasts, maintaining its acceleration.
During the time inverval between time T 2 and time T 3 , the microprocessor places normal/invert circuit 29 in the invert condition (portion 74a) to reverse the polarity of the intertrack error signal. Simultaneously, the signal 33 to the track and hold circuit 25 is changed, as depicted at portion 72b of waveform 72, to issue a tracking signal. The reference signal "E" and sensor tracking signal "E", are, again, used to create a polarity corrected difference or error signal "e", at lead 31, which is input to the function generator 5, and to the driver 3, and during that interval the sensor head is thus again placed under closed loop control to control its motion.
During the time interval between time T 3 and T 4 , the sensor head again coasts. The track and hold signal 33 is changed to hold (portion 72c of waveform 72), with the waveforms 70, 74 and 75 remaining unchanged. The process described is thus repeated.
The process continues until the sensor head is positioned at the mid-point, designated T/2 in FIG. 2, which is midway through the cycle between the initial position T-0 and the intended final position T-END. At that time, the microprocessor in circuitry 17 terminates the accelerate positive signal 7, as shown by portion 70a of waveform 70 in FIG. 5C and, instead, places an accelerate negative signal on lead 9 as represented by the portion 75a of waveform 75 in FIG. 5d. The process continues until the end time T-END, at which time the microprocessor in control circuit 17 terminates the accelerate negative signal 9. The sensor is now located over the correct track, that is, the requisite number of track jumps have been completed.
An alternative to microprocessor control as represented in block 17, is a hardware circuit consisting of logic elements and counters which drives a ROM, of conventional structure that contains the desired data. The ROM is outputted to D/A block 19. With that hardware arrangement, each time that the reference signal passes through zero an output is provided from the ROM. These outputs ("ZEROS") are counted down in order to determined the mid-point of the jump. In addition, a second set of outputs ("PREZEROS") from the ROM is counted down in order to provide a signal occurring prior to the mid-point. This signal is used to initiate deceleration of the head; it is advanced in time to compensate for the unavoidable delays associated with the head. A special group of "PREZEROES" prior to the end of a jump provides an advanced timing for the end of deceleration. A programmed delay in the start of the reference waveform compensates for the starting delay of the head.
If a specific program is written for each jump length, and many different lengths are required, the amount of memory may cause a problem. If available memory is exceeded in a particular design, additional approaches may be used. First, one need store only the program which synthesizes the reference signal for the longest jump that may be required. For shorter jumps, the middle portion of the synthesized signal may be depleted by using the following algorithm: In the program which synthesizes the reference signal R for the longest jump, "max track" make a program jump from [(actual track)/2] to [(max track-actual track)/2]. The result is a reference signal R which is correct for the actual number of tracks in the jump. If the jump is very long, a velocity limited or "flat top" profile may be required. This does not affect the basic technology described. It is noted that if the direction of the jump is reversed, the preceding description is changed by reversing the polarities of the reference signal and acceleration commands from those used in the preceding description.
It is believed that the foregoing description of the preferred embodiment of the invention is suffucient in detail to allow one skilled in the art to make and use the invention. However, it is expressly understood that the invention is not limited to the details disclosed for that purpose. Inasmuch as alternative elements which may be substituted for those described and improvements become apparent to those skilled in the art upon reading this specification. Accordingly, the invention is to be broadly construed within the full scope and the appended claims. | In a disc drive head positioning system a reference signal generator synthesizes a real time analogue representation of a perfect signal as would be outputted by the tracking sensor during a theoretically perfect movement to the desired disc track, which is used as a reference; the analogue representation is subtractively combined with the actual signal generated by the sensor during movement; and the difference forms the error signal that controls the sensor's position. | 6 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of and claims priority to U.S. patent application Ser. No. 12/194,966, filed on Aug. 20, 2008 titled DOOR ASSIST SYSTEM CONTROLLER AND METHOD which application is incorporated by reference in this application in it entirety.
FIELD OF THE INVENTION
[0002] This invention relates to a door assist system to aid a user in opening doors by providing a power assist and controls to operate the power assist. In particular, the invention relates to a door assist system adapted for use in a motor vehicle, such as an armored motor vehicle used in military operations, to aid the user in opening doors by providing a power assist and controls to operate the power assist.
BACKGROUND
[0003] To protect military personnel during combat, military vehicles are provided with layers of armor. In some vehicles, the armor may be provided on the vehicle in the factory during manufacture of the vehicle. However, it has become increasingly common for armor to be applied to existing vehicles in the field.
[0004] The military started adding armor to its High Mobility Multipurpose Wheeled Vehicle, or “HMMWV” or “Humvee” well before Operation Iraqi Freedom, but attacks from small anus, rocket-propelled grenades and “improvised explosive devices,” or IEDs in military parlance, prompted the military to increase protection for vehicles already in the field. The “up-armored” HMMWV can weigh thousands of pounds more than the standard HMMWV and includes several hundred pound steel-plated doors. Such heavy armored doors make opening and closing the doors increasingly difficult for personnel.
[0005] There is a need for a mechanism to assist with moving heavy armored doors on military vehicles. There is also a need for such mechanisms to be able to retrofit to existing vehicles that are up-armored in the field.
SUMMARY
[0006] A system for motorizing movement of at least one door of a vehicle relative to a door frame of the vehicle is provided. Vehicle power is provided by a vehicle power supply. An electric drive system is coupled at least in part to the door frame and one of the doors of the vehicle and moves the door between a closed door position and an open door position. A local power source that is different from the vehicle power supply is coupled at least in part with the electric drive system to allow for movement of the door between the closed door position and the open door position independent of the vehicle power supply. The local power source has priority over the vehicle power supply to provide power to the electric drive system when moving the door between the closed door position and the open door position. A controller is coupled at least in part with the electric drive system and is also coupled at least in part with the local power source such that the controller manages the local power source.
[0007] A method of controlling operation of a vehicle door using a door assist system is further provided. The door assist system has a motor assist and an inner door switch and an outer door switch that respectively initiate opening of the vehicle door when actuated. The motor assist is activated to move the vehicle door between an open door position and a closed door position. A desirable current supply is maintained to the motor assist when moving the vehicle door between an open door position and a closed door position. A determination that a lockout switch is engaged is made. The outer door switch is overridden in favor of the inner door switch such that the vehicle door cannot be opened via the outer door switch when the lockout switch is engaged.
[0008] In another example, a method of controlling the operation of a door of a vehicle relative to a door frame of the vehicle is provided. The position of the door is sensed and a door open command or a door close command is received. Opening or closing of the door at preselected speeds is initiated based on the command received. The length of time that the open command or close command is continuously received is then determined. The door is moved at a relatively slow speed for a predetermined initial time period and after the predetermined initial time period has ended the door is moved at a relatively faster speed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 is a schematic diagram of a door assist system according to one embodiment.
[0010] FIG. 2 is a plan perspective view of a door of a vehicle adapted with a door assist system according to another embodiment.
[0011] FIG. 3 is a plan perspective view of a portion of the outer side of the door of FIG. 2 .
[0012] FIG. 4 illustrates a general schematic of an exemplary rack and pinion gear.
[0013] FIGS. 5-10 are logic sequence diagrams illustrating overviews of methodologies for controlling an exemplary door assist system.
[0014] FIG. 11 illustrates an exemplary control system for a door assist system.
[0015] FIG. 12 is a schematic illustrating an example controller according to yet another embodiment.
DETAILED DESCRIPTION
[0016] A door assist system is provided that relieves vehicle occupants of having to manually maneuver a vehicle's heavily armored entry/exit doors in a rapid and safe manner. While the description below is made with reference to armored military vehicles, it should be appreciated that the systems described may be applied to other types of doors.
[0017] It should be noted that the basic system components remain the same for all four doors of the vehicle. However, because of the differences in the manner that each of the vehicle doors open (i.e. left doors open to the left, right doors to the right, front doors are geometrically different from back doors) the implementation of the door assist system on each of the four doors is slightly different. All operating modes of the system can be implemented with various and alternative mechanical implementations.
[0018] FIG. 1 illustrates a general schematic illustration of a motorized door assist system 30 for moving a door relative to a door frame of a vehicle. The door assist system 30 is designed to assist a single door, and each door in a vehicle can be equipped with a separate one of door assist system 30 . A dashed line 32 indicates a division of the recited components that are inside (below line 32 ) and outside (above line 32 ) of the vehicle.
[0019] The motorized door assist system 30 includes a drive system 34 coupled to the door and the door frame of the vehicle. As used herein, “door frame” refers to any part of the vehicle adjacent the door or door opening, including without limitation the vehicle frame or vehicle roof. The drive system 34 , when activated, moves the door between a closed door position and an open door position. The drive system 34 includes a motor and an actuator device, such as a hydraulic piston or rack and pinion gear that extends between the door and the vehicle. The activated motor in turn moves the piston or gears which causes movement of the door relative to the vehicle frame. When retrofitted to an existing vehicle, the drive system 34 desirably includes the motor and any accompanying gearing attached to an upper side of the external side of the door. The actuator device extends from the motor to the vehicle, e.g., the vehicle frame or roof. The actuator device is connected to the vehicle by, for example, a bracket and clevis pin. In another embodiment, the motor is mounted on the vehicle and the actuator device extends from the motor to the door. As will be appreciated by those skilled in the art following the teachings herein provided, various and alternative configurations are available for the drive system, and components thereof, depending on, for example, the design of the vehicle.
[0020] The drive system 34 may selectively include a manual override actuator, illustrated in FIG. 1 as a manual override lever 36 . The manual override lever 36 is located on the top inside of the door and is connected with the external drive system 34 . Actuating (e.g., pulling or rotating) the lever disengages the drive system, e.g., disengages the drive system actuator from the drive motor or disengages a mechanical gear train of a motor/gear drive system, and allows the occupant to manually open and close the door.
[0021] A controller 40 is electrically connected to the drive system 34 . The controller 40 is the brain of the door assist system 30 , and can include a circuit board and memory component. All system stimuli (i.e., switches, sensors, power, etc.) are desirably fed to the controller 40 . Based on the values read from the various inputs discussed below, the controller 40 may or may not take action. For instance, should the door be closed and the controller 40 receives a signal to open the door, the controller 40 will supply power to the drive system 34 to open the door. The controller 40 monitors the various inputs to determine when to stop supplying power to the drive system 34 . In another example, if the controller 40 receives a signal to open the door, but is also receiving a signal input that the door is at maximum open, the controller 40 will not provide power to the drive system 34 .
[0022] The door assist system 30 may contain a separate rechargeable electrical power supply, such as local battery 42 , at each door, in combination with each controller 40 . In another embodiment, the local battery 42 and controller 40 can be mounted onto or integrated with the vehicle itself. No user interaction is required regarding the battery 42 during operations. The battery 42 or controller 40 can include a battery power level indicator, such as an LED panel, to indicate the remaining power supply. In the embodiment of FIG. 1 , the controller 40 is connected to or includes a battery charger 44 to recharge the battery from the vehicle's power system. The condition upon the battery 42 being recharged can vary. For example, the battery 42 can be recharged whenever the vehicle is in operation (i.e., when the alternator is in operation), every time the local battery 42 is used or cycled (e.g., the battery is recharged to full power after every door opening or closing), upon reaching a predetermined power level, or upon complete discharge. A trickle charge can be used to charge the battery 42 when the vehicle is of and if the battery 42 is in danger of being depleted. In one embodiment, the charge from the vehicle battery is dependent upon the vehicle battery having a sufficient, predetermined charge, so that the system does not deplete the vehicle battery and render the vehicle inoperable.
[0023] As will be appreciated by those skilled in the art following the teachings herein provided, various and alternative powering schemes can be used to power the door assist system. For example, in other embodiments, the door assist system 30 may pull primary power from the vehicle battery, and use the local battery 42 as a back-up power source.
[0024] The door assist system 30 includes an external close switch 46 mounted to an external side of the door, or otherwise outside the vehicle, and in communication with the controller 40 . When activated, the external close switch 46 signals the controller 40 to move the door toward the closed door position. In the example seen in FIG. 1 , the external close switch 46 is integrated in the same housing as the controller 40 , and is embodied as a button on the side of the housing of the controller 40 . The external close switch 46 , as with other switches of this invention, is not limited to any particular type of switch, and can be, for example, a spring loaded toggle switch.
[0025] The door assist system 30 further includes an internal close switch 50 mounted to an internal side of the door, or otherwise inside the vehicle, and in communication with the controller 40 . When activated, the internal close switch signals the controller 40 to move the door toward the closed door position. In the example seen in FIG. 1 , the internal close switch 50 is integrated with a junction box 52 , and is shown as a button on the side of the junction box 52 .
[0026] The junction box 52 is located on the inside of the vehicle, desirably approximately in the middle of the door. The junction box 52 desirably serves as a gathering point for the cabling from internal components. The junction box 52 also houses a door stop switch 54 . When the door stop switch 54 is depressed it deactivates any opening or closing operation, and will optionally open a stopped dosing door a moderate amount, such as to allow any obstruction to be removed. When the door stop switch 54 is released, no further movement will take place. If desired, the occupant must initiate a new door opening or closing action.
[0027] The door assist system 30 includes a door open sensor 58 in combination with the controller 40 and the door latch mechanism 60 . As shown in the example of FIG. 1 , the door latch mechanism 60 includes an internal latch actuator 62 and an external latch actuator 64 . In one embodiment, the door open sensor 58 is a magnetically activated switch, e.g., a Hall Effect sensor, that is triggered by the movement of a magnet embedded in the door latch mechanism 60 . When the door latch mechanism 60 is activated to open the door, the portion of the mechanism containing the embedded magnet is moved closer to the door open sensor 58 , activating the sensor. When the door latch mechanism 60 is released the embedded magnet will be moved away from the door open sensor, deactivating the door open sensor 58 . In up-armored M1114 HMMWV, a multi-point locking system is commonly employed. The latch actuators 62 and 64 are connected to a vertical component 65 connecting an upper and lower latching point. In such a latch mechanism, the magnet can be attached to the vertical component 65 , which moves vertically toward the door open sensor 58 upon actuation of either of actuators 62 and 64 .
[0028] A door position sensor 66 is mounted on the inside of the vehicle close to the door hinge. The door position sensor 66 is mounted so that one end or part of the sensor 66 is attached to the door assembly while the other end or part is attached to the door frame. The door position sensor 66 detects movement and position of the door and relays this information to the controller 40 , via junction box 52 in the example seen in FIG. 1 . In one embodiment, the door position sensor 66 includes a Hall Effect sensor. The controller 40 uses the provided information to determine the position of the door.
[0029] In one embodiment, the door assist system 30 includes a safety switch 68 . The safety switch 68 activates should the door assist system 30 be closing the door and any part of the switch 68 is depressed. When depressed the switch 68 will cause the door assist system 30 to immediately cease closing the door and, optionally, will moderately open the door. This safety mechanism is intended to prevent door closures while obstructions remain between the door and the door frame. The safety switch 68 can include one or more sensors strategically placed around at least portions of the outside perimeter of the door. In one embodiment, the safety switch 68 includes a multi-segmented, large surface area, single pole switch that is located around at least portions of the inside perimeter of the door.
[0030] As discussed above, military vehicles are often up-armored in the field, and a retrofit kit is contemplated for the door assist system provided herein. FIGS. 2 and 3 generally illustrate a representative HMMWV door 120 (not to scale or shown in full detailed) retrofitted with a door assist system 130 . The door 120 includes a door latch mechanism 160 coupled to the door. The door latch mechanism 160 includes an internal door latch actuator 162 . The door 120 is connected to a vehicle frame, generally illustrated as frame 122 , by a hinge (not shown).
[0031] In the embodiment shown in FIG. 2 , a drive system 134 is a hydraulic motor. The hydraulic motor includes a hydraulic piston 135 having a first end attached to the door 120 and a second end attached to the door frame 122 . As discussed above, alternative drive systems are available, such as linear actuators, pneumatic drive systems (either dynamic using an air source or static through a pressure cylinder), and geared drive systems, such as the rack and pinion drive system 134 shown in FIG. 4 .
[0032] The drive system 134 , a control box for controller 140 , and local electrical power supply (not shown) can be attached to the external side of the door by various means, such as, without limitation a welded or bolted on attachment plate. Desirably, the external components of the system are covered to protect them from battlefield damage. As shown in FIG. 3 , the control box for controller 140 includes a button operated external close switch 146 for initiating the closing of the door 120 from outside of the vehicle.
[0033] Referring back to FIG. 2 , a junction box 152 includes an internal close switch 150 and a door stop switch 154 . The junction box 152 is electrically connected to the controller 140 , as well as door position sensor 166 , vehicle battery 128 , and a safety switch 168 by electrical connectors 126 . The connector 126 extending between the controller 140 and the junction box 152 extends through an opening 125 in the door. It is generally preferred to limit the amount of holes drilled through the door 120 , so as to not compromise the armor applied to the door 120 .
[0034] The safety switch 168 extends around the inside perimeter of the door 120 . The safety switch 168 is a multi-segmented single pole switch. Sensor segments 17 Q of the safety switch 168 are strategically placed depending on need in areas where obstructions to the door closing likely will occur. The sensor segments 170 are connected to electrical connections (e.g., wires or cables) 172 . The segments 170 and the connectors 172 can be secured to the door 120 by any suitable means, such as adhesives or clips. When the door is closing and any one of the segments 170 are contacted, the safety switch 168 sends a door stop signal to the controller 140 to stop the dosing motion to allow the obstruction to be removed.
[0035] FIG. 3 shows a portion of the external side of the door. A door open sensor 158 is connected to the controller 140 for detecting whether the door latch mechanism 160 is in a latched state or an unlatched state. A magnet 159 is bolted to a vertical component 166 of the latch mechanism 160 . As discussed above, when the latch mechanism 160 is activated to open the door, the magnet 159 is moved closer to the door open sensor 158 , which signals the controller 140 to activate the drive system 134 to open the door 120 .
[0036] FIGS. 5-10 are flow charts illustrating the operation of an exemplary door assist system as described above in FIGS. 1-3 . Referring to FIG. 5 , to open the door from the inside, the vehicle occupant simply pulls back on the internal latch actuator. The door will immediately begin to open by the drive system. Should the occupant quickly release the internal latch actuator, the door will cease opening immediately. Should the occupant after initial pull back on the internal latch actuator maintain that position for a predetermined time, such as a minimum of 2 seconds, the door will be opened fully by the door assist system regardless of whether or not the occupant continues to pull back on the internal latch actuator. In one embodiment, the occupant can determine when the door assist system has achieved the “Auto” mode by a noticeable speed up of the door opening. The predetermined times may be user-programmable, such as in the field and/or at installation, depending on need.
[0037] Referring to FIG. 6 , to open the door from the outside, the occupant simply pulls back on the external latch actuator. The door will immediately begin to open. Should the occupant quickly release the external latch actuator, the door opening will cease immediately. Should the occupant after initial pull back on the external latch actuator maintain that position for a predetermined, and optionally user-programmable, time, such as a minimum of 2 seconds, the door will be opened fully by the door assist system regardless of whether or not the occupant continues to pull back on the external latch actuator. Again, the occupant can determine when the door assist system has achieved “Auto” mode by a noticeable speed up of the door opening.
[0038] Referring to FIG. 7 , to close and latch the door from the inside of the vehicle, the occupant simply presses the internal close switch button (located on the side of the junction box in FIGS. 1-3 ). The door will immediately begin closing. Should the occupant quickly release the close switch, the door will cease closing. If after initial depression of the internal close switch, the occupant continues to depress the internal close switch for a predetermined, and optionally programmable, time, such as a minimum of 2 seconds, the door will automatically fully close regardless of whether or not the occupant continues to depress the internal close switch. The occupant can detect when the door closing has entered into the “Auto” mode by the noticeable speed increase of the door closing.
[0039] Referring to FIG. 8 , to close and latch the door from the outside of the vehicle, the occupant simply presses the external close switch button located on the side of the control box located at the top of the door. The door will immediately begin closing. Should the occupant quickly release the switch, the door will cease closing. If after initial depression of the external close switch button, the occupant continues to depress the external close switch for a predetermined, and optionally user-programmable, time, such as a minimum of 2 seconds the door will automatically fully close regardless of whether or not the occupant continues to depress the external close switch button. The occupant can detect when the door closing has entered into the “Auto” mode by the noticeable speed increase of the door closing.
[0040] Referring to FIG. 9 , to open the door from the inside without the use of the door assist system, the occupant must first disengage the drive system by actuating (e.g., pulling or rotating) the manual override actuator located at the top inside of the door. Once the manual override has been activated, the occupant must pull on the internal actuator and manually push the door open. The door assist system may supply power to the drive system once the latch actuator is pulled, if the battery is charged, but the drive system will not operate due to the manual override. Manually closing the door from the inside also requires the disengagement of the drive system.
[0041] Referring to FIG. 10 , to open or close the door from the outside without the use of the door assist system, the drive system must be removed from the vehicle frame. For example, where the drive system is attached to the vehicle from by a Clovis pin, the Clevis pin can simply be removed. The occupant must pull on the external latch actuator to pull the door open.
[0042] The door assist system may be programmed to stop at a predetermined open position for the convenience of the occupant. In one embodiment, to program the door open position, the door must first be in the fully opened position. To do this the occupant should pull on either the internal or external latch actuator. The occupant must disengage the drive system by pulling on the manual override actuator located at the top inside of the door. The occupant then manually positions the door to the desired opening. Once the door is positioned to the desired maximum opening, the occupant pulls on and holds either the internal or external latch actuator for a minimum of 30 seconds. The occupant releases the latch actuator and reengages the drive system by releasing the manual override actuator. The door may now be operated normally. When opened, it will not open beyond the programmed maximum value. Should the occupant desire to change the maximum door opening, the procedure will need to be repeated.
[0043] The door assist system is desirably designed such that the battery for each door can support approximately 50 full openings or closings on a full charge. Exact capacity may vary due to battery life, temperature, and increased or decreased door loads. In one embodiment, the door assist system desirably does not draw power from the vehicle when the vehicle is not running. The door assist system batteries will only recharge once the engine of the vehicle is operational and its alternator output is, for example, greater than 27 volts. This is intended to prevent excessive door closures and openings from rendering a vehicle inoperative due to a discharged vehicle battery or batteries.
[0044] FIG. 11 illustrates a further embodiment of a control system for the door assist system. The vehicle illustrated in FIG. 11 is a two-door vehicle, such as Mine Resistant Ambush Protected (MRAP) vehicles, but the control system can be similarly applied and adapted for a four-door vehicle. In FIG. 11 , control system 230 includes a vehicle mounted internal switch box 232 . The switch box 232 , for example, may be centrally located between the two doors, such as on the dash or above the windshield. The switch box 232 includes two internal open/close switches 234 , one for each of two doors representatively shown in phantom. In the embodiment of FIG. 11 , each switch 234 has at least two positions, one for opening the corresponding door and the other for closing the corresponding door. In one embodiment, the switch box 232 can optionally include two additional lockout switches that, when activated, disable the corresponding external open/close switch 250 (i.e., the driver side lockout switch disables the driver side external open/close switch 250 , and the passenger side lockout switch disables the passenger side external open/close switch 250 ). These lockout switches desirably do not disable the interior internal open/close switches 234 , and are used to keep unwanted third parties from being able to open the door from the outside when an operator is inside.
[0045] The internal open/close switches 234 each communicate with a corresponding controller 240 . Each controller 240 is in communication with a corresponding drive system (not shown) as discussed above, and can be powered by a local battery 242 . A door stop switch 244 and a multi-segment sensor safety switch 246 for each door communicate with the corresponding controller 240 . The door stop switch 244 is a particularly beneficial safety feature in embodiments where the switches are simply actuated and stay in the actuated position without requiring the operator to hold the switch in the actuated position. In another embodiment, the switch must be maintained in the actuated position by the operator, or the switch will return to a non-actuated position and stop the movement of the door.
[0046] A notable difference in this embodiment is that the external open/close switch 250 is routed through the switch box 232 . In one embodiment, where the vehicle has additional armor added, and the armor prevents the operator from reaching the external switch 250 , an extension switch 250 ′ can be added to connect to the original switch 250 . In another embodiment, the external open/close switch may be integrated with the existing vehicle door handle or latch mechanism, without the need for a further added switch.
[0047] As described, the example door assist systems preferably include a controller (e.g., controllers 40 , 140 , 240 ) for controlling a motor assist, i.e., any system components that provide mechanical, electrical, hydraulic and/or pneumatic assistance, in actuating a door to move between an open position and closed position. The motor assist employed may be activated by the controller to actuate the door and may or may not necessarily include a motor. According to such embodiments as described, the controller operates in connection with an outer door switch (e.g., external close switch 46 / 146 , door open sensor 58 / 158 , external open/close switch 250 , or other suitable means) and an inner door switch (e.g., internal door switch 50 / 150 , internal open/close switch 234 , or other suitable means). FIG. 12 schematically illustrates a representative controller 260 according to one example embodiment. It is contemplated that controllers 40 , 140 , and 240 will operate in a similar manner as controller 260 , described hereinafter, however, each controller 40 , 140 , 240 may include more, less or variations of features to those described, depending on need and the design of the vehicle and/or door assist system.
[0048] As shown schematically in FIG. 12 , controller 260 , in this example, includes one or more circuits 310 , 320 , 330 , 340 , 350 , 360 for operation and control of the door 300 . As used herein, “circuit” refers to a complete wired or wireless communications channel for effecting a result between controller 260 and one or more additional components of the door assist system described herein.
[0049] In this embodiment, controller 260 includes charging circuit 310 for maintaining a desirable power level in a power supply. In this embodiment, the power supply may comprise local battery 428 connected between the motor 420 and the charging circuit 310 , wherein the local battery 428 is further connected to a primary energy supply, such as a vehicle battery 400 , desirably through the charging circuit 310 . The charging circuit 310 may further selectively draw power from the vehicle battery 400 to ensure that the vehicle battery 400 is not drained by charging the local battery 428 .
[0050] As further shown in FIG. 12 , controller 260 , in this example, includes a detection circuit 320 for stopping the motor 420 if movement of the door 300 is obstructed. For example, if the door 300 moves into a position where it is blocked by an obstacle for a preset period of time, then detection circuit 320 provides a signal to motor 420 to discontinue further motion and/or cut power to motor 420 . Following deactivation of the motor 420 , a user can either manually operate the door 120 or reverse the door under power assist.
[0051] Controller 260 may additionally include a cessation circuit 330 for stopping the motor 420 if door operation exceeds a maximum time threshold. For example, cessation circuit 330 may be operable to provide a signal to motor 420 to discontinue further motion and/or cut power to motor 420 should door operation exceed a preset time threshold, such as a time required to reach a desirable opening threshold of the door 300 .
[0052] Controller 260 may additionally include a position circuit 340 for determining a relative position of the door 300 . To facilitate operation of position circuit 340 as described, controller 240 may be connected relative to a door position sensor 366 connected with respect to the position circuit 340 , as shown schematically in FIG. 12 . Position circuit 340 is preferably utilized to set and maintain presets for door operation. That is, a user may program a desired position for the door 300 to arrive at a fully opened position.
[0053] In addition, controller 260 may further include an override circuit 350 permitting the inner door switch, or a dedicated lockout switch as described above, to override the outer door switch. Such operation may be particularly desirable in an emergency scenario whereby users inside the vehicle seek to prevent operation of the door 300 by a person or persons outside of the vehicle.
[0054] As briefly described above, controller 260 communicates with respect to one or more safety systems that are positioned in association with the door 120 . Accordingly, controller 260 may further include a safety circuit 360 for actuating or stopping the door following an emergency input. A safety switch, such as safety switch 246 described above, for example, may be connected or positioned along or relative to the door and electrically connected with respect to the safety circuit 360 . In addition, controller 260 may include a sleep mode wherein the controller 260 will only draw a minimal amount of power when the door is not being activated.
[0055] As shown schematically in FIG. 12 , the controller 260 may further include a status display 380 indicating at least one of battery capacity, battery charging, safety switch activation, door switch activation and door position. The status display 380 may comprise indicator LEDs, an external display, an integrated LCD display and/or any other suitable status display for conveying at least the listed information. Status display 380 is preferably multifunctional and may further be used as a debugging tool for the motorized door assist system. The status display 380 may indicate a battery capacity, particularly while the door is moving. For example, a series of bars may be lit to represent the battery capacity remaining and/or exhausted. The status display 380 may indicate battery charging status. For example, a series of upwardly cascading lights may represent charging status. The status display 380 may indicate safety switch operation; for example, one or more lights may flash rapidly. The status display 380 may indicate a door open or door closed condition. For instance, the lights may flash in a predetermined manner. In addition, the status display 380 may confirm programming steps. For instance, following programming of a preferred door stop increment, the lights may go blank for a predetermined amount of time and then reilluminate.
[0056] As described above, the door assist system may include programmable options for inputting one or more position presets of the door 30 . According to this embodiment, the controller 260 may include a memory for retaining one or more trainable stops of the door. The memory may comprise a fixed internal memory, an external memory, a replaceable magnetic memory device such as a diskette, a memory stick or a compact flash card and/or any other suitable memory for retaining such programmable options with the door assist system.
[0057] An external programmer may be used to program various features of controller 260 . Such features may include: a maximum forward speed; a maximum reverse speed; a minimum speed; a maximum forward acceleration; a maximum reverse acceleration; a maximum acceleration during direction change; a maximum reverse deceleration; a maximum deceleration during direction change; a motor compensation value; and/or an “indoor” mode for a second mode of operation. Additional programmable features may include: scaling for throttle types and values; deadband value around throttle neutral; failband above and below throttle maximum and minimum; setting for a non-linear throttle response; compensation values for load conditions; timing for application of mechanical brake; deceleration parameter for quickstep using key or switch; compensation value for power wire resistance; power down period for controller inactivity; lower current limit bound; upper current limit bound; and delay time before controller 260 drops from the upper current limit to the lower current limit.
[0058] The external programmer, for example, may be connected with respect to the controller 260 to permit programming of various functions and features described herein. In addition, various functions and/or presets such as door position presets may selectively be programmed by the user without use of the external programmer and yet such functions and/or presets may be retained by the controller 260 . To facilitate such programming at least one of the outer door switch and the inner door switch may be connected with respect to the controller 260 to permit actuation of such switch to establish the presets. In operation, a user may open and hold the outer door switch and/or the inner door switch to set a door position preset to a desired position.
[0059] As described, a method of operation of the controller 260 for actuating a door having a motor assist and an outer door switch and an inner door switch includes one or more of the following steps. As an initial matter, a user engages a switch, latch, or similarly described means for activating the motor assist. The controller 260 thereafter maintains a desirable current supply to the motor assist; determines a relative position of the door; determines whether movement of the door is obstructed; actuates the door to an appropriate position; determines whether door operation exceeds a maximum time threshold; and/or deactivates the motor assist once the door reaches the appropriate position or the door operation exceeds the maximum time threshold.
[0060] In addition, a lockout switch may be connected relative to the controller to override the outer door switch in favor of the inner door switch. The motor assist may be activated in response to a manual activation of an inside door handle. Additionally, should a safety switch be activated, the door may be reversed to a closed position or, preferably, a preset amount. Such reversal permits the safety hazard to be cleared and normal operation of the door may be resumed.
[0061] The outer door switch may be activated for a preset period of time thereby activating the motor assist until the door is in a fully open or fully closed position. More particularly, the controller 240 may sense a current position of the door and subsequently move the door to a position opposite the current position.
[0062] In another example, the controller 240 , 260 may determine a load required to move the door by sensing a current required to move the door. In doing so, the controller 240 , 260 may determine an approximate weight of the door during ordinary operation, that is, during operation under normal load conditions on a level surface. Such ordinary operation may determine a baseline or nominal load required to move the door. If subsequent operation requires an adjustment in the desired current for operation of the door, the controller 240 , 260 will deliver power to the door in a controlled manner to open or close the door in a controlled manner. As such, if the current is outside of a nominal threshold required to move the door, the controller 240 , 260 will not permit the door to quickly open or “fling” open if on a downhill side or to open slowly if on an uphill side. Such operation results in safe operation in that it permits an operator an expected response to an open or close activation.
[0063] The invention illustratively disclosed herein suitably may be practiced in the absence of any element, part, step, component, or ingredient which is not specifically disclosed herein.
[0064] While in the foregoing detailed description this invention has been described in relation to certain preferred embodiments thereof, and many details have been set forth for purposes of illustration, it will be apparent to those skilled in the art that the invention is susceptible to additional embodiments and that certain of the details described herein can be varied considerably without departing from the basic principles of the invention. | A method of controlling the operation of a door of a vehicle relative to a door frame of the vehicle is provided. The position of the door is sensed and a door open command or a door close command is received. Opening or closing of the door at preselected speeds is initiated based on the command received. The length of time that the open command or close command is continuously received is then determined. The door is moved at a relatively slow speed for a predetermined initial time period and after the predetermined initial time period has ended the door is moved at a relatively faster speed. | 7 |
FIELD OF THE INVENTION
This invention relates to a breathing mask and method for use in cold weather to supply warm air for inhalation to persons having respiratory and heart ailments and the like.
BACKGROUND OF THE INVENTION
Many breathing masks have been developed for protecting humans from exposure to a variety of particulate and gaseous matter. However, prior masks have been unsuccessful in supplying sufficiently heated air to persons having respiratory and heart ailments to enable them to move about and work normally outside in cold weather without experiencing discomfort and pain. Typically, this discomfort and pain is experienced by persons having respiratory conditions such as asthma, bronchitis, chronic bronchitis, emphysema or coronary conditions such as angina pectoris, post myocardial infarction, congestive heart failure, coronary heart disease, post coronary bypass and the like.
Usually such persons experience sufficient pain and discomfort that they must cease exerting themselves and get into a warm environment and rest. Hence, their activity in cold weather must be severely curtailed and in some instances substantially eliminated.
SUMMARY OF THE INVENTION
A face mask apparatus which obviates the pain and discomfort experienced by persons with many respiratory and heart ailments when breathing cold air by supplying warm air for inhalation. Cold air is heated and intermittently supplied in response to the normal breathing process through a face mask worn over the nose and mouth of a person. Cold air is heated for inhalation by an electric heater element carried by the mask and powered by an electric current. Preferably, the flow of air through the mask is controlled by inlet and outlet check valves responsive to the normal breathing process.
Preferably, the temperature of the heater element is controlled by suitable electronic circuitry to produce warm air for inhalation preferably having a temperature in the range of about 50° F. to 80° F. Preferably, the heater element is powered by a portable battery pack carried by the person. However, if desired, when the face mask is worn in a motor vehicle, the heater element can be powered by the electrical system of the motor vehicle to which it is preferably connected by being plugged into a cigarette lighter receptacle.
Objects, features and advantages of this invention are to provide an apparatus which greatly reduces and, in most instances, eliminates the discomfort and pain experienced by persons with many respiratory and heart ailments when exposed to cold weather, prevents hypothermia, is highly reliable, dependable, of relatively simple design and operation, and of economical manufacture, assembly and use.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other objects, features and advantages of this invention will be apparent from the following detailed description, appended claims and accompanying drawings in which:
FIG. 1 is a fragmentary perspective view of a heated face mask apparatus embodying this invention being worn by a person;
FIG. 2 is an exploded perspective view of the heated face mask of FIG. 1 illustrating some of its component parts;
FIG. 3 is a fragmentary sectional view of an inlet, heater element and inlet valve assembly of the face mask of FIG. 1;
FIG. 4 is a fragmentary sectional view of an outlet and outlet valve assembly of the face mask of FIG. 1; and
FIG. 5 is an electrical schematic diagram of a suitable electronic control for the heater element of the face mask of FIG. 1.
DETAILED DESCRIPTION
Referring in more detail to the drawings, FIG. 1 illustrates a face mask 10 embodying this invention being worn by a person 12 and powered by a battery and control pack 14 with a shoulder strap 16 received over the shoulder of the person. As shown in FIGS. 1 and 2, the face mask has a body housing 18 which in use encircles, overlies and encloses the nose and mouth of the person wearing the mask and is positioned and retained on the face by adjustable and preferably resilient straps 20 encircling the head. Preferably, the housing 18 is of a flexible material such as rubber and its outer periphery 22 will readily conform to the contour of the face and bear gently on the skin to provide a substantial gas-tight seal between the housing and the face of the wearer.
The face mask has an air inlet 24 and air outlets 26 carried by the housing 18 in which inlet and outlet check valve assemblies 28 and 30 are mounted. As shown in FIGS. 2 and 4, each outlet check valve assembly has a flexible diaphragm 32 providing a flap valve secured to a perforated carrier disc 34. The valve assembly and a filter disc 36 are mounted in assembled relation on the outlet 26 by a threaded cap 38 which is removably screwed thereon and has outlet air passages 40 therethrough.
The inlet check valve has a flexible diaphragm 42 providing a flap valve secured to a perforated carrier disc 44 which is removably received in a groove 46 adjacent the inner end of the inlet 24. A filter disc 48 is received in a threaded cap 50 removably screwed on the inlet 24 and having inlet air passages 52 therethrough. A suitable face mask, as thus far described, is commercially available from American Optical of Southbridge, Mass. 01550, as Model No. A/O R2090N.
In accordance with this invention, a heater assembly 54 is mounted in the inlet 24 to heat cold air to an elevated temperature to provide warm air for inhalation by the user of the mask. The heater assembly has a radiator and heat sink which is preferably a perforated disc 56 of a thermally conductive metal, such as aluminum. The disc is heated by an electric resistance element, such as a power transistor 58 in heat transfer relationship with the disc. Preferably, the power transistor is fixed to the disc by a mechanical fastener such as a bolt or rivet or an adhesive such as an epoxy. Preferably, to sense the temperature of the radiator disc for controlling the temperature of the air heated by it, a thermistor 60 is also mounted on the disc in heat transfer relationship with it by an adhesive such as an epoxy. An electric current is supplied to the power transistor through a suitable electric cable 62 which is anchored to the disc by a restrainer block 64 and passes through a hole 66 in the inlet.
A chamber 68 in which the cold air is heated is defined by the inlet 24, cap 50 and inlet check valve assembly 28. The air is primarily heated as it passes through the heater assembly 54 during inhalation. It has been found to be very satisfactory for the chamber 68 to have a volume of about 3 to 10 cubic inches.
CONTROL CIRCUIT
In accordance with another feature of this invention, the temperature to which the air to be inhaled is heated,is adjusted within predetermined limits and controlled by a control circuit 70 shown schematically in FIG. 5. The control circuit has a first comparator 100 having a non-inverting input connected to the thermistor 60 and an inverting input connected to a available resistor 102. Resistor 102 is connected in series with resistors 104, 106 to form a voltage divider across the battery power 14. The output of comparator 100 drives the gate of the MOSFET power transistor 58 through a second variable resistor 108. A second comparator 110 has an inverting input connected to a voltage divider 117 across battery power and a non-inverting input connected to the thermistor 60. The output of comparator 110 is connected to the base of a transistor 112 which has its emitter and collector connected between the output of comparator 100 and ground (through current limiting resistors).
A double-pole, triple throw switch 114 has a first contact 115 connected to battery 14 for supplying battery power to the temperature control electronics. The second pole 117 of switch 114 has its common contact connected to ground and one of its normally-open contacts connected to the junction of resistors 102 and 106. At the center position of switch 114, contact 115 connects battery 14 to a charging circuit 130 which includes a constant current regulator 132 coupled through a diode bridge 134 to a suitable source of A.C. power (not shown). An NPN transistor 136 has collector and emitter contacts connected across a low-battery LED 138 coupled to battery power, and a base connected through a zener diode 140 to battery power.
A compartor 142 has its inverting input connected to battery power through the voltage divider 144, and its non-inverting input connected across the zener diode 146. The output of compartor 142 drives a voltage-to-frequency converter 148 which includes a compartor 150 and a transistor 152. Transistor 152 drives a piezoelectric buzzer 154.
CONTROL CIRCUIT OPERATION
In operation, and with the switch 114 in the "high" position shown, comparator 100 energizes MOSFET 58 when the temperature of the heat radiator disc 56 (FIG. 2) detected by thermistor 60 is below the reference level set by resistor 102 in combination with resistors 104, 106. That is, as the temperature of the heat radiator 56 drops and the resistance of the thermistor 60 correspondingly increases, the voltage at the non-inverting input of comparator 100 eventually exceeds the voltage at the inverting input, so that the comparator output drives MOSFET 58 through resistor 108. Resistor 102 thus effectively sets the temperature at which comparator 100 energizes MOSFET 58, and resistor 108 sets the MOSFET drive voltage when comparator 100 is turned on.
As MOSFET 58 heats radiator disc 56 and the resistance of thermistor 60 drops accordingly, the voltage at the non-inverting input of comparator 100 eventually decreases below that at the inverting input, and comparator 100 terminates the drive voltage to the MOSFET 58. Hysteresis at comparator 100 prevents oscillation of the comparator and drive circuit about the set point of resistor 102. When switch 114 is placed in the "low" position, resistor 106 is effectively short circuited, thus changing the effective set point of resistor 102 and comparator 100. Thus, switch 114 cooperates with the voltage divider consisting of resistors 102-106 to provide differing "high" and "low" temperature sensitivities.
Comparator 110 clamps the output of comparator 100 and inhibits operation of the MOSFET 58 in the event that thermistor 60 fails in the open-circuit mode. That is, if thermistor 60 fails in the open-circuit mode, the voltage applied to the non-inverting input of comparator 110 will exceed the reference level at the inverting input set by resistor voltage divider 117, and the output of comparator 110 will turn on transistor 112. In this event, the collector of transistor 112 effectively clamps the output of comparator 100 through its emitter to ground, so that energizing voltage cannot be applied to MOSFET 58 through resistor 108. In the event that thermistor 60 fails in the short-circuit mode so as to effectively ground junction 131, the voltage at the non-inverting input of comparator 100 will not exceed that at the inverting input at either the "high" or "low" position of switch 114, so that comparator 100 will not energize the MOSFET 58.
Application of battery power energizes the power-on LED 156. As long as the battery voltage remains above the level determined by zener diode 140, transistor 136 shunts current from LED 138. However, when battery voltage declines, transistor 136 turns off and "low battery" LED 138 is energized. Comparator 142 drives V/F converter 148 at a level which varies as a function of comparison between battery voltage divider 144 and the reference level set by zener diode 146. As battery voltage declines below the reference level of zener diode 146, drive voltage to converter 148 increases and the frequency of energization of buzzer 154 increases accordingly. Thus, the wearer is continuously advised by buzzer 154 not only that battery charge is decreasing, but also the level of declining charge. As long as the voltage at divider 144 remains above the level set by zener diode 146, compartor 142 and buzzer 154 remain off.
FACE MASK OPERATION AND USE
Typically, the face mask is used by a person having a respiratory or heart condition in which they will experience discomfort and pain if they breathe cold air, such as when being outside in cold weather, and particularly if they are active or exerting themselves while in the cold air. It can also be used by healthy persons engaging in strenuous activity in cold weather such as construction work and recreational activities. In use, the face mask 10 is placed over the nose and mouth of the person (as shown in FIGS. 1 and 2), and secured to and retained on the persons head by adjustable and preferably resilient straps.
In use of the mask, the person breathes in the normal manner. When the person inhales, inlet valve 28 opens and cold air is drawn from the exterior atmosphere through the inlet 24 and the chamber 68 where it is heated by heater assembly 54. The heated air is then drawn through the valve 28, housing 16 and into the nose and/or mouth of the person. While the person is inhaling, the outlet check valves 30 remain closed. When the person exhales, the air emitted from the person's nose and/or mouth is discharged into the housing 18 and through the outlet valves 30 to the atmosphere exteriorly of the mask. While the person is exhaling the inlet valve 28 remains closed.
The radiator disc 56 of the heater assembly is heated by the power transistor 58 to which an electric current is supplied through the control circuit 70 and connecting wires 62. Preferably, current is supplied to the control circuit by the portable battery pack 14 carried by the user. However, if desired, current can be supplied from the electric system of a motor vehicle preferably through an appropriate connector (not shown) plugged into a receptacle for a cigarette lighter, or from any other suitable power source. The temperature to which the radiator disc 56 is heated, and hence the temperature of the air inhaled by the user, is controlled and varied within predetermined limits by the control circuit 70. This is accomplished by the thermistor 60 which senses the temperature of the disc 58 and its associated circuitry which intermittently turns the power transistor 58 on and off. The control circuit 70 has a high heat range and a low heat range provided by the switch 114 and associated circuitry. An indication that the control circuit has been turned on by the switch is provided by a light emitting diode 156 and associated circuitry. An indication that the battery of the power supply is running low and should be recharged or replaced is provided by light-emitting diode 138 and buzzer 154. Heating of the air to an excess temperature due to a malfunction of the temperature sensing thermistor 60 is prevented by associated fault detecting circuitry which automatically turns off the current to the power transistor 58. | A face mask for use in cold weather to supply warm air for inhalation by normal breathing to persons having respiratory and heart ailments to avoid the discomfort, pain and limited mobility caused by breathing cold air and to healthy people engaged in strenuous cold weather activities. The face mask has inlet and outlet check valves and a cold air intake chamber with an electric heater element therein which heats the cold air to supply warm air for inhalation. The heater element is preferably powered by a portable battery pack and controlled by electronic circuitry to maintain the heated air in a predetermined temperature range. | 0 |